Grant External Vecta Installation And Servicing Instructions

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Page 1

Grant External Vecta

4-16kW Condensing Wood Pellet Boiler and Side Pellet Store

Installation and Servicing Instructions

UK | DOC 0104 | Rev 1.1 | March 2017

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Important Note for Installers

This manual is intended to guide Installers who have completed the Grant Wood Pellet Boiler Installer training course on the installation, commissioning and servicing of the Grant Vecta Condensing Wood Pellet Boiler.

A separate manual is available to guide users in the operation of the boiler.

Special Text Formats

The following special text formats are used in this manual for the purposes listed below:

Warning of possible human injury as a consequence of not following the instructions in the warning.

Caution concerning likely damage to equipment or tools as a consequence of not following the instructions in the caution.

Used for emphasis or information not directly concerned with the surrounding tex t but of importance to the reader.

WARNING

CAUTION

NOTE

GRANT ENGINEERING (UK) LIMITED

Hopton House, Hopton Industrial Estate, Devizes, Wiltshire, SN10 2EU Tel: +44 (0)1380 736920 Fax: +44 (0)1380 736991 Email: [email protected] www.grantuk.com

This manual is accurate at the date of printing but will be superseded and should be disregarded if specifications and/or appearances are changed in the interests of continued product improvement. However, no responsibility of any kind for any injury, death, loss, damage or delay however caused resulting from the use of this manual can be accepted by Grant Engineering (UK) Limited, the author or others involved in its publication. All goods sold are subject to our official Conditions of Sale, a copy of which may be obtained on application. © Grant Engineering (UK) Limited 2017. No part of this manual may be reproduced by any means without prior written consent.

Page 3

1 Introduction 4

1.1 How the Condensing Wood Pellet Boiler Operates 5

1.2 Boiler Description 5

1.3 Access 5

1.4 Flue System 5

1.5 Boiler Components 6

1.6 Logo Indicator 7

1.7 Boiler Cleaning and Servicing 7

2 Technical Data 8

2.1 Technical Specifications 8

2.2 Burner Settings 9

2.3 Flue Gas Analysis 9

2.4 Clearances and Dimensions 9

3 Pellet Specification 11

3.1 Pellet Specification 11

3.2 Biomass Suppliers List 11

4 Installation Information 12

4.1 Boiler Location 12

4.2 Regulations 12

4.3 Heating System 12

4.4 Pipework Materials 13

4.5 Connections 13

4.6 Wash System 14

4.7 Before you Commission 14

4.8 Completion 14

4.9 ‘Meter Ready’ Installations 14

5 Condensate Disposal 16

5.1 General Requirements 16

5.2 Connections 16

5.3 Pipework 16

5.4 External Pipework 16

5.5 Condensate Trap 17

5.6 Inspection and Cleaning of Trap 17

6 Sealed Systems 18

6.1 Sealed System Requirements 18

6.2 Filling the Sealed System 19

6.3 Venting the Pump 19

6.4 Pressure Relief (Safety) Valve Operation 19

7 Flue System and Air Supply 20

7.1 Air Supply 20

7.2 Flue Terminal Position and Clearances 20

7.3 Flue System Specification 21

7.4 Flue System Assembly 22

7.5 Flue Testing 23

7.6 Flue Notice Plate 23

7.7 Typical Flue Systems 24

7.8 Flue System Component Dimensions 27

7.9 Flue System Components 28

8 Electrical 30

8.1 General Requirements 30

8.2 Boiler Electrical Connections 30

8.3 Remote Grant Logo Indicator Connections 31

8.4 Connecting the Power Supply 31

8.5 Heating System Controls 31

8.6 Frost Protection 31

8.7 S-plan 32

8.8 Y-plan 32

8.9 Boiler Wiring Diagram 33

9 Boiler Operation 34

9.1 General 34

9.2 Modulation 34

9.3 Automatic Cleaning 35

9.4 Boiler Control Panel 36

9.5 Boiler Setpoint Temperature 37

9.6 Service Menu (including Parameter Menu) 37

9.7 Parameter Menu 38

9.8 Boiler Operating Sequence 40

9.9 Boiler Operation Flow Chart 41

10 Side Pellet Store 42

10.1 General 42

10.2 Operation 42

10.3 Installation 43

10.4 Electrical Connections 46

10.5 Commissioning the Side Store 47

11 Commissioning 48

11.1 Equipment Required 48

11.2 Preliminary Inspection 48

11.3 Boiler 48

11.4 Hopper Lid Cut-out Switch 51

11.5 Control Settings 51

11.6 Priming the Pellet Feed Auger 51

11.7 Lighting the Boiler 51

11.8 Combustion Chamber Draught 52

11.9 Flue Gas Analysis 52

11.10 Customer Handover 52

11.11 Commissioning Report Form 52

11.12 Commissioning Check List 53

12 Servicing 54

12.1 General 54

12.2 Checks Before Servicing 54

12.3 Heating System 54

12.4 Flue System 55

12.5 Combustion Ventilation 55

12.6 Boiler 55

12.7 Burner 58

12.8 Ignition Element 59

12.9 Condensate Disposal System 60

12.10 Boiler Settings 60

12.11 Hopper Lid Cut-out Switch 60

12.12 Combustion Checks 60

13 Fault Finding 61

13.1 Fault Codes 61

13.2 Fault Details 62

14 Spare Parts 64

15 The Clean Air Act 1993 and 66 Smoke Control Areas

16 Declaration of Conformity 67

17 Health and Safety Information 68

18 Disposal and Recycling 69

19 Guarantee 70

Contents Page 3

Page 4

1 Introduction

Figure 1-1: Front/left side view of boiler

Figure 1-2: Front/left side view of boiler - side access panel removed

Figure 1-3: Front/left side view of boiler - top hooper lid open

Figure 1-4: Front/left side view of boiler - hinged door open

Section 1: IntroductionPage 4

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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 External Vecta contains a unique extra (secondary) condensing heat exchanger which has been designed to capture some of this lost heat energy that would otherwise be lost, so it maintains extremely high efficiencies.

It does this by cooling the flue gases to their dew point (below 55°C) thus extracting more sensible heat.

The boiler has been independently tested to BS EN 303-5:2012 and BS EN 12809:2001+A1:2004 and will achieve the following net efficiencies when both the boiler and system are correctly set:

Operating Condition Full load efficiency Par t load efficiency

Condensing 101.5% 97.5%

To ensure maximum efficiency from the Grant External Vecta 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 80°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.

The Grant External Vecta condensing wood pellet boiler 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.

1.3 Access

The External Vecta wood pellet boiler enclosure is fitted with the following means of access:

• A hinged door (with lockable door catch*) at the front - for access to the boiler for routine cleaning (emptying the ash pan) and access to boiler/burner controls.

• A hinged top hopper lid (with lockable door catch*) - to allow pellets to be tipped into the hopper by the user and for access to the top of the boiler for commissioning and servicing.

• A removable side access panel (with lockable door catch*) on the left hand side - to allow access to the electrical wiring/PCB enclosure, photocell ignition heater element, etc., and also the water and condensate connections.

* These door catches can be fitted with a small padlock (not supplied) if required.

To unlock and open any of the above, unlock/remove the padlock (if fitted). Rotate the knob of the catch clockwise to unlatch and open the front door, top hopper lid or side access panel.

Close and lock the door, lid or panel using the reverse of the above procedure.

1.4 Flue System

The Grant External Vecta wood pellet boiler must be connected to a conventional flue system.

The ONLY flue suitable for use with the Grant Vecta wood pellet boilers is the Grant ‘Biomass’ conventional flue system. This is a 125mm (5”) diameter twin wall insulated, powder coated stainless steel flue system. Refer to Section 7 for details.

NOTE

1.2 Boiler Description

Grant External Vecta wood Pellet boilers have an insulated weatherproof enclosure made of galvanised steel with a powder coated finish, and are designed for external installation, either against a wall or free standing some distance away from the proper ty, as required.

The boiler is suitable for use on a sealed or open vented central heating system. When commissioned and set correctly, the Grant External Vecta wood pellet boiler will operate automatically, using a typical heating control system.

The boilers are 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.

Refer to Section 4 for boiler installation.

Section 1: Introduction Page 5

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1.5 Boiler Components

1.5.1 Burner

The Grant External Vecta boiler uses a drop feed t ype burner with modulated heat output. The burner output is determined by varying the feed and pause time of the pellet feed auger supplying pellets to the burner. Refer to Section 9 for details of burner operation.

The burner is supplied factory-fitted in the boiler and is equipped with a self-cleaning device to prevent a build-up of ash and clinker in the burner brazier.

The boiler is supplied with the control parameters factory set to default settings.

During commissioning these control parameters should be checked to ensure they are correct. Refer to Section 11.5 for details.

1.5.2 Heat exchangers

The Grant External Vecta 4-16 condensing boiler is supplied with a combined primary and secondary heat exchanger. Both heat exchangers are equipped with a self-cleaning system.

1.5.3 Boiler controls

After the burner has been switched off (either manually by the ON/STANDBY switch on the control panel, or automatically by the boiler control system, 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 ‘Standby’.

The Setpoint temperature of the boiler is user adjustable via the boiler control panel - refer to Section 9.4 for details.

The boiler control panel is located at the upper left corner of the boiler (behind the hinged front door of the boiler). Refer to Figure 1-5. To unlock/open the front door of the boiler, first unlock and remove the padlock (if fitted). Rotate the knob of the catch clockwise to unlatch and open the front door.

This control panel includes the following items (refer to Section 9.4 for further details of the control panel functions):

• ‘ON/STANDBY’ switch – to switch the burner off when required, by interrupting the switched live supply to the burner. This switch does not isolate the electrical supply to the burner.

• LCD screen – to display the boiler operating condition and (when necessary) a fault code

• Boiler control setting buttons – Refer to Section 9 for boiler control system operation and setting.

WARNING

overheat thermostat bulb is situated in the top front left corner of the boiler, along with the boiler control thermistor sensor. Refer to Section

11.3 for the location of the bulb and sensor.

This overheat thermostat allows the boilers to be used on a sealed central heating system and will automatically switch off the boiler if the pre-set temperature of 100°C is exceeded.

1.5.4 Boiler Pellet Hopper

The Grant External Vecta boiler has an integral pellet hopper with a capacity of 80kg. This is accessed by lifting the hinged hopper lid on the top of the boiler so that pellets can be tipped into the hopper by the user.

The hopper is fitted with a contents switch. This detects when the level of pellets in the hopper falls to a pre-set minimum value. At this point the LCD screen will flash and display the ‘Fuel Low Warning’ message. The Grant logo indicator will also flash slowly to indicate the pellet level has fallen to the pre-set minimum. Refer to Section 1.5.

As soon as this happens the hopper should be topped up with more pellets. This will automatically cancel the flashing Grant logo and the flashing ‘Fuel Low Warning’ message on the control panel LCD screen.

If the pellet hopper is not topped up at this point, the boiler will continue to operate for a short period before the burner is automatically stopped. The Grant logo will continue to flash slowly, with the flashing ‘Low Fuel Warning’ message on the control panel LCD screen, to indicate the lack of pellets in the boiler.

If this happens, simply top up the hopper with more pellets. A minimum of 20kg of pellets will operate the contents switch and automatically re-start the burner (as long as there is a demand for the boiler to run).

To top up the hopper, first set the ‘ON/STANDBY’ switch to ‘STANDBY’ and wait for the boiler to stop. Then open the hinged hopper lid (on the top of the boiler) and tip in the required amount of pellets. Then close the hopper lid and reset the ‘ON/STANDBY’ switch to ‘ON’. Whilst topping up with pellets, ensure that no foreign debris enters the hopper.

The hinged hopper lid is fitted with a safety cut-out switch and MUST BE CLOSED for the boiler to operate. If the lid is opened for longer than 5 seconds, whilst the boiler is operating, the burner will be automatically stopped. Closing the hopper lid resets the cut-out switch and the boiler will restart. Refer to Section 11.4 for details of the hopper lid cut-out switch operation.

NOTE

Figure 1-5: Boiler control panel

The boiler also includes an overheat thermostat – located at the bottom left corner of the boiler (inside the front door) with the reset button under the removable plastic cap. Refer to Figure 11-3. The

1.5.5 Frost Protection

The Grant External Vecta wood pellet boiler is supplied with a factoryfitted frost protection thermostat. This is pre-set to operate when the air temperature falls to 2°C.

This frost thermostat is located inside the PCB enclosure and wired to the boiler terminal block. For details of the frost thermostat electrical connections, refer to Section 8.6.

Section 1: IntroductionPage 6

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1.5.6 Side Pellet Store

An optional separate 140kg capacity pellet store is available to increase the pellet storage for the External Vecta boiler. This side pellet store is the same external design as the External Vecta boiler and is designed to be located at the right hand side of the boiler only. It incorporates an auger to automatically transfer pellets from the side pellet store to the boiler pellet store when activated by the contents switch. Refer to Section 10 for full details of the installation and operation of the side pellet store.

This side pellet store CANNOT be installed on the lef t hand side of the External Vecta boiler.

NOTE

1.6 Logo Indicator

The illuminated Grant logo indicator, supplied with the boiler, should be mounted on a standard electrical back box (either recessed or surface mounted) in a convenient and visible position within the property. Refer to Section 8 for electrical connection details.

The Logo Indicator has been designed to assist the user by clearly indicating the following boiler conditions:

Logo illuminated (low brightness):

Indicates the following:

• The electrical power supply is connected to the boiler and it is switched on

• There is no demand from the heating system controls for the boiler to operate

AND/OR

• The ON/STANDBY switch on the boiler control panel is set to OFF

This does not indicate that the boiler is operating or that the burner is firing. Refer to Section 9.

Logo illuminated (high brightness):

Indicates the following:

• The electrical power supply is connected to the boiler and it is switched on

• There is a demand from the heating system controls for the boiler to operate

AND

• The ON/STANDBY switch on the boiler control panel is set to ON

This does not necessarily indicate that the boiler is operating or that the burner is firing. Refer to Section 9.

1.7 Boiler Cleaning and Servicing

The Grant External Vecta wood pellet boiler is equipped with an automatic cleaning system for the burner brazier and both heat exchangers.

The ash pan (located inside the combustion chamber) MUST be periodically emptied by the user. This simple task must be carried out when indicated by the Grant logo Indicator flashing (fast flash). Refer to Section 1.6.

The boiler is fitted with a hinged front door with a lockable door catch. This door must be opened to gain access to the ash pan for the periodic cleaning of the boiler. Refer to Section 12.6.5.

To open the door, first unlock and remove the padlock (if fitted). Rotate the knob of the catch clockwise to unlatch and fully open the front door.

A multi-purpose tool is supplied with the boiler for ser vicing and cleaning. This is used for the following functions:

• As the door catch handle – required to open the combustion chamber door

• As the ash pan carrying handle*

• To open the brazier catch

• To remove the brazier front plate, the brazier base plate and the

brazier cotter pin

The multi-purpose tool is hung on a hook located on the panel to the left of the combustion chamber door. Always replace the tool back on this hook af ter use to ensure it is available when next required.

*An ash pan carrying handle is also supplied with the boiler. This must be used in conjunction with the multi-purpose tool, to suppor t the opposite end of the ash pan, when removing it from the boiler. Refer to Section 12.6.5. The ash pan, once removed can only be replaced one way. If replaced incorrectly the combustion door cannot be closed.

Whilst removing the ash from the boiler, 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 the ‘Service’ message is displayed on the control panel LCD screen, whichever comes FIRST.

Servicing should only be carried out by a Grant Trained Installer and details of each service should be recorded in the Service Log in the back of the User Guide.

CAUTION

Logo flashing (slow flash):

Indicates a low pellet level – when the minimum level of pellets in the pellet hopper has been reached. Top up the pellet hopper in the boiler without delay. Refer to Sections 1.4.4 and 3.

If a side pellet store is installed, also top up this store at the same time. Refer to Section 10.

Logo flashing (fast flash):

Indicates ash pan needs empt ying – empty ash pan without delay. Refer to Section 1.7.

Section 1: Introduction Page 7

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2 Technical Data

2.1 Technical Specifications

Units 4-16

Maximum heat output

Minimum heat output

Flow connection mm 22

Return connection mm 22

Mains water connection mm 15

Water content litres 35

Minimum flow rate litres/hour 690

Waterside resistance ∆T=10°C mbar 27

Waterside resistance ∆T=20°C mbar 9

Maximum mains inlet water pressure kPa 800 (8 bar)

Minimum mains inlet water pressure kPa 100 (1 bar)

Condensate connection - 1¼ BSP (female)

Combustion chamber draught requirement mbar 0.75 to 1.25

Maximum static head metres 28

Minimum circulating head metres 1

Boiler temperature set point range °C 55 to 75

Boiler temperature cut out point °C 80

Minimum return temperature °C 40

Water system overheat cut-out temperature °C 100

Electrical supply - ~230V 1ph 50 Hz 5A fused

Maximum operating pressure - sealed system bar 2.0

Maximum operating pressure - open system bar 2.0

Maximum operating pressure - pressure relief valve bar 2.5

Flue length - minimum metres 1.4

Flue length - maximum metres 12.0

Ignition element rating Watts 283

Efficiency - full load (condensing)* % 101.5

Efficiency - par t load (condensing)* % 97.5

Combustion gas temperature - maximum output °C 56

Combustion gas temperature - minimum output °C 47

Combustion gas mass flow rate - maximum output m³/h 66

Combustion gas mass flow rate - minimum output m³/h 26.35

Safety charge pipe thermostat cut-out temperature °C 90

Total boiler starting current Amps 2.5

Total boiler running current Amps 0.45

Weight of boiler - including water content and full pellet hopper kg 380

Weight of boiler - excluding water content and empty pellet hopper kg 265

Integral pellet hopper capacity kg 80

Weight of side store (optional) - full pellet hopper kg 220

Weight of side store (optional) - empty pellet hopper kg 80

Side pellet store hopper capacity (optional) kg 140

* Refer to Section 1.1

Btu/h

16.2

55,300

4.5

15,300

Section 2: Technical DataPage 8

Page 9

2.2 Burner Settings

868

MAX flame MIN flame

Model

4-16 1.7 sec 3.0 sec

Notes *Heat input is based on a calorific value of 4.81 kWh/kg. Heat input and output data given above is approximate only. All burner settings must be checked as part of commissioning and ser vicing. Refer to Section 9.6 for full details of the burner settings and how to access, check and, where necessary, how to adjust them.

Burner setting

TIME

LOAD

MAX

TIME

PAUSE

MAX

Heat

output

(Btu/h)

16.2

(55,300)

Heat input

(Btu/h)

17.2

(58,700)

Full eff.

101.5 3.53

Input

kg/hr*

Draught CO

mbar

(in.wg)

0.75 - 1.25 (0.30 - 0.5)

8-12 14.0 sec

Burner setting Heat output

TIME PAUSE

MIN

(Btu/h)

4.5

(15,400)

2.3 Flue Gas Analysis

As part of both the commissioning and servicing procedures, the CO2 content of the flue gases must be checked.

There is no combustion test point on the boiler. A test point (and flue inspection hatch) is provided in the Inspection Pipe (product code: WPBOM/IP) that MUST be fitted to the boiler flue outlet.

To gain access to this test point, the circular outer cover must be removed. To do this, turn the knob in the centre of the outer cover approximately one turn anticlockwise and pull the cover away from the inspection pipe. The combustion test point is located immediately below the flue inspection hatch. Refer to Figure 11-11.

Unscrew and remove the test point screw to insert the combustion analyser probe.

Replace the outer cover using the reverse procedure, turning the knob approximately one turn clockwise to secure the cover in place.

Always replace the test point screw and outer access cover following combustion testing. Do not overtighten test point screw.

Use only a calibrated flue gas analyser with a ‘Wood Pellet’ fuel setting. Setting the fuel to any thing other than wood pellets will give an incorrect reading.

To ensure correct combustion, the burner settings given in the table (in Section 2.2) must NOT be changed unless instructed to do so by Grant UK.

NOTE

2.4 Clearances and Dimensions

2.4.1 Clearances

Clearances

Right hand side 150 mm

Left hand side 400 mm

Front 850 mm

Rear 30 mm

2.4.2 Dimensions

Refer to Figures 2-1 to 2-7.

868

119

868

1843

1657

Figure 2-1: Boiler dimensions - left side view

Figure 2-2: Boiler dimensions - top view

Section 2: Technical Data Page 9

Page 10

868

870

119

1843

868870

LEFT SIDE

VIEW

1843

1657

868

TOP

VIEW

868870

141

132

1216

FRONT

VIEW

LEFT SIDE

VIEW

1340

196 119

1843

TOP

VIEW

868

119

196

1340

1216

141

Figure 2-3: Boiler dimensions - front view Figure 2-4: Boiler dimensions - rear view

793

112

132

Figure 2-5: Boiler dimensions - right side view

1552

216 682

150

114

265

804

150

260312

Figure 2-6: Boiler dimensions - top view of base

NOTE

1341

1216

Figure 2-7: Boiler and side store dimensions - front view

When the side store lid is open, it is the same height as the boiler lid open, i.e. 1,843 mm.

Section 2: Technical DataPage 10

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3 Pellet Specification

3.1 Pellet Specification

Grant Vecta boilers are designed to ONLY run on EN Plus Grade A1 wood pellets that comply with BS EN ISO 17225-2:2014 and meet the following criteria. Failure to use approved pellets will invalidate the product guarantee.

Proper ty class Unit Limits as per BS EN ISO 17225-2

Origin and source

Diameter (D)

Length (L) 6 ± 1

Moisture (M) w-% ≤ 10

Ash (A) w-% dry ≤ 0.7

Mechanical durability (DU) w-% ≥ 97.5

Fines (F)

Additivies

Net calorific value (Q)

Bulk density (BD)

w-% ≤ 1.0

w-%

MJ/kg or ≥ 16.5

kWh/kg ≥ 4.6

kg/m

Chlorine (Cl) w-% dry ≤ 0.02

1.13 Stemwood

1.2.1 Chemically treated wood residues

3.15 < L ≤ 40

≤ 2 Type and amount to be stated

≥ 600

The following terms are commonly used when describing the properties of wood pellets:

Additives

Ash

Average length To provide a predictable flow of fuel into the burner, the recommended length of a pellet is between 3.15 and 40mm.

Bulk density

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 6mm only.

Fines

Mechanical durability

Moisture content

Net calorific valve

Nitrogen and sulphur High levels of Nitrogen and Sulphur in the flue gases emissions can give rise to corrosion.

Footnotes

Negligible levels of glue, grease and other timber production additives used in sawmills during production of timber and timber product from virgin wood are

acceptable, if all chemical parameters of the pellets are clearly within the limits and/or concentrations are too small to be concerned with.

At factory gate in bulk transport (at time of loading) and in small (up to 20kg) and big bags (at time of packing) or when delivering to end-user.

Type of additives to aid production, deliver y or combustion.

It is recommended actual value of bulk density to be stated.

Additives are used to improve the stability of the pellets. If manufactured correctly, and of a suf ficiently low moisture content, quality pellets will require no additives.

Ash represents the non-combustible content of the pellet. Higher ash content reduces the calorific value of the pellet and requires the appliance to be cleaned more frequently.

Bulk density is the ratio bet ween 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

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 qualit y 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 go od quality pellet.

Moisture affects the calorific value of the pellet. Low moisture content guarante es 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.

3.2 Biomass Suppliers List

The Biomass Suppliers List (BSL) is a list of suppliers of wood fuel who have been accredited as demonstrating that their fuel meets the sustainability criteria required under the RHI.

Recipients of the Domestic RHI will be obliged to source their fuel from suppliers on the BSL unless they are supplying themselves.

To find an approved supplier in your area go to w ww.biomass-suppliers-list.service.gov.uk/find-a-fuel

Section 3: Pellet Specification Page 11

Page 12

4 Installation Information

4.1 Boiler Location

The Grant External Vecta wood pellet boiler must be installed externally, either against the building or ‘free standing’ some distance away from the building. Refer to Section 7.7.

If the ‘free standing’ option is chosen, then the boiler flue system must be at least 2,300mm away from any buildings or structure that are higher than the flue outlet. Refer to Section 7.7.

If this distance cannot be achieved, then the External Vecta boiler will have to be located with the back of the enclosure close to or against the building and the flue system extended such that the terminal is above the eaves of the roof. Refer to Section 7.7.

The Grant External Vecta boiler must be positioned such that sufficient clearance is provided for maintenance, servicing and filling the pellet hopper. In the par ticular, the following minimum clearances are required around the External Vecta:

• Front: 850mm (to open the hinged front door to commission or service the boiler)

• Left hand side: 400mm (to access the PCB, water and condensate connections)

• Right hand side: 150mm (to access pellet hopper for filling with pellets)

• Rear: 30mm

The Grant External Vecta boiler must stand on a solid, level, noncombustible surface capable of supporting both the weight of the boiler when full of water and the pellet hopper is full of pellets. Refer to Section 2 for weights.

Grant recommends a prepared concrete standing (at least 150mm thick) with a smooth finish on the top ex tending beyond the enclosure base at least 100mm all around. Refer to Section 2.4 for boiler dimensions.

4.2 Regulations

Installation of a Grant Vecta wood pellet boiler must be in accordance with the following:

• National Building Regulations and any local Byelaws.

• Model Byelaws and the Water Supply Regulations.

The installation should also be in accordance with the latest edition of the following standards and codes of Practice:

• BS 715:2005 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. Heating systems in buildings. Method for calculation of the design heat load.

• BS EN 14336: 2004. Heating systems in buildings. Installation and commissioning of water based heating systems.

• BS 7593:2006 Code of Practice for treatment of water in heating systems.

• BS 7671:2008 Requirements for electrical installations, IET wiring regulations.

• ONORM M7137 standard should be used as a guideline for DIY bulk storage units.

4.3 Heating System

Before star ting any work on the boiler or fuel supply please read the Health & Safet y information given in Section 17.

To achieve the ma ximum efficiency possible from the Grant Vecta condensing wood pellet boiler, the heating system should be designed to the following parameters:

Radiators

• Flow temperature 70°C

• Return temperature 50°C

• Differential 20°C

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 55°C.

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

•Flowtemperature50°C

•Returntemperature40°C

•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 ‘primary’ jacket.

Open Vented Systems

The presence of ‘pumping over’ in an open vented heating system connected to the Grant Vecta boiler will invalidate the product guarantee.

Open vented systems must be correctly designed and installed. The open safety vent pipe must be positioned to prevent ‘pumping over’ (i.e. the discharge of water from the open safety vent pipe into the feed and expansion cistern under the pressure created by the circulator).

For detailed information on the correct design of open vented heating systems, and the correct location of the open safety vent pipe, refer to the CIBSE Domestic Heating Design Guide.

WARNING

NOTE

Failure to install and commission the appliance correctly will invalidate the boiler guarantee.

NOTE

Section 4: Installation InformationPage 12

Page 13

4.4 Pipework Materials

The Grant Vecta boiler is 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 7291-1:2010) for the application concerned.

On either sealed or open-vented systems; where plastic pipe is used a minimum of ONE metre of copper pipe (or as per pipe manufacturers instructions) MUST be connected between both the boiler flow and return connections and the plastic pipe.

Do not connect plastic pipe directly to the boiler.

Grant does 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 7291-1:2010.

NOTE

The flow and return connections are located on the left hand side of the boiler. Refer to Figure 4-1. Both connections are supplied fitted with 22mm Tectite elbow connectors.

Two 150mm diameter pre-cut ‘knock-out’ openings are provided for flow and return pipes and also the condensate disposal pipe. Refer to Figure 4-1:

• One is located in the lower left corner of the boiler back panel

• The other is located in the base of the boiler

The flow and return pipes can pass downwards and then to the rear of the boiler, through the opening in the boiler back panel and then through the wall and into the building.

Alternatively, if required, the flow and return pipes can pass downwards and through the opening in the base of the boiler to pass underground and into the house.

It is NOT possible to have the flow and return pipes (or condensate pipe) passing through either the right or lef t hand side of the boiler casing.

NOTE

The system MUST incorporate a 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 (product code: MPCBS63).

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.

WARNING

4.5 Connections

4.5.1 Flow and return connections

Flow

Return

4.5.2 Condensate Connection

The boiler is supplied with the condensate trap factory-fitted. Refer to Section 5.5. This trap is located inside the boiler casing and is accessed by removing the side access panel on the left hand side of the boiler. Refer to Section 1.3 for details.

Refer to Section 5 for details on the condensate disposal pipework.

4.5.3 Drain Cock

A drain cock is factory fitted to enable the draining of the boiler. This is located at the rear of the water jacket and accessed by removing the side access panel on the left hand side of the boiler. Refer to Figure 4-2.

To enable draining of the system, a suitable drain cock must be fitted at the lowest point of the heating system.

Rear

opening

Base

opening

Figure 4-1: Location of flow and return connections and openings in rear panel and base

Figure 4-2: Location of drain cock (left hand side and rear panel removed for clarity)

Section 4: Installation Information Page 13

Page 14

4.6 Wash System

The Grant Vecta condensing boiler is supplied with an automatic cleaning system to wash any ash build up from the tubes of the condensing (secondary) heat exchanger.

This factory fitted wash system consists of two spray jets, mounted on the heat exchanger access cover, connected by a manifold pipe located on the upper side of the cover. Refer to Figure 4-3.

Figure 4-3: Location of wash system in top of boiler

This is fed with mains cold water via a solenoid valve located in the left side of the boiler. This is connected to the manifold by a flexible hose and isolating valve (with integral check valve). Refer to Figure 4-3.

Connect the mains water supply for the wash down system to the 15mm compression connection located at the bottom rear corner of the left side panel.

Connect the mains water supply for the wash system to the 15mm compression connection on the water solenoid valve. This is located at the side of the primary heat exchanger on the left hand side of the boiler and accessed by removing the access panel on the left hand boiler side panel.

The appliance must not be connected to the mains water supply via a flexible hose.

A minimum inlet water pressure of 100 kPa (1 bar) is required to maintain an adequate supply for cleaning purposes. The maximum inlet water pressure is 800 kPa (8 bar).

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.

NOTE

4.7 Before you Commission

To avoid the danger of dir t 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 impor tant where the boiler is to be installed on an older 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 Sentinel X300 (new systems), Sentinel X400 (existing systems), or Fernox Restorer.

After cleaning, it is vitally important that all traces of the cleaner are thoroughly flushed from the system.

For long term protection against corrosion and scale, after cleaning/ flushing a suitable inhibitor should be added to the system water, such as Sentinel X100 or Fernox MB-1, in accordance with the manufacturers’ instructions.

Failure to follow the above will invalidate the guarantee.

In order to provide further protection should there be a power failure in cold weather, a combined anti-freeze and corrosion inhibitor can be used such as Sentinel X500 or Fernox Alphi-11. Follow the manufacturers’ instructions supplied to achieve the level of anti-freeze protection required.

For details of the Sentinel Products visit www.sentinel-solutions.net and for Fernox products visit www.fernox.com.

A Grant Mag-One in-line magnetic filter/s (or equivalent*) must be fitted in the heating system pipework. This must be installed and regularly ser viced in accordance with the filter manufacturers’ instructions.

* As measured by gauss. The Mag-One magnetic filter has a gauss measurement of 12000

4.8 Completion

Please ensure that the Grant Vecta 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 to register the installation of the boiler.

Ensure that the user guide (supplied with the boiler) is handed over to the householder along with this Installation and Servicing manual.

4.9 ‘Meter Ready’ Installations

Grant Vecta wood pellet boiler installations that are receiving a Domestic Renewable Heat Incentive (RHI) payment will not usually require a heat meter to be fitted.

However, all such domestic RHI installations must be ‘meter ready’ in accordance with MCS requirements. Refer to the MCS Domestic RHI Metering Guidance Document for full details.

Section 4: Installation InformationPage 14

Page 15

Figure 4-4: Water connection to wash system (via flexible hose from solenoid valve)

Section 4: Installation Information Page 15

Page 16

5 Condensate Disposal

5.1 General Requirements

When in condensing mode the Grant Vecta 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:

• into a soil stack – either directly or via an existing waste system

• into an gulley

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 or hopper.

Every Grant Vecta boiler is supplied with a trap and this MUST be used. Refer to Section 5.5 for trap details.

MCS Product Certification Scheme Requirements for Biomass (MCS

008) state that:

“Because of the volume of wash-down/condensate discharge, it is NOT recommended to discharge into a purpose-made soakaway.”

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 can be connected directly into waste/soil systems connected to septic tanks, providing a neutraliser has been installed.

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.

When using a condensate pump and holding tank, the Boiler control set ting for ‘Clean Boiler’ (time between boiler cleaning operations) must not be set less than 480 minutes. Changing this setting could result in a more frequent wash down of the boiler which could exceed the capabilities of the tank and condensate pump.

The ‘Max Cleaning Time’’ (maximum time boiler cleaning is in operation) is factory set at 60 seconds.

Refer to Section 9 for further details on boiler control settings.

WARNING

5.4 External Pipework

Ideally, external pipework, or pipework in unheated areas, should be avoided. If unavoidable, external pipework should be kept as short as possible (less than 3 metres) and 38mm (1½”) 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.

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 Vecta boiler must have a minimum ‘nominal’ diameter of 32mm (1 ¼”) 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 (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 into a waste system or to a gulley, it will be necessary to use a condensate pump.

When using a condensate pump with a Grant Vecta 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 system 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. This must be located indoors.

NOTE

Section 5: Condensate DisposalPage 16

Page 17

5.5 Condensate Trap

The boiler is supplied with a factory-fitted condensate trap. This trap is located inside the boiler casing and is accessed by removing the side access panel on the left hand side of the boiler.

Only this trap must be used with the Vecta boiler. No alternative trap should be used as it will not give the required depth of water seal. The trap is designed to be fitted as supplied, i.e. inside the boiler casing on the left hand side only.

Two 150mm diameter pre-cut ‘knock-out’ openings are provided in the boiler enclosure for the condensate disposal pipe (and also the flow and return pipes). Refer to Figure 4-1.

• One is located in the lower left corner of the boiler back panel (as viewed from the front)

• The other is located in the base of the boiler

The condensate disposal pipe can pass downwards from the trap outlet and then to the rear of the boiler, through the opening in the boiler back panel. It can then run either to an external gulley or external soil pipe or it could pass through the wall and into the building to connect to an internal waste system or soil pipe.

Alternatively, if required, the condensate disposal pipe can pass downwards from the trap outlet, through the opening in the base of the boiler, and run underground and into soil pipe or waste system.

If the waste system for the property concerned is connected to a septic tank an in-line Condensate Neutraliser should be fitted in the condensate disposal pipe.

To connect the disposal pipe to the trap

To gain access to the condense trap:

• Unlock/ remove the padlock (if fitted) to the door catch on the side access panel

• Rotate the door catch knob to unlatch and remove the side access panel.

Carefully press out the required pre-cut hole in either:

• The lower left corner of the boiler back panel

• The base of the boiler (directly below the condensate trap)

Adjust the outlet position of the trap to suit the required route of the disposal pipe.

Pass the 32mm (1¼”) plastic waste pipe through the opening in the enclosure (either the back panel or base, as required).

Fit the end into the trap outlet and tighten the connector to secure the pipe in place.

NOTE

Figure 5-1: Condensate trap

5.6 Inspection and Cleaning of Trap

The boiler condensate trap must be checked at regular intervals (e.g. on every service) and cleaned as necessary to ensure it is clear.

With the trap removed, also check the condensate outlet of the heat exchanger. Ensure it clear and remove any debris as necessar y.

Failure to regularly check and clean the condensate trap may result in damage to the boiler and this will not be covered by the product guarantee.

CAUTION

All condensate pipework must be adequately protected against freezing.

Section 5: Condensate Disposal Page 17

CAUTION

Page 18

6 Sealed Systems

5 6

Static head of system

6.1 Sealed System Requirements

1. Expansion vessel

2. Pressure gauge

3. Pressure relief valve

4. Tundish

5. Removable filling loop

6. Double check valve

7. Automatic air vent

8. HW/HTG zone valves

9. Thermostatic radiator valve

10. Automatic bypass

11. Drain point

Figure 6-1: Sealed heating system components

All Grant Vecta boilers are suitable for use with sealed systems complying with the requirements of BS EN 12828:2003, BS EN 12831:2003 ad BS EN 14336:2004.

The system must be provided with the following items:

• Diaphragm expansion vessel complying with BS EN 13831:2007

• Pressure gauge

• Pressure relief (safety) valve

• Approved method for filling the system

6.1.1 Expansion 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, 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 the expansion vessel is connected via a flexible hose, care must be taken to ensure that the hose is not twisted.

Ensure that the expansion vessel used is of suf ficient size for the system volume. Refer to BS 7074:1:1989 or The Domestic Heating Design Guide for sizing the required vessel.

NOTE

6.1.2 Pressure Gauge

The pressure gauge must have an operating range of 0 to 4 bar.

It must be located in an accessible place next to the filling loop for the system.

6.1.3 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 damage to property.

6.1.4 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 af ter filling the system.

6.1.5 Heating System

The maximum ‘setpoint’ temperature for 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 bypass must be fitted. The by-pass must be an automatic type.

All fittings used in the system must be able to withstand pressures

Section 6: Sealed SystemsPage 18

Page 19

up to 3 bar. Radiator valves must comply with the requirements of BS 2767:1991.

One or more drain taps (to BS 2879) must be used to allow the system to be completely drained.

11. Close the fill point and double check valves either side of the filling loop and disconnect the loop.

12. Check the system for water soundness, rectifying where necessary.

6.2 Filling the Sealed System

Filling of the system must be carried out in a manner approved by the local Water Undertaking.

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. Check the air charge pressure in the expansion vessel BEFORE filling the system.

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). Refer to Figure 6-1.

The charge pressure must not be less than the actual static head at the point of connection.

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.

WARNING

NOTE

6.3 Venting the Pump

For those heating circulating pumps fitted with a vent plug, it is important that the pump is properly vented to avoid an air lock and also prevent it running dry and damaging the bearings.

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 over tighten.

Some heating circulating pumps are not fitted with a vent plug so it is not possible to vent these pumps in the manner described above. Refer to pump manufacturers own instructions for further details.

NOTE

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 anticlock wise 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. Top-up the system pressure, as necessary.

Check that the small cap (or screw) on all automatic air vents is open at least one turn. The cap (or screw) remains in this position from now on.

2. Open the hinged hopper lid. Undo the t wo screws (one on the right and one on the left) and remove the access cover from the top of the boiler.

Pull out the air vent tube so that it will discharge any water outside the boiler and have a small container available to catch this water. Open the manual air vent located under the access cover. Refer to Figure 6-2.

3. Ensure that the flexible filling loop is connected and that the double 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.

4. Open the fill point valve.

5. Gradually open the double check valve from the water supply until water is heard to flow.

6. When the needle of the pressure gauge is between 0.5 and 1.0 bar, close the valve.

7. Vent each radiator in turn, starting with the lowest one in the system, to remove air.

8. 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.

9. Repeat steps 7 and 8 as required until system is full of water at the correct pressure and vented.

10. Water may be released from the system by manually operating the safety valve until the system design pressure is obtained

Figure 6-2: Location of manual air vent (wash system removed for clarity)

Section 6: Sealed Systems Page 19

Page 20

7 Flue System and Air Supply

7.1 Air Supply

The Grant External Vecta wood pellet boiler draws air for combustion from the surrounding atmosphere. The combustion air inlet to the boiler is provided by the gap along the bottom edge of the hinged front door. This opening must not be blocked off or obstructed in any way. Refer to Figure 7-1.

Boiler air inlet

Figure 7-1: Boiler air inlet

7.2 Flue Terminal Position and Clearances

The Grant External Vecta wood pellet boilers have high operating efficiencies and low flue gas temperatures. Only the Grant ‘Biomass’ insulated twin-wall flue system can be used with the Grant External Vecta boiler.

The flue installation must be in accordance with the requirements of The Building Regulations Approved Document J – Section 2: Appliances burning solid fuel.

The following points MUST be taken into consideration with regard to the design and installation of the flue system:

• The flue system must include the Inspection Pipe (product code: WPBOM/IP) , which should be fitted directly to the flue outlet of the boiler. This incorporates both a combustion test point and a flue inspection hatch. Refer to Section 7.4.5.

• Grant recommends that the flue is vertical for a minimum distance of 600mm (measured from the top of the boiler) before any elbow. However, this is not essential for the operation of the boiler.

• There must NOT be any change of direction greater than 45° from the vertical, e.g. two 45° elbows must NOT be used together to form a 90° elbow.

• The flue system must NOT include any horizontal sections of flue.

• Grant recommends that an adjustable flue extension be fitted in

the flue system as close to the boiler as possible, to enable the flue system to be disconnected from the boiler flue connection, as and when required, for future boiler maintenance.

• The weight of the flue system must NOT be carried by the boiler, but must be supported using the various support options available in the Grant ‘Biomass’ flue system. Refer to Section

7.4.4.

• The minimum distance between the outer surface of any part of the flue system and any combustible material is 60mm. Refer to Section 7.3 for flue system designation. A minimum clearance of 25mm around the flue is required for the fitting/removal of locking bands.

• 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. The flue outlet positions shown in Figure 7-2 (from Approved Document J) can meet this requirement.

• The heights and separation distances shown in Figure 7-2 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.

• No other appliance can be connected to the boiler flue.

• Any condensate in the flue can run back into the boiler. A

condensate drain at the base of the flue system is not required as the flue system is designed to allow the condensate to run back into the boiler.

NOTE

Section 7: Flue System and Air SupplyPage 20

Page 21

Adjacent

building

Regulated building

Figure 7-2: Flue terminal positions

Point where flue passes through weather surface (Notes 1, 2) Clearances to flue outlet

A At or within 600mm of the ridge At least 600mm above the ridge

At least 2300mm horizontally from the nearest point on the weather surface and:

B Elsewhere on a roof (whether pitched or flat)

Below (on a pitched roof) or within 2300mm horizontally to an openable

rooflight, dormer window or other opening (Note 3)

Within 2300mm of an adjoining or adjacent building, whether or not

beyond the boundary (Note 3)

Notes

1. The weather surface is the building ex ternal surface, such as its roof, tiles or ex ternal walls.

2. A flat roof has a pitch less than 10°.

3. The clearance given for A or B, as appropriate, will also apply.

4. A ver tical flue fixed to an outside wall should be treated as equivalent to an inside flue emerging at the nearest edge of the roof.

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 any part of the adjacent building within 2300mm.

The above clearances are as specified in Building Regulations Approved Document J. Also refer to Approved Document J of either the England and Wales Building Regulations for further requirements on the installation of flue systems for solid fuel appliances.

7.3 Flue System Specification

The Grant ‘Biomass’ 125mm (5in) flue system is a fully insulated stainless steel t win-wall flue finished with either a Black or White 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 CE designation of this flue system (to EN1856-1) is:

T450 N1 W V2 L50 050 G 60

Where:

• T450 (Temperature rating) - 450°C maximum temperature for continuous operation

• N1 (Pressure rating) - Negative pressure

• W (Condensate resistance) - Able to contain condensate within the flue

• V2 (Corrosion resistance) - Resistant to attack from products of combustion from natural wood

• L50 (Liner material) - 316L stainless steel

• 050 (Material thickness) - 0.5mm

• G (Soot fire resistance) - Tested at 1000°C for 30mins

• 60 (Distance to combustibles) - 60mm minimum clearance is required from combustibles

Masonry chimneys MUST be lined using the 125mm stainless steel flexible ‘smoothbore’ liner – available as part of the Grant ‘Biomass’ flue system. Refer to Section 7.4.9.

Section 7: Flue System and Air Supply Page 21

Page 22

7.4 Flue System Assembly

Male collar

7.4.1 Boiler Flue Connection

The Grant External Vecta boiler is supplied with a flue outlet located on the top of the boiler in the rear left corner and is designed to fit the Grant ‘Biomass’ flue system. Refer to Figure 7-3.

Figure 7-3: Boiler flue connection

The flue system must include the Grant Inspection Pipe (Grant Ref. WPBOM/IP), which should be fitted to the outlet of the boiler. This incorporates both a combustion test point and a flue inspection hatch. Refer to Figure 7-4 and also Section 7.4.5.

Figure 7-4: Inspection pipe

When fitting the flue to the boiler flue outlet, the lip seal supplied with the flue component must be fitted into the groove around the inside surface of the flue, and the locking band fitted to secure the joint.

NOTE

Figure 7-6: Twist lock joint between components

To join two components together:

All flue joints must have a lip seal gasket fitted. This seal is supplied with the flue component.

To temporarily assemble the flue system components, to check component lengths, alignment of connections, etc. DO NOT fit the lip seals. However, for FINAL assembly the lip seals provided MUST be fitted at EVERY joint.

First fit the lip seal supplied into the groove (in the inner flue liner) at the ‘male collar’ end of the flue component. Refer to Figure 7-5. The lip seal should be fitted ‘dry’, i.e. with no lubricating grease applied at this stage. The lubricating grease (also supplied with the component) should be applied to the seal after it is fitted but before fitting the two flue components together.

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 7-6.

Ensure that the two beaded ends of the flue components are in contact with each other all round. Position the locking band and 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 7-7.

To allow for alignment, the female collars of the elbows do NOT have the twist lock flutes, but the locking band MUST still be used to secure the two flue components together.

The Inspection Pipe should be positioned such that the cover plate faces to the left, not towards the right or front of the boiler.

7.4.2 Joining Components

All the ‘Biomass’ system twin-wall flue components (with the exception of the elbows) use a ‘twist lock’ jointing system. The ‘male collar’ end of the flue component MUST always be uppermost when fitted.

Insulation

Female collar

Figure 7-5: Male and female flue connections

Viton gasket seal detail

Locking band

Figure 7-7: Fitting of locking band

Section 7: Flue System and Air SupplyPage 22

Page 23

7.4.5 Flue Inspection Pipe (product code: WPBOM/IP)

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.

7.4.3 Adjustable Length

The Grant ‘Biomass’ flue system includes an Adjustable flue extension. Refer to Section 7.9. This allows any of the straight flue extension components to be extended in length by between 00mm to 230mm (this does not apply to the 200mm extension). This adjustable extension must be used in conjunction with any straight extension (1000mm, 500mm, 333mm or 200mm) to achieve the actual straight length required.

To fit the adjustable ex tension, 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.

The adjustable section is NOT loadbearing, therefore adequate support of the flue system MUST be provided immediately above the adjustable extension.

7.4.4 Support Components

The weight of the flue system is considerable. It must NOT be carried by the flue connection on the appliance, but requires independent support using one or more of the various flue support options available in the Grant ‘Biomass’ flue system.

Intermediate Top Plate (product code: WPB/TP)

Flue systems running up against an external wall surface can be supported using the Intermediate Top Plate. This is mounted on either a pair of Wall Support Side Plates (product code: WPB/WS or WPB/ WS) or a pair of Cantilever brackets (product code: WPB/CANT), 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 twistlock connection into the flue above. Both joints are secured using the clamp bands provided.

Wall Brackets (product codes: WPB/WB60 and WPB/WB300)

Both the Wall bracket and the Adjustable Wall Bracket (Grant Ref. WPB/WB60 and WPB/WB300) are NOT load-bearing but are designed to give lateral support only. Wall 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.

WARNING

NOTE

Failure to maintain a clean flue can result in the emission of flue gases into the dwelling or damage from fire in the flue. Refer to Section 11.4.

The Building Regulations Approved Document J requires a flue system to have the means to be inspected and cleaned as required. To meet this requirement, a Flue Inspection Pipe incorporating an inspection hatch and combustion test point is available as part of the Grant ‘Biomass’ flue system. This must be fitted directly to the boiler flue connector with the inspection hatch facing to the LEFT.

7.4.6 Elbows

Two elbows are available - 30° (product code: WPB/30) and 45° (product code: WPB/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.

There should be no more than 2 elbows – of maximum angle 45° from the vertical – fitted between the inspection hatch of the flue Inspection pipe (at the boiler) and the terminal. This can be increased to a maximum of four elbows (maximum 45°) bet ween the boiler and terminal if there is a second flue Inspection Pipe fitted between the second and third elbows. Any Inspection hatch must be accessible for checking and cleaning purposes.

Roof Cowl (product code: WPB/RC)

The Rain Cap type terminal is fitted either directly to the Intermediate Top Plate on the top of the flue or, if necessar y (i.e. to achieve the required distance between the terminal and the roof surface), to a length of flue that is, in turn, connected to the Intermediate Top Plate.

Fit the Terminal to either the Intermediate Top Plate or flue extension and twist through 1/6 of a turn to lock in place. Ensure that the locking band (supplied with the terminal) is correctly fitted to secure the terminal in place. Refer to Section 7.4.2 for further details on connecting the flue components.

WARNING

7.5 Flue Testing

Once installed, the flue system should be tested in accordance with the requirements of The Building Regulations Approved Document J, Appendix E, Section E13 – Smoke Test I.

7.6 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-adhesive notice plate is supplied with the Grant ‘Biomass’ flue system and this must be completed by the installer and displayed in an unobtrusive but obvious position within the building concerned, e.g. on the inside of the boiler door.

Structural Locking Band (product code: WPB/LBEX T)

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 ex tended Structural locking band at the joint immediately below, and at every joint above, the last flue support.

Section 7: Flue System and Air Supply Page 23

Page 24

7.7 Typical Flue Systems

Rain cap

600

Minimum

Cantilever

45° bend

Inspection pipe facing left (when viewed from front of boiler) for ease of access.

Adjustable extension

Section 7: Flue System and Air SupplyPage 24

Page 25

Minimum

Additional access

before second offset

Rain cap

600

Adjustable extension

Wall bracket

Extension

Wall support side plate

Inspection pipe facing left (when viewed from front of boiler) for ease of access.

Adjustable extension

Section 7: Flue System and Air Supply Page 25

Page 26

1400

Minimum

2300

Minimum

Section 7: Flue System and Air SupplyPage 26

Page 27

7.8 Flue System Component Dimensions

Ø125 Ø180

Nominal length

200mm

333mm

500mm

1000mm

Straight pipe lengths (mm)

Product code Nominal length Ef fective length

WPB/EXT200 200 160

WPB/EXT333 333 293

WPB/EXT500 500 460

WPB/EXT1000 1000 960

Adjustable

75 - 250mm

Complete with locking band. Telescopes over pipe below. Minimum engagement should be half the diameter. This component is NOT load-bearing.

WPB/ADJ250 and

Adjustable pipe length (mm)

Product code Nominal length Ef fective length

WPB/ADJ250 75- 250 mm 50 - 230mm

Straight and adjustable pipe lengths (mm)

Product code

WPB/EXT200

WPB/EXT333

WPB/EXT500

WPB/EXT1000

Minimum Ma ximum

350 440

393 573

560 740

1060 1240

Effective length

Ø125 Ø180

Section 7: Flue System and Air Supply Page 27

Page 28

Double 30° bend and straight pipe length (mm)

Effective

length

960 A / B 1061 / 542

460 A / B 628 / 292

293 A / B 483 / 208

160 A / B 368 / 142

Double 45° bend and straight pipe length (mm)

Effective

length

960 A / B 933 / 784

460 A / B 580 / 431

293 A / B 462 / 313

160 A / B 367 / 218

Dimension Length

7.9 Flue System Components

WPB/WB300 - Wall bracket (50 - 300mm)

WPBOM/IP - Inspection pipe

WPB/WB60 - Wall bracket (60mm)

WPB/CANT - Cantilever (570mm)

Section 7: Flue System and Air SupplyPage 28

Page 29

WPB/WS - Wall support side plate

WPB/RC - Rain cap

WPB/TP - Intermediate top plate

WPB/LBEXT - Structural locking band

Section 7: Flue System and Air Supply Page 29

Page 30

8 Electrical

8.1 General Requirements

The Grant External Vecta wood pellet boiler requires a ~230V 1ph 50 Hz electrical supply. The unit must be connected to a mains power supply that is protected by a 5A fuse.

As a stationary appliance not fitted with a means for disconnection from the supply mains having a contact separation in all poles that provide full disconnection under overvoltage category III, means for disconnection must be incorporated in the fixed wiring in accordance with the wiring rules.

A fused double pole switch, with contact separation of at least 3mm in both poles, should be used for connection to the mains electrical supply, serving the boiler and heating system controls only.

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 – IET Wiring Regulations 17th Edition (including all amendments).

All the wiring and supplementary earth bonding external to the boiler must be in accordance with the above mentioned wiring regulations.

Any heating system controls, e.g. room thermostat, frost thermostat, etc. connected to this boiler must be suitable for use on mains voltage.

The boiler requires a permanent mains supply and switched live (for the heating and hot water control) to operate the boiler. For details of heating and hot water system controls refer to Sections 8.5 and 8.6.

Do NOT interrupt the permanent supply to the hopper/boiler with any external controls.

WARNING

8.2 Boiler Electrical Connections

All the electrical connections (permanent mains supply and switched live from the heating control system) to the boiler are made via the terminal block in the lower left corner of boiler. Refer to Figures 8-7 and 8-10.

To access the terminal block, the terminal block cover must be removed using the following procedure:

1. Open the front door of the boiler. First unlock and remove the padlock (if fitted), rotate the knob of the catch clockwise to unlatch and fully open the door.

2. Switch the electrical isolator to OFF. Refer to Figure 11-4.

3. Fit the multi-purpose tool (provided with the boiler) into the slot in the door catch. Refer to Figure 11-5.

4. Lift the tool handle to release the door catch and fully open the combustion chamber door of the boiler. Refer to Figure 11-6.

5. Undo the seven screws and remove the grey left hand cover panel from the boiler

6. Remove the side access panel from the left side of the boiler. Unlock/remove padlock (if fitted). Rotate the knob of the catch clockwise to unlatch and remove the access panel

Figure 8-1: Boiler terminal block location (cover removed)

7. Slacken and remove the four screws securing the PCB housing. Refer to Figure 8-2.

Figure 8-2: PCB housing screws

8. Carefully swing the PCB housing out from the side of the boiler casing. Refer to Figure 8-3.

Figure 8-3: PCB housing pivoted

9. It will be necessary at this point to remove the photocell from the mount on the left side of the boiler heat exchanger. Refer to Figure 8-4.

Figure 8-4: Removing the photocell

Section 8: ElectricalPage 30

Page 31

10. Locate the two terminal block cover fixing screws. Refer to Figure

LIVE

8-5.

Connect the mains supply to the boiler terminal block from left to right, as per Figure 8-7.

Figure 8-5: Terminal block cover fixing screws

11. Unscrew both screws and remove the cover from the boiler.

12. After making the electrical connections the terminal block cover must be re-fitted using the reverse of this procedure.

8.3 Remote Grant Logo Indicator Connections

The Grant logo indicator, supplied with the boiler, should be mounted on a standard electrical back box (either recessed or surface mounted) in a convenient and visible position within the house.

Using a suitable length of 0.75mm² 2-core PVC flex, connect the remote Logo indicator to the corresponding terminal block in the boiler. This terminal block is located to the lef t of the main boiler terminal block, at the front lower left corner of the boiler (behind the inner access cover). Refer to Figure 8-6 for electrical connection details.

When connecting the Remote Grant Logo Indicator, ensure that the terminal with the red wire on the boiler terminal block is connected to the terminal with the red wire on the logo indicator terminal block.

Likewise, ensure that the terminals with the black wire on both the boiler and logo indicator terminal blocks are connected together.

Black

Red

GRANT

VECTA

SWITCHED

LIVE

PERMANENT

LIVE

NEUTRAL

Figure 8-7: Boiler terminal block

If the 4-core flex bet ween the heating controls aand the boiler terminal block is damaged at anytime, it must be replaced by a comptent engineer in accordance with the requirements of the Electricity at Work Regulations 1989 and BS7671:2008 – IET Wiring Regulations 17th Edition (including all amendments).

NOTE

EARTH

SIDE STORE

NEUTRAL

EARTH

SIDE STORE

8.5 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 for typical control system wiring diagrams.

8.6 Frost Protection

The Grant External Vecta wood pellet boiler is supplied with a factoryfitted frost protection thermostat. This is pre-set to operate when the air temperature falls to 2°C.

This frost thermostat is located inside the PCB enclosure and is connected between the Terminal 2 and Terminal 3 on the boiler terminal block.

For details of the frost thermostat electrical connections refer to Figures 8-8 and 8-9.

Red

Black

Figure 8-6: Connection diagram for Remote Grant Logo Indicator

8.4 Connecting the Power Supply

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.

Use a suitable length of 4-core flex, at least 1.5mm2 PVC between the heating controls wiring centre or junction box and the terminal block in the boiler. Ensure that the flex passes through and is secured by the cable clamp next to the terminal block.

WARNING

In order for the frost protection thermostat to operate, ensure that a link is fitted between terminal 1 and the permanent live terminal on the boiler terminal block.

Grant recommends the use of a pipe thermostat (not supplied) in conjunction with the frost thermostat to avoid unnecessary and wasteful overheating of the property. This pipe thermostat should be located on the boiler return pipe and set to operate at 25°C.

To connect a pipe thermostat:

• Remove the factory fitted link between terminals 1 and 2 on the boiler terminal block.

• Connect the pipe thermostat between terminals 1 and 2 on the boiler terminal block.

Refer to the Figures 8-8 and 8-9 for details of the frost thermostat and pipe thermostat electrical connections.

For total system protection against freezing, particularly during extended periods without electrical power, Grant recommends the use of a combined heating system antifreeze and corrosion inhibitor, used in accordance with the manufacturer’s instructions.

NOTE

Section 8: Electrical Page 31

Page 32

8.7 S-plan type system connection diagram

2-Port Zone Valve

Motor

Room

Stat

2 1 3

Grant 2-Channel

Wall Mounted

Programmer ESKIT

240V

50HZ

L N E

2-Port Zone Valve

Motor

1 2 3 4 5 6 7 8 9 10

HTG

L 1 2

3 4

Wiring Centre

Grey Grey

Orange Orange

Brown

Blue

Green/Yellow

Brown

Blue

Brown

Blue

Green/Yellow

OFF OFF ON ON

HW HT HW HT

Cylinder

Stat

1 C 2

Blue

Green/Yellow

Brown

Pump

E N L

Vecta terminal block

Pipe Stat

(if fitted)

SWITCHED

LIVE

PERMANENT

LIVE

NEUTRAL

EARTH

SIDE STORE

NEUTRAL

SIDE STORE

EARTH

SIDE STORE

LIVE

Link

Frost Stat

(factory

fitted)

Link

Link*

Figure 8-8: Heating system controls - S-plan type system connection diagram

8.8 Y-plan type system connection diagram

Figure 8-9: Heating system controls - Y-plan type system connection diagram

240V

50HZ

L N E

Blue

Brown

L 1 2 3 4

OFF OFF ON ON

HW HT HW HT

Grant 2-Channel

Wall Mounted

Programmer ESKIT

Green/Yellow

Orange

Grey White

Cylinder

Stat

1 C 2

Room

Stat

2 1 3

1 2 3 4 5 6 7 8 9 10

Link

Frost Stat

(factory

fitted)

Pipe Stat

(if fitted)

Link*

Link

Vecta terminal block

Blue

Green/Yellow

SWITCHED

LIVE

Motor

13k2W270k

0.25W

3-Port Mid Position

Zone Valve

Wiring Centre

Brown

PERMANENT

LIVE

NEUTRAL

EARTH

Green/Yellow

Blue

SIDE STORE

NEUTRAL

* If a pipe stat is

fitted, please remove

the factory fitted link

between terminals 1

and 2

E N L

* If a pipe stat

is fitted, please remove the factor y fitted link between

SIDE STORE

EARTH

LIVE

terminals 1 and 2

Pump

Section 8: ElectricalPage 32

Page 33

8.9 Boiler Wiring Diagram

NOTE

Earth and some Neutral connections

have been excluded for clarit y.

All switches are shown in the closed

position.

Figure 8-10: Boiler wiring diagram

Section 8: Electrical Page 33

Page 34

9 Boiler Operation

9.1 General

The control system automatically regulates all aspects of the boiler operation including:

• Burner start up and shut sequences

• Output modulation

• Combustion

It also controls the automatic cleaning sequences for both the burner and heat exchanger(s) and indicates when a service is required. The automatic cleaning of the burner brazier and heat exchanger(s) is activated after the pellet feed auger running time has exceeded the period pre-set in the burner control settings. Refer to Section 9.3.

The boiler control panel (located on the front panel of the boiler) features a display screen and six control buttons. These buttons are used to access and adjust the boiler control parameters. Refer to Section 9.4.

The control system also has a diagnostic feature, where a fault code will be displayed on the control panel LCD. Refer to Section 12 – Fault Finding.

9.2 Modulation

Adjustable boiler control parameter numbers are shown in square brackets. Refer to Parameter Menu in Section 9.7.

The boiler has a ‘setpoint’ temperature. This is the target flow temperature from the boiler. The default ‘setpoint’ temperature is 75°C, but this can be adjusted by the installer if required. The boiler temperature is monitored by a thermistor located in the water jacket of the boiler and this is used by the control system to control the modulation of the boiler output.

When a demand from the heating system controls is detected and the ON/STANDBY switch is set to ON, the circulating pump runs and the boiler control checks that the boiler water temperature is cool enough for the boiler/burner to start. The boiler water temperature must be at least the ‘Hysteresis On’ temperature value below the ‘Set Point’ (i.e. boiler temperature < ‘Set Point’ – ‘Hysteresis On’).

If not, the circulating pump continues to run and the boiler water temperature checked until the conditions to start the boiler/burner are met.

Figure 9-1: Boiler modulation

Figure 9-2: Pellet auger modulation

Section 9: Boiler OperationPage 34

Page 35

The boiler water temperature is continually monitored during boiler operation. If it exceeds ‘Hysteresis On’ temperature plus ‘Set Point’ temperature (i.e. boiler temperature > ‘Set Point’ + ‘Hysteresis On’), OR the ‘Temp Off H2O’ value, the boiler/burner will stop operating.

The boiler water temperature will now have to drop to below the ‘Set Point’ – ‘Hysteresis On’ temperature before the boiler/burner will operate again.

There is a pre-set ‘Temp Delta’ value (5°C). This gives the temperature band above and below the ‘Set Point’ temperature – within which the boiler output will be modulated. Refer to Figure 9-1.

When the boiler temperature is below the ‘Set Point’ temperature minus ‘Temp Delta’ value, the modulation of the burner is set to maximum.

When the boiler temperature is above the ‘Set Point’ temperature plus ‘Temp Delta’ value, the modulation of the burner is set to minimum.

When the boiler temperature is within the modulation band, the modulation level is varied in direct proportion to the boiler temperature, i.e. boiler output varies linearly from maximum at the bottom of the modulation band (boiler temperature = ‘Set Point’ – ‘Temp Delta’) to minimum at the top of the modulation band (boiler temperature = ‘Set Point’ + ‘Temp Delta’). Refer to Figure 9-1.

Pellets are delivered to the burner by switching the pellet feed auger on and off. The auger ‘On’ period is defined by the pre-set ‘Time Load’ parameter (1.7s).

The burner is modulated by varying the ‘pause’ time between the preset parameters ‘Pause Max Power’ [7] at ma ximum output and ‘Pause Min Power’ [6] at minimum output. Refer to Figure 9-2.

The fan speed is automatically controlled to maintain the required air supply for the output of the boiler as the burner modulates, i.e. if the output decreases the air supply (and fan speed) will be automatically reduced, if the output increases the air supply (and fan speed) will be automatically increased.

This control of the air supply is achieved using the Lambda sensor, located at the top of the primary heat exchanger. This measures the oxygen level in the combustion gases and, via the boiler control system, automatically adjusts the fan speed to achieve the required level of oxygen for the output level of the burner at that time. Thus, as the output changes so will the fan speed and air supply rate.

As this system is monitoring the oxygen level and adjusting the air supply rate accordingly it will automatically compensate for the gradual increase of ash blockage in the boiler over time, ensuring that the combustion remains at the optimum throughout the period between boiler services.

9.3 Automatic Cleaning

Adjustable boiler control parameter numbers are shown in square brackets. Refer to Parameter Menu in Section 9.7.

The control system is programmed to carry out a self-cleaning function on the burner brazier, heat exchanger and secondary (condensing) heat exchanger at pre-set intervals.

This self-cleaning operation is automatically performed:

• on power-up, i.e. when the power to the boiler is connected (this includes the cleaning of the condensing heat exchanger)

• after the pellet feed auger running time exceeds the pre-set ‘Clean Boiler’ parameter (480 mins).

The control system will inform the user when a service is required by displaying a ‘Service’ message on the boiler control panel LCD when the auger run time exceeds the pre-set ‘Hours ser vice’ period [14]. Once the service is completed, the service engineer can reset the auger run time hours to zero so that the control will indicate when the next service is required (after the ‘Hours Service’ value is exceeded). Refer to Section 12 – Servicing.

If a fault occurs with the operation of the boiler, the control panel LCD will display a fault code to assist in the diagnosis and rectification. Refer to Section 13 – Fault Finding.

Section 9: Boiler Operation Page 35

Page 36

9.4 Boiler Control Panel

T: 69.5°C

SP: 75.0°C

Modulation Level

Heating Demand

STANDBY

T: 69.5°C

SP: 75.0°C

Heating Demand

• Parameter Menu – to check/adjust the boiler control parameters (Refer to Section 9.7) – this is accessed from the Service Menu.

Figure 9-3: Boiler control panel

The boiler control panel is located at the top front of the boiler (behind the control panel cover) and includes the following:

• LCD screen: this displays the boiler operating condition and (when necessary) a ‘Service’, ‘Fault’ or ‘Fuel Low Warning’ message for the user.

• Boiler control setting buttons: for boiler control system operation and setting

• ‘ON/STANDBY’ switch: to switch the burner off when required, by interrupting the switched live supply to the burner. This switch does NOT isolate the electrical supply to the burner.

9.4.1 Function of buttons

The six control buttons perform different tasks depending on which mode the control is in, as follows:

Button No.1

In ‘Service Menu’ mode – to scroll up In ‘Parameter Menu’ mode – to both enter parameter menu password

and to scroll up

Button No.2

In ‘Service Menu’ mode – to scroll down In ‘Parameter Menu’ mode – to scroll down

Button No.3

In ‘Service Menu’ mode – to exit function In ‘Parameter Menu’ mode – to exit parameter

In ‘Home screen’ mode (when Fault Message is displayed) – to reset control

Button No.4

In ‘Home screen’ mode – to enter boiler set point temperature adjustment

In ‘Service Menu’ mode – to select function In ‘Parameter Menu’ mode – to enter parameter

Button No.5

In ‘Home screen’ mode – to decrease boiler set point temperature In ‘Parameter Menu’ mode – to decrease parameter value

Button No.6

In ‘Home screen’ mode – to increase boiler set point temperature In ‘Parameter Menu’ mode – to increase parameter value

Access to the Service Menu (and thus the Parameter Menu) is password protected.

9.4.3 ‘Home Screen’ Display

NOTE

Modulation Level

Figure 9-4: Home screen display

This indicates the following information for the boiler:

• The current boiler temperature (top left corner)

• The boiler ‘Setpoint’ temperature (top right corner)

• Heating demand present or not (upper centre)

• Functions in operation (mid centre) – Lambda sensor (λ symbol

flashes to indicate operation), fan, ignition element, auger, flame on.

• Operating sequence stage (bottom left)

• Modulation indicator (bottom right) – e.g. 4 segments =100%, 3

segments = 75%, etc.

9.4.4 Information and Service information

To access these displays:

• Press button 3 (i) once ‘Information’ screen is displayed, showing: Flame lux: % Fan Speed: RPM

• Press button 3 again ‘Oxygen Level’ screen is displayed showing Target level: % Actual level %

• Press button 3 again ‘Service Information’ screen is displayed, showing Run time: Hrs. Service in: Hrs.

• Press button 3 again to return to the ‘Home screen’ display

9.4.2 Boiler Control LCD screen

The control LCD screen can show six different display types:

• Home Screen – Indicating the current stage in boiler operating

• Information - Displays the ‘Flame lux’ and ‘Fan speed’ at that

• Oxygen Level - displays the target level and actual level of

• Service Information – Displays pellet auger ‘Run time’ and

• Service Menu – To select ‘Brazier Clean’, ‘Restore Default Setup’,

sequence (Refer to Section 9.6)

moment

oxygen in the combustion gases, as measured by the Lambda sensor

‘Service In’ period (both in hours)

‘Reset Service Timers’, ‘Parameter Menu’ and ‘Prime Auger’ functions

Section 9: Boiler OperationPage 36

Page 37

9.5 Boiler Setpoint Temperature

To adjust the boiler ‘Setpoint’ temperature (when in ‘Home Screen’)

• Press button 4

• Adjust ‘Setpoint’ temperature by pressing button 5 (to decrease)

or button 6 (to increase)

• Press button 4 to confirm the new setting and return to ‘Home Screen’ display

The boiler ‘setpoint’ temperature can be set between 55 and 75°C. The factory default setting is 75°C.

The boiler ‘setpoint’ can also be adjusted in the ‘Parameter Menu’. Refer to Section 9.7.5.

9.6 Service Menu (including Parameter Menu)

To access ‘Ser vice menu’:

• Press and hold button 1 (until four zeros are displayed)

• Enter the 4-digit access code – use buttons 5 or 6 to set first digit

– then press button 1 Repeat process for remaining three digits

• Press button 4 to enter ‘Service Menu’

• Press button 2 to scroll down through ‘Service menu’ functions

(Press button 1 to scroll up)

• Press button 4 to select function in ‘Service menu’

• Press button 3 to exit function and return to ‘Service menu’

• Press button 3 again to return to ‘Home screen’

The six functions in the ‘Service Menu’ are as follows:

9.6.1 Fan Power Select

Used to manually test the fan operation, if required.

9.6.2 Brazier Clean

Used to manually operate the brazier and boiler (both primary and condensing heat exchangers) cleaning function. Press button 4 (Confirm) to start boiler cleaning function. Press button 3 (Cancel) to exit this function if manual operation is not required.

9.6.3 Restore Default Setup

Used to reset all control parameters to the factory-set default values. Press button 4 (Confirm) to restore default values. Press button 3 (Cancel) to exit this function if restoring the default values is not required.

9.6.4 Reset Service Timers

Used to reset the service time period after the boiler has been serviced. Press button 4 (Confirm) to reset the service time period. Press button 3 (Cancel) to exit this function if resetting the service time period is not required.

9.6.5 Parameter Menu

Used to access the boiler control parameters to check and adjust as required. Refer to Section 9.7.

9.6.6 Prime Auger

Used to prime the boiler pellet feed auger during commissioning or after pellet hopper and auger has been emptied.

To prime the auger, press and hold button 4 (Prime Auger) for at least 3 minutes, or until pellets are heard dropping into the burner. The control panel LCD screen shows the countdown (time remaining) from the 5 minute start point. Refer to Section 11.6.

If necessary the ‘Prime Auger’ function can be repeated, using the above procedure.

Once priming is completed, exit the ‘Prime Auger’ function and return to the ‘Service Menu’ by pressing Button 3.

Section 9: Boiler Operation Page 37

Page 38

9.7 Parameter Menu

The boiler control parameters accessible to the installer are given in the ‘Parameter Menu’ – accessed via the ‘Service Menu’.

Refer to Section 9.6 for guidance to access ‘Service Menu’ and ‘Parameter Menu’.

When in the ‘Parameter Menu’:

• Press button 1 to scroll up through parameters (in numerical order)

• Press button 2 to scroll down through parameters (in numerical order)

• Press button 4 to select parameter (parameter flashes)

• Press button 5 to decrease parameter or button 6 to increase

parameter

• Press button 3 to exit parameter (stops flashing)

• Press button 3 to exit boiler control parameters menu

9.7.13 Cleaning Cycles

This parameter sets the number of operations of the brazier cleaning actuator at every brazier cleaning operation.

9.7.14 Clean Boiler

The total pellet feed auger run time before the automatic brazier cleaning operation is activated.

9.7.15 Pause Max Power

The time between pellet feed auger operations when the burner is operating at maximum output. Adjusting this parameter adjusts the boiler input at maximum output, i.e. the longer the pause period the lower the input and the shorter the pause period the higher the input. Refer to Section 2.2 and Figures 9-1 and 9-2.

NOTE

9.7.1 Pause Min Power

The time between pellet feed auger operations when the burner is operating at minimum output.

Adjusting this parameter adjusts the boiler input at minimum output, i.e. the longer the pause period the lower the input and the shorter the pause period the higher the input. Refer to Section 2.2 and Figures 9-1 and 9-2.

9.7.2 Temp Off H

The maximum temperature at which the burner shuts down.

9.7.3 Hysteresis Of f

The temperature above the setpoint at which the burner will stop operating, i.e. if the water temperature exceeds the ‘Set Point’ + ‘Hysteresis Off’ value, or the ‘Temp Of f H2O’ value (see above) the burner will stop.

9.7.4 Hysteresis On

The temperature below the setpoint at which the burner will start to operate, i.e. the water temperature must be less than the ‘Set Point’ – ‘Hysteresis On’ value for the burner to start.

9.7.5 Setpoint

This is an alternative means of setting the boiler ‘setpoint’ temperature between 55 and 75°C. The factory default setting is 75°C.

9.7.6 Short Cleaning Cycles

The control system will perform a short clean operation after a preset number of completed burner operations (or demands). After the post purge is completed for the last of these burner operations, the cleaning arm will move the brazier forwards and back once only.

The heat exchanger cleaning shaker mechanism and wash systems are NOT operated during this short cleaning operation.

9.7.7 Fan Power Post Purge

This parameter sets the fan speed when the burner is in the post purge mode.

9.7.8 Fan Power Lighting

This parameter sets the fan speed when the burner is in pre-load, lighting and flame stabilisation modes.

9.7.9 Fan Power Min

This parameter sets the fan speed at minimum boiler output.

9.7.10 Fan Power Max

This parameter sets the fan speed at ma ximum boiler output.

9.7.11 Hours service

The total pellet feed auger run time before the control panel LCD displays ‘Service’. This indicates that a service is now due.

Following every boiler ser vice this MUST be reset using the ‘Reset Service Timers’ function. Refer to Section 9.6.4.

9.7.12 Motor Type

This parameter defines the power supply required for the cleaning motor.

All parameters (excluding setpoint) MUST be left at the default settings unless instructed to do so by Grant UK.

Number Parameter Units Range

6 Pause Min Power Seconds 0.5 to 60 14.0

3 Temp Off H20 °C 0 to 95 80

2 Hysteresis Off °C 0 to 20 5

1 Hysteresis On °C 0 to 20 5

0 Setpoint °C 55 to 75 75

54 Short Clean Cycles Demands 0 to 100 5

18 Fan Power Post Purge RPM 1000 to 4500 4500

17 Fan Power Lighting RPM 1000 to 4500 2000

16 Fan Power Min RPM 1000 to 4500 1600

15 Fan Power Max RPM 1000 to 4500 3100

14 Hours Ser vice Hours 1 to 1000 400

11 Motor Type - - 24V DC

9 Cleaning Cycles Cycles 1 to 20 2

8 Clean Boiler Minutes 0 to 4800 480

7 Pause Ma x Power Seconds 0.5 to 60 3.0

Table 9-5: Boiler control parameters (installer settings)

Default

settings

Section 9: Boiler OperationPage 38

Page 39

Password

Press and hold

6 Pause Min Power

Service Menu

3 Temp Off H20

2 Hysteresis Of f

Home screen

Information

Flame Lux: %

Fan Speed: RPM

Oxygen level

Target Level: % Actual Level: %

Service information

Run Time: Hrs Service in: Hrs

Setpoint Screen

Fan Power Select

Restore Default

Brazier Clean

Setup

Reset Service

Timers

1 Hysteresis On

0 Setpoint

54 Short Clean Cycles

18 Fan Power Post Purge

17 Fan Power Lighting

16 Fan Power Min

15 Fan Power Max

14 Hours Service

NOTE

After adjusting a parameter: Press but ton 4 to confirm setting

- then press but ton 3 to return to ‘Service Menu’

Figure 9-6: Control system flowchart

Parameter Menu

Prime Auger

11 Motor Type

9 Cleaning Cycles

8 Clean Boiler

7 Pause Max Power

Section 9: Boiler Operation Page 39

Page 40

9.8 Boiler Operating Sequence

The following stages of the boiler operation are displayed on the control panel LCD screen.

The number shown in brackets [X] indicates the parameter setting – refer to Section 9.7 and Table 9-5.

Standby

Boiler not operating but ready to start in response to the following:

• A switched live input signal from control system for heating or hot water.

• The boiler temperature drops below the ‘Setpoint’ [0] minus ‘Hysteresis On’ (5°C) temperature – if boiler temperature has exceeded the pre-set ‘Temp Off H

• The ON/STANDBY switch on the control panel is set to the ‘ON’ position.

Wait Pre Load Brazier

Initial loading of pellets into the brazier to start the burner.

• Activated when a switched live input signal and/or temperature drops below the pre-set ‘Setpoint’ minus ‘Hysteresis On’ value (5°C).

• Deactivated when the pre-set ‘Preload Time’ period of 46 seconds has elapsed.

• Fan is operating at ‘Fan Power Lighting’ speed setting [17].

Lighting

Period of time allowed for pellets to light.

• Activated after ‘Wait Pre Load Brazier’ stage is completed.

• Deactivated once photocell lux reading exceeds pre-set ‘Flame

On’ setting of 20%.

• Note: ignition element remains on until end of pre-set ‘Flame Stabilisation’ stage (10 seconds).

• Fan is operating at ‘Fan Power Lighting’ speed setting [17].

Flame Stabilisation

Period of time allowed for flame to stabilise after pellets have ignited.

• Activated after ‘Lighting’ stage is completed.

• Deactivated when the pre-set ‘Time Flame Stabilisation’ period of

10 seconds has elapsed.

• Fan is operating at ‘Fan Power Lighting’ speed setting [17].

NOTE

O’ setting (80°C).

Modulation Level

The boiler is now firing.

• Activated after pre-set ‘Feed Time Reduced’ period of 220 seconds has elapsed.

• Deactivated when either the demand ceases or the temperature exceeds pre-set ‘Temp Off H

Initially, the boiler will operate at 25% output – indicated by one segment showing on the modulation indicator.

After 25 seconds the boiler output will increase to 50% - indicated by two segments on the modulation indicator.

After a further 25 seconds the boiler output will increase to 75% (three segments on modulation indicator).

Finally, after a further 25 seconds the boiler output will increase to 100% (four segments on modulation indicator). The boiler is now operating at maximum output.

After that, the boiler temperature and set point are used to determine the required output and level of modulation. This in turn controls the auger operating cycle. Refer to Section 9.2 for details of boiler modulation.

• Fan is operating between ‘Fan Power Max’ [15] and ‘Fan Power Min’ [16] speed settings to suit the modulating burner output.

Turning Of f Brazier

Burn down period to remove any pellets remaining in the brazier. Pellet feed auger is switched off.

• Fan speed changes to pre-set ‘Fan Power Post Purge’ [18] setting (4500rpm).

• Activated once switched live input signal is switched off or the boiler temperature exceeds the pre-set ‘Temp Off H setting.

• Deactivated once photocell Lux reading has dropped below preset ‘Flame Off’ setting of 4%.

Wait Post Purge

Burner fan continues to run at pre-set ‘Fan Power Post Purge’ [18] setting (4500rpm) for a period of time after burn down is completed.

• Activated after ‘Turning off Brazier’ stage is completed.

• Deactivated when pre-set ‘Post Ventilation’ period of 120

seconds has elapsed.

O’ [3] setting (80°C).

O’ [3]

Lighting Feed Reduced

Period when pellet feed provides intermittent quantities of pellets to the brazier to increase the flame.

The auger off period is given by the pre-set ‘Time Pause Lighting’ setting of 22 seconds and the auger on time is given by the pre-set ‘Time Load Lighting’ setting of 1 second.

• The combustion fan is operating at ‘Fan Power Max’ speed setting [15].

• Activated after pre-set ‘Flame Stabilisation’ stage period (10 seconds) is completed.

• Deactivated when the pre-set ‘Feed Time Reduced’ period of 220 seconds has elapsed.

Section 9: Boiler OperationPage 40

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9.9 Boiler Operation Flow Chart

Time > ‘Post Ventilation’

Lux % < ‘Flame Pellet auger run

time > 480 mins

Mains Power

Time > ‘Pre Load Time’ setting

Switched Live

Switched Live Input Off

Lux % < ‘Flame

Time > ‘Feed Time Reduced’

Lux % > ‘Flame On’ Setting (20%)

Time > ‘Time Flame Stabilisation’

Fan Proving Check OK Temp < (Set point – Temp Delta)

& Switched Live Input on

Switched Live Input Off

Wait Pre Load Brazier

Fan Proving Check

Lighting Feed

Reduced

to Boiler On

Boiler Clean

Standby

Wait Pre Load Brazier

(46 seconds)

Lighting

Input Off

Flame Stabilisation

Setting (10 seconds)

Setting (220 seconds)

Modulation Level

Turning Off Brazier

Off’ Setting (4%)

Turning Off Brazier

Off’ Setting (4%)

Wait Post Purge

Setting (120 seconds)

Wait Post Purge

Figure 9-7: Boiler control sequence flow chart

Section 9: Boiler Operation Page 41

Boiler Clean

Page 42

10 Side Pellet Store

10.1 General

The optional side pellet store for the Grant External wood pellet boiler is designed to provide an increased storage capacity, allowing the boiler to run for longer periods before topping-up is required.

The capacity of the side pellet store is 140kg. With the 80kg capacity of the boiler pellet hopper this gives a total pellet storage capacity of 220kg.

This side pellet store is the same external design as the External Vecta boiler and is designed to be located at the right hand side of the boiler only. It incorporates an auger to automatically transfer pellets from the side pellet store to the boiler pellet store when activated by

the contents switch. Refer to Section 10.2.

This side pellet store can only be fit ted on the right hand side of the Grant External Vecta boiler. It CANNOT be fit ted on the left hand side of the boiler under any circumstances.

The side pellet store auger pipe is supplied in two pieces. The lower section is supplied factory-fitted in the bottom of the side pellet store along with the auger motor and spiral. The end of the auger spiral is secured to the side pellet store by the packaging.

NOTE

10.2 Operation

When fitted to the boiler, the side pellet store auger extends from within the side pellet store into the boiler pellet hopper.

The side pellet store is connected to the electrical controls of the boiler. When the diaphragm contents switch fitted to the boiler pellet hopper detects a low fuel level the side pellet store auger will be automatically operated.

The control panel LCD screen will show ‘Fuel Low Warning’ and the Remote Grant logo indicator (located inside the house) will also flash (slowly) to indicate that the pellet level in the boiler hopper has fallen to the pre-set minimum.

Pellets will be transferred from the side pellet store to the boiler pellet hopper. This will continue until the contents switch in the boiler pellet hopper is satisfied, at which point the side pellet store auger will stop.

Both the ‘Fuel Low Warning’ on the control panel LCD screen and the slow flashing Grant logo indicator will be automatically cancelled.

The boiler pellet hopper will not be completely filled by the side pellet store. The auger will only transfer pellets to the boiler pellet hopper until the contents switch is satisfied.

NOTE

Great care must be taken when removing the packaging holding the auger spira as the end of the auger spiral can spring out and cause injury.

The auger extension pipe is supplied loose and must be fitted as described in these installation instructions. Refer to Section 10.3 for full details.

WARNING

The side pellet store is also fitted with a diaphragm contents switch.

The side pellet store auger will only operate when this contents switch indicates there are sufficient pellets in the side pellet store. If this level drops below the minimum to activate the contents switch, the auger will no longer operate to transfer pellets to the boiler pellet hopper.

In this instance, when the boiler pellet hopper contents switch detects a low fuel level no pellets will be transferred to the boiler pellet hopper.

If the boiler pellet hopper is not topped up at this point, the boiler will continue to operate for a short period before the burner is automatically stopped.

Topping up the boiler pellet hopper with at least 20kg of pellets will operate the contents switch and automatically re-start the burner (as long as there is a demand present for the boiler to run). Both the ‘Fuel Low Warning’ on the boiler control panel LCD screen and the slow flashing Grant logo indicator will be automatically cancelled.

In order to ma ximise the combined pellet storage capacity of the boiler and side pellet store, it is recommended that both the boiler pellet hopper and the side pellet store are filled to the top when topping-up.

NOTE

Section 10: Side Pellet StorePage 42

Page 43

10.3 Installation

10.3.1 Boiler Installation

Install the boiler in the required location allowing sufficient room for the installation of the side pellet store. Refer to Section 2.4 for details of dimensions and clearances required for the boiler and side pellet store.

10.3.2 Preparing the Boiler

Do NOT position the side pellet store alongside the boiler at this stage.

Prepare the boiler for the installation of the side pellet store as follows:

1. Ensure that the electrical supply to the boiler is isolated.

2. Open the hinged hopper lid on the boiler.

3. Undo and remove the three screws along the top edge of the right hand side panel. Refer to Figure 10-1. Keep these screws for re-fitting later.

NOTE

It is NOT necessary to unscrew and remove the diaphragm seal plate to make this hole in the side of the boiler pellet hopper.

Figure 10-3: Removing the knockout in the pellet hopper

It is NOT necessary to unscrew and remove the diaphragm seal plate to make this hole in the side of the boiler pellet hopper.

8. Then, working through the rectangular opening, use a screwdriver to prise the circular part from the opening, remove it from the boiler and discard. This will leave the opening in the boiler pellet hopper and the rubber diaphragm seal through which the auger pipe will be fitted.

9. Undo and remove the t wo hex head screws from along the bottom edge of the boiler right hand side panel. Refer to Figure 10-4. Keep these screws for re-fitting later.

NOTE

Figure 10-1: Removing the three screws

4. Undo the t wo screws (one on each side) and remove the access cover from the top of the boiler. Refer to Figure 11-2.

5. Remove the pellet hopper grille. Pull up the front edge. Lif t the grille off the three tabs in the slots along at the rear edge, and remove it from the boiler. Refer to Figure 10-2.

Figure 10-2: Removing the pellet hopper grille

6. Ensure that the boiler pellet hopper is empt y of pellets. If not remove all pellets before proceeding any fur ther.

7. Remove the pre-cut knock-out in the lower right hand side of the boiler pellet hopper to provide the hole for the side pellet store auger.

To do this, use a hammer to strike the pre-cut round section from within the pellet hopper just enough to start to break it out of the panel. Refer to Figure 10-3.

Figure 10-4: Removing the two hex head screws

Section 10: Side Pellet Store Page 43

Page 44

10.3.3 Side Pellet Store Installation

Install the side pellet store using the following procedure:

1. Undo and remove the three screws along the top edge of the left hand side panel of the side pellet store. Refer to Figure 10-5. Keep these screws for re-fitting later.

Figure 10-5: Removing the three screws from the side store

2. Remove the front panel from the side pellet store. Undo and remove the four panel retaining screws at the top edge of the front panel. Refer to Figure 10-6. Lift the front panel upwards and off the side pellet store casing.

4. Whilst firmly holding the end of the auger spiral in position, cut and remove the packaging securing it to the side pellet store.

The end of the auger spiral MUST be FIRMLY held to prevent it from springing out and possibly causing injur y when the packaging is cut and removed.

Slacken the clamp bolt on the auger pipe socket so that the auger extension pipe can be fitted. Refer to Figure 10-8 for location of auger pipe clamp bolt.

Clamp bolt

WARNING

Figure 10-6: Removing the four screws and front panel

3. Remove the centre section of the grille inside the side pellet store. Undo the single fixing screw and lift the centre section away from the surrounding part of the grille. Refer to Figure 10-7.

Figure 10-8: Location of auger pipe clamp bolt

6. Manoeuvre the side pellet store into position alongside right hand side of the boiler, carefully feeding the end of the auger spiral through the hole in the diaphragm seal plate in the side of the boiler pellet hopper.

Leave a gap of approximately 10mm bet ween the spacer channel and the side of the boiler at this stage of the installation.

Lubricate the outer surface of the auger extension pipe (at the unpainted end) with some silicone grease, washing up liquid or similar.

8. Working from within the boiler hopper, locate the unpainted end of the auger extension pipe over the end of the auger spiral.

9. Looking through the 10mm gap between the boiler and side pellet store spacer channel, carefully push the end of the auger extension pipe through the diaphragm seal and into the auger pipe socket.

10. Ensure it is fully pushed in and then secure in place by tightening the auger pipe clamp bolt.

NOTE

Figure 10-7: Removing the single fixing screw and grille

Do not over tighten the clamp bolt as this can distort the auger extension pipe and prevent the auger spiral from rotating freely.

11.

Now push the side pellet store into its final position with the left side of the side pellet store hard up against the right hand side of the boiler casing.

12. From inside the side pellet store enclosure; re-fit the two hex head screws through the bottom left hand edge of the side pellet

NOTE

Section 10: Side Pellet StorePage 44

Page 45

store and into the boiler casing. Leave finger tight at this stage. Refer to Figure 10-9.

Figure 10-9: Refitting the two hex head screws

13. Fit the top joining channel between the boiler and side pellet store with the V-shaped tongue facing towards the back of the boiler/side store. Carefully slide the jointing channel in the V-shaped groove formed bet ween the t wo boilers. Refer to Figure 10-10.

Figure 10-11: Fitting the top joining channel screws

16. Re-fit the centre section of the grille inside the side pellet store and secure with the single fixing screw previously removed. Refer to Figure 10-7.

17. Finally, from inside the side pellet store; tighten the two hex head screws to secure the bottom of the side pellet store to the boiler casing.

Figure 10-10: Fitting the top joining channel

14. Push the channel as far back as possible – until the fixing holes in the flat sections (on each side of the V) line up with the holes in the top edges of the side panels on both the boiler and side pellet store.

15. Secure the channel in place using the six screws previously removed from the top edges of the side panels. Refer to Figure 10-11.

The hinged lids on both the boiler and side pellet store are each fitted with a cut-out switch and BOTH must be closed in order for the boiler to operate.

NOTE

Section 10: Side Pellet Store Page 45

Page 46

10.4 Electrical Connections

LIVE

10.4.1 Pellet side store contents switch

1. Feed the white cable from the side pellet store contents switch through the opening between the side pellet store and the boiler and into the boiler casing.

2. Route it under the hopper and around to the boiler wiring terminal block at the left front of the boiler.

3. Remove the terminal block cover (refer to Section 8.2) and feed the cable through the right hand cable clamp.

4. Connect the cable to the terminal block as follows (Refer to Figure 10-12):

• Blue wire – ‘side store neutral’

• Green/Yellow wire – ‘side store ear th’

• Brown wire – ‘side store live’

5. Tighten the cable clamp to secure the cable and re-fit the terminal block cover.

10.4.2 Pellet side store lid cut-out switch

1. Locate the in-line male and female connectors nex t to the boiler lid cut-out switch (under the upper front edge of the boiler front panel in the centre) and carefully separate the two connectors.

2. Feed the grey cable, from the side pellet store lid cut-out switch, through the opening between the side pellet store and the boiler and into the boiler casing.

3. Route the cable up inside the right hand boiler side panel. Pass it through the two cable loops (under the upper front edge of the boiler front panel at the right hand side).

4. First connect the male connector on the grey cable to the female connector from the boiler lid cut-out switch.

5. Then connect the female connector on the grey cable to the male connector from the boiler lid cut-out switch. The boiler lid cut-out switch is now connected in series with the side pellet store lid cut-out switch.

Cable from side pellet store contents switch

Blue

Green/Yellow

SWITCHED

LIVE

PERMANENT

LIVE

NEUTRAL

Figure 10-12: Pellet side store electrical connection diagram

EARTH

SIDE STORE

NEUTRAL

EARTH

Brown

SIDE STORE

If either the boiler hinged hopper lid OR the side pellet store lid is opened for longer than 5 seconds, whilst the boiler is operating, the burner will be automatically stopped. Closing the hopper lid resets the cut-out switch and the boiler will restart. Refer to Section 11.4 for details of the hopper lid cut-out switch

Re-fit the front panel to the side pellet store. First engage the three tabs on the bottom edge of the front panel into the corresponding slots in the bottom of the side pellet store. Then secure it in place by re-fitting the four panel retaining screws previously removed.

NOTE

Section 10: Side Pellet StorePage 46

Page 47

10.5 Commissioning the Side Pellet Store

Following installation, the operation of the side pellet store auger must be checked using the following procedure:

1. Open the hinged lid and put 30kg of pellets (e.g. three 10kg bags) in the side pellet store.

2. Close both the side pellet store and boiler hinged lids.

3. Check that the ON/STANDBY switch on the boiler control panel is set to STANDBY.

4. Switch the power supply to the boiler to ON. The boiler will go through the automatic cleaning operation. Refer to Section 9.3 for details.

5. The boiler control panel LCD will flash with the message ‘Low Fuel Warning’, and the remote Grant Logo Indicator will also flash slowly, indicating a low pellet level and that the boiler hopper needs to be topped-up.

DO NOT PUT PELLETS INTO THE BOILER PELLET HOPPER AT THIS TIME.

6. The side pellet store auger should star t operating to transfer pellets from the side pellet store into the boiler pellet hopper.

7. Wait for about five minutes and then briefly (i.e. for less than five seconds) open the hinged hopper lid on the boiler. There should be pellets in the bottom of the hopper.

8. Close the lid immediately and leave the side pellet store auger running until enough pellets are transferred into the boiler pellet hopper to satisfy the contents switch.

9. At this point both the remote Grant Logo Indicator and ‘Low Fuel Warning’ message on the boiler control panel LCD will stop flashing.

10. Both the boiler hopper and the side pellet store can now be filled to the top with pellets. Use only ENPlus Grade A1 pellets that

comply with BS EN ISO 17225-2:2014.

The operation of the side pellet store auger MUST be checked BEFORE filling the boiler pellet hopper with pellets.

NOTE

Section 10: Side Pellet Store Page 47

Page 48

11 Commissioning

It is important that the following commissioning procedure is carried out following installation to ensure safe and efficient operation of the boiler.

11.1 Equipment Required

To carr y out a complete and comprehensive commissioning of the Grant Vecta wood pellet boiler the following equipment is required:

• Electronic draught meter.

• Flue gas analyser (with ‘wood pellet’ fuel setting).

11.2 Preliminar y Inspection

Before switching on the power supply to the boiler, the following must be checked:

11.2.1 Heating System

Check the following:

• That corrosion inhibitor and, where necessary antifreeze, is present in the system water. Refer to Section 4.7.

• That a magnetic in-line filter has been fitted in the system return. Refer to Section 4.7.

• Both the boiler and heating system is filled and vented.

• On sealed systems the expansion vessel charge pressure is

correct and system is filled to correct pressure.

• For any leaks at joints, fittings, etc.

11.2.2 Electrical Connections

Check the following:

• The electrical connections to the boiler are correct. Refer to Figure 8-7.

11.2.6 Combustion Ventilation

Check that the combustion air inlet to the boiler along the lower front edge of the boiler front door is unobstructed. If necessar y remove any obstructions, e.g. leaves, etc.

Check that the combustion air inlet to the burner, located in the font of the boiler, is unobstructed. Refer to Figure 11-1.

Boiler air inlet

Figure 11-1: Air inlet

11.3 Boiler

11.3.1 Control Thermistor and Overheat Thermostat

• Isolate the electrical supply to the boiler.

• Open the hinged hopper lid on the boiler.

• Undo the two screws (one on each side) and remove the access

cover from the top of the boiler. Refer to Figure 11-2.

11.2.3 Wash-down System

Check the following:

• The inlet to the wash-down system (located at the bottom rear corner of the left side panel) is connected to an uninterrupted mains water supply.

• All valves in this water supply are open.

11.2.4 Condensate Disposal System

Check the following:

• The condensate trap (supplied with the boiler) and condensate disposal pipework has been fitted correctly. Refer to Section 5.

• If a condensate pump is fitted, that a condensate holding tank of at least 40 litres capacity has also been installed. Refer to Section 5.

11.2.5 Flue System

Check the following:

• The correct flue system has been used. Only the Grant ‘Biomass’ flue system should be used.

• The flue system is correctly connected to the boiler flue outlet. Refer to Section 7.4.

• The boiler combustion air inlet along the bottom of the front door is clear and unobstructed.

• The flue system conforms to the relevant requirements of The Building Regulations Approved Document J for solid fuel appliances.

Figure 11-2: Removing the access cover

• Remove the pellet hopper grille. Pull up the front edge. Lift the grille off the three tabs in the slots along at the rear edge, and remove it from the boiler.

• Ensure that the boiler pellet hopper is empty of pellets. If not remove all pellets before proceeding any fur ther.

• The pocket, containing both the boiler control thermistor sensor and overheat thermostat bulb, is located in the upper left front of the boiler, to the left of the heat exchanger housing. Refer to Figure 11-3.

Section 11: CommissioningPage 48

Page 49

Figure 11-3: Location of boiler control thermistor sensor and overheat

thermostat bulb

Check the following:

• That both the overheat thermostat bulb and control thermistor probe bulb are fully inserted in the boiler waterway pocket and the retaining clip is fitted.

• The condition of thermistor cable and thermostat capillary, i.e. not damaged, broken or kinked.

Check the following:

• The ash pan is empty and correctly located on the base of the combustion chamber

• The horizontal and vertical baffles are correctly fitted in the rear of the combustion chamber.

• The burner flame pot is correctly located in the top of the burner.

• Close the combustion chamber door.

• Remove the multi-purpose tool from the door catch and hang

it back on the hook provided on the panel to the lef t of the combustion chamber door.

11.3.2 Combustion Chamber

Open the front door. First unlock and remove the padlock (if fitted), rotate the knob of the catch clockwise to unlatch and fully open the front door.

Switch the electrical isolator to OFF. Refer to Figure 11-4 for location of isolator.

The electrical isolator switch does NOT isolate the electricity supply to the boiler. The power supply to the boiler wiring terminal block will still be live when the isolator is set to OFF. If required, the electrical supply to boiler should be isolated at the fused spur supplying the heating system and controls.

WARNING

Figure 11-5: Opening combustion chamber

Figure 11-6: Combustion chamber door open

Figure 11-4: Location of electrical isolator

Fit the multi-purpose tool (provided with the boiler) into slot in door catch. Refer to Figure 11-5.

Lift the tool handle to release the door catch and fully open the combustion chamber door of the boiler. Refer to Figure 11-6.

Section 11: Commissioning Page 49

Page 50

11.3.3 Primary Heat Exchanger

To gain access to the top of the heat exchanger:

• With hinged hopper lid open and top access cover removed (as per Section 11.3.1)

• Shut off the cold water supply to wash system.

• Disconnect the water supply hose from the wash system. Refer

to Figure 12-2.

• Unscrew and remove the five nuts (and washers) securing the heat exchanger cover and remove it from the top of the heat exchanger. Refer to Figure 11-7.

• Check that the spiral baffles in the heat exchanger are all in place. Lift and drop each one to check all are free to move in their respective tubes. Refer to Figures 11-8.

11.3.4 Secondary Heat Exchanger

There are two dif ferent t ypes of spiral baffle fitted to the secondary heat exchanger.

The spiral baffles fitted to the right hand side have a 2½ turn spiral and are dif ferent to those on the lef t hand side which have 4½ turn spiral.

Whenever these are removed, it is important that they are refitted in the correct side of the secondary heat exchanger.

With the hinged hopper lid open and both top access cover and heat exchanger cover removed (as per Section 11.3.3).

• Check that the spiral baffles in the secondary heat exchanger are all in place.

• Check that all spiral baffles are correctly aligned with the top edges running ‘front to back’. Refer to Figure 11.9.

• Refit the heat exchanger cover to the top of the heat exchangers and secure with the nuts previously removed. Do not over tighten

• Re-connect water supply hose to connection on wash system manifold. Refer to Figure 12-2.

NOTE

Lambda sensor

Figure 11-7: Heat exchanger cover and Lambda sensor position

Figure 11-8: Primary heat exchanger spirals

Figure 11-9: Secondary heat exchanger spirals

11.3.5 Boiler Pellet Hopper

If the optional side pellet store is fit ted, the operation of the side pellet store auger MUST be checked BEFORE filling the boiler pellet hopper. Refer to Section 10.5 for details.

Before filling the boiler pellet hopper with pellets for the first time, ensure that hopper is empty of all other debris or objects, e.g. screws, nuts, etc.

NOTE

CAUTION

•

Check that the pellet hopper is full of pellets. Fill the hopper with pellets by hand from bags. Ensure that only EN Plus Grade A1 pellets, that comply with BS EN ISO 17225-2:2014, are used with the Grant Vecta boiler. Refer to Section 3 for details.

Section 11: CommissioningPage 50

Page 51

11.4 Hopper Lid Cut-out Switch

With the power supply to the boiler switched OFF:

• Set the ON/STANDBY switch on the boiler to STANDBY and switch the power to the boiler ON.

• Open the hinged hopper lid and wait.

• After 5 seconds, the control panel LCD screen will flash and

indicate a ‘Hopper Lid Open’ (Error Code 16) fault.

• Wait for at least 15 seconds for the fire damper in the pellet feed system to fully close.

• Close the pellet hopper lid. The control panel LCD screen will flash and indicate a ‘Safety Flap Closed’ (Error Code 22) fault. Wait for 30 seconds, for the fire damper to re-open. The fault message will automatically disappear from the LCD screen and ‘Standby’ will be displayed.

11.7 Lighting the Boiler

BEFORE attempting to light the boiler, open the combustion chamber door and remove ALL pellets from the burner. Close the combustion chamber door and proceed to lighting the boiler.

Ensure that the electrical supply to the boiler is switched ON and that the heating system controls are operating and are calling for heat. Set the burner ON/STANDBY switch to ON. The 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

11.5 Control Set tings

The boiler comes with the control system 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 boiler switched ON and the burner ON/STANDBY switch set to STANDBY,

• Check ALL control settings in the ‘Parameter Menu’. Refer to Section 9.7 for details of how to access and check these settings.

• Set the boiler ‘Set Point’ temperature using buttons 4, 5 and 6 on the boiler control panel. Refer to Section 9.5 for detail on how to adjust boiler setpoint temperature. Refer to Section 1.1 for required flow and return temperatures.

11.6 Priming the Pellet Feed Auger

The pellet feed auger MUST be fully primed BEFORE attempting to start the boiler. To prime the auger proceed as follows;

• Check the burner ON/STANDBY switch is set to STANDBY.

• Access the ‘Service Menu’ (refer to Section 9.6 for guidance).

• When in the ‘Service Menu’ - press button 2 to scroll down to

‘Prime Auger’ function.

• Press button 4 to select ‘Prime Auger’ function. This function has a pre-set maximum time of 5 minutes.

• Press and hold button 4 for at least 3 minutes or until a steady stream of pellets are heard dropping into the burner.

• The control panel LCD screen shows the countdown (time remaining) from 5 minute start point

• If necessary the ‘Prime Auger’ function can be repeated, using the above procedure.

If the priming is stopped during the 5 minutes, the timer automatically resets to 5 minutes (and this is displayed on the boiler control panel LCD screen).

If the boiler ON/STANDBY switch is set to STANDBY during the initial pellet pre-load period, the pellet feed will stop. The burner may go into post purge with error message ‘False flame’ (and fault code 19) displayed on the control panel LCD screen. The burner will complete the shut-down sequence before it can start-up again, even if the ON/STANDBY switch is reset to ON.

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 star t-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. ‘Modulation Level’ is displayed on the burner control panel LCD screen with all four segments showing (i.e. burner firing at 100% output).

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.

NOTE

WARNING

Section 11: Commissioning Page 51

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11.8 Combustion Chamber Draught

The combustion chamber draught must be checked and adjusted (where necessary) as follows:

• Ensure the control panel LCD screen is showing ‘Modulation’ and the Modulation Indicator (in the lower right corner of display) is showing FOUR segments (100% output).

• Remove the screw from the draught test point, located to the bottom left corner of the combustion chamber door. Refer to Figure 11-10.

• Ensure the control panel LCD screen is showing ‘Modulation’ and the Modulation Indicator (in the lower right corner of display) is showing FOUR segments (100% output).

• There is no combustion test point on the boiler. A test point (and flue access door) is provided in the Inspection Pipe (product code: WPBOM/IP) that MUST be fitted to the boiler flue outlet.

• To access the flue inspection hatch, remove the circular outer cover. To do this, turn the knob in the centre of the outer cover approximately one turn anticlockwise and pull the cover away from the inspection pipe. Refer to Figure 11-11.

• Remove the flue inspection hatch. Turn the knurled knob (in the centre of the hatch) approximately one turn anticlockwise, pull the hatch out of the flue and inspect the inside of the flue system.

• Unscrew and remove the test point screw to insert combustion analyser probe.

• Monitor the %CO2 for a few minutes to see the ma ximum and minimum values reached.

• The %CO2 measured should range between a minimum of 8% and a maximum of 12%.

• If the %CO2 measured is outside of this range, set the ON/ STANDBY switch to STANDBY and contact Grant UK for advice.

Draught

test

point

Figure 11-10: Draught test point

• Ensure that the draught test point hole is open right through into the combustion chamber. If necessar y push a suitably sized screwdriver through to ensure that the hole is clear.

• Using an electronic draught gauge - check 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 fully pushed through the door insulation and into the combustion chamber.

• A draught reading of between 0.75 and 1.25 mbar is required.

If the draught reading is outside of this range, set the ON/ STANDBY switch to STANDBY and contact Grant UK for advice.

11.9 Flue Gas Analysis

Always replace the test point screw and outer access cover on the flue inspection pipe following combustion testing. Do not over tighten test point screw.

NOTE

11.10 Customer Handover

The customer/user must be informed of the correct operation and use of their Grant Vecta 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 guide supplied with the boiler.

• The use of the heating system controls – how to set the programmer, room and cylinder thermostats, etc.

• The importance of using the correct type of wood pellet.

• The need to routinely check the pellet level in the pellet hopper

and how to re-fill it.

• How to access the ash pan and the need to periodically empt y the ash pan. Refer to Section 1.6 and the user guide.

• The need to have the boiler ser viced either annually or when ‘Service’ is shown on the boiler control panel display (whichever comes first). Refer to Section 1.6 and the user guide.

• That servicing should only be carried out by a Grant trained installer.

Figure 11-11: Combustion test point

Once the combustion chamber draught has been checked, as described in Section 11.8, the %CO2 in the flue gases must be checked as follows:

• Allow the boiler to run for a period of at least 15 minutes, until the boiler and flue system are warmed up.

11.11 Commissioning Report Form

The Commissioning Report form (supplied with the boiler) must be completed at the end of the commissioning process. Refer to Section

4.8.

The following information must be entered on the form:

• Boiler details (model, serial number, etc.)

• Combustion readings

• Installation details

• Burner settings

• 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. Refer to Section 4.8.

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11.12 Commissioning Check List

The following checklist must be used in conjunction with the preceding information given in this section:

Preliminary Inspection Tick box

Heating system 

Electrical connections 

Condensate disposal 

Flue system 

Combustion ventilation 

Boiler

Control panel 

Overheat and temperature control thermistor 

Combustion chamber 

Heat exchanger – primary 

Heat exchanger – secondary 

There are two dif ferent t ypes of spiral baffle fitted to the secondary heat exchanger.

The spiral baffles fitted to the right hand side have a 2½ turn spiral and are dif ferent to those on the lef t hand side which have 4½ turn spiral.

Whenever these are removed, it is important that they are refitted in the correct side of the secondary heat exchanger.

NOTE

Notes

Pellet Hopper

Pellets 

Safety Device Checks

Hopper cover cut-out switch 

Combustion chamber door cut-out switch 

Burner settings checked 

Priming pellet feed auger 

Lighting the boiler 

Flue gas analysis 

Combustion chamber draught 

Customer handover 

Commissioning Report Form completed 

Section 11: Commissioning Page 53

Page 54

12 Servicing

12.1 General

It is essential that Grant Vecta boilers are serviced at regular inter vals of no longer than 12 months OR when ‘Service’ is shown on the burner control panel display – whichever comes FIRST.

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 9.6 for details on how to access and check this setting in the boiler control parameter menu.

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 boiler control parameter menu.

The ash pan (located inside the combustion chamber) MUST be periodically emptied by the user. This simple task must be carried out when indicated by the Remote Grant Logo Indicator, located within the house, flashing (fast flash).

Refer to Sections 1.5 and 1.6.

The amount of ash produced varies bet ween dif ferent pellet brands and this will affect the frequency of cleaning and maintenance required.

Servicing and replacement of parts must only be carried out by a Grant Trained installer, or Grant Ser vice Engineer, who has successfully completed the Grant Vecta wood pellet boiler training course.

Details of every service should be entered in the Service log section of the user guide.

A multi-purpose tool is supplied with the boiler for ser vicing and cleaning. This is used for the following functions:

• As the door catch handle – required to open the combustion chamber door

• As the ash pan carrying handle – required to remove the ash pan from the boiler*

• To open the brazier catch

• To remove the brazier front plate

• To remove the brazier base plate

• To remove the brazier cotter pin

CAUTION

NOTE

12.2 Checks before Ser vicing

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.

BEFORE starting any service work on the boiler installation:

• Set the ON/STANDBY switch, on the boiler control panel, to STANDBY. If the boiler was operating, wait for it to shut-down and ‘STANDBY’ is shown on the burner control panel display, before proceeding fur ther.

• Isolate the electrical supply to the boiler and remove the fuse from the fused spur.

WARNING

12.3 Heating System

Open the hinged hopper lid.

Undo the two screws (one on each side) and remove the access cover from the top of the boiler. Refer to Figure 11-2.

Remove the top access cover from inside the top of the boiler.

Check the boiler for any indication of leaks from:

• Flow and return connections

• Manual air vent. Refer to Figure 12-1.

Remake any joints and re-check tightness of any fitting that may be leaking.

If the boiler is part of a sealed heating system, check the following:

• System pressure

• Pressure relief valve operation

• Expansion vessel air charge pressure (when the system pressure

is zero)

Re-fill and vent the system to the required pressure. Refer to Section

On either sealed or open-vented systems:

• Inspect and clean the in-line magnetic filter in accordance with the filter manufacturer’s instructions.

• Ensure that adequate corrosion protection is present in system.

Figure 12-1: Location of manual air vent (water connection to wash system removed for clarity)

Section 12: ServicingPage 54

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12.4 Flue System

12.4.1 Flue Terminal

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.

Check the flue terminal and ensure that it is not blocked or damaged.

12.4.2 Flue

To access the flue inspection hatch, remove the circular outer cover. To do this, turn the knob in the centre of the outer cover approximately one turn anticlockwise and pull the cover away from the inspection pipe.

Remove the flue inspection hatch. Turn the knurled knob (in the centre of the hatch) approximately one turn anticlockwise, pull the hatch out of the flue and inspect the inside of the flue system.

Clean the flue by sweeping as required.

Replace the inspection hatch using the reverse procedure turning the knurled knob approximately one turn clockwise to secure it in the flue.

Replace the circular outer cover using the reverse procedure, turning the knob approximately one turn clockwise to secure the cover in place.

12.4.3 Smoke Test

Following inspection and cleaning of the flue system, carry out a smoke test as specified in The Building Regulations Approved Document J, Appendix E, Section E15 – Smoke Test II.

WARNING

Figure 12-2: Wash system connection

• Unscrew and remove the five nuts (and washers) securing the heat exchanger cover and remove it from the top of the heat exchangers. Refer to Figures 12-3.

12.5 Combustion Ventilation

Check that the combustion air inlet to the boiler along the lower front edge of the boiler front door is unobstructed. If necessar y remove any obstructions, e.g. leaves, etc.

Check that the combustion air inlet to the burner, located in the font of the boiler, is unobstructed.

12.6 Boiler

12.6.1 Overheat thermostat and Temperature probe

With the hinged hopper lid open and top access cover removed: Check the following:

• That both the overheat thermostat probe and thermistor bulb are fully inserted in the boiler waterway pocket (on the upper left side of the boiler), and the retaining clip is fitted. Refer to Figure 11-3.

• The condition of thermistor cable and thermostat capillary, i.e. not damaged, broken or kinked.

12.6.2 Primary heat exchanger

With the hinged hopper lid open and top access cover removed (as Section 12.3 above):

• Shut off the cold water supply to wash system.

• Disconnect the water supply hose from the wash system. Refer

to Figure 12-2.

Figure 12-3: Heat exchanger cover

Clean primary heat exchanger as follows:

• Remove all eight mild steel spiral baf fles by lifting them vertically up and out from the primary heat exchanger tubes. Refer to Figure 12-4.

Figure 12-4: Primary heat exchanger spirals

• Clean down any ash inside tubes, using a suitable pipe brush, into the combustion chamber and ash pan below.

• Carefully clean the Lambda sensor - located on the left side in the top chamber of the primary heat exchanger. Remove any ash deposits using a soft bristle brush (e.g. a small paint brush) and

Section 12: Servicing Page 55

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vacuum.

• Clean all ash deposits from top chamber of the primary heat exchanger (above tubes) and shaker mechanism/plates, using brush and vacuum.

• Clean and check condition of all spiral baffles.

• Re-fit baffles into heat exchanger tubes, fitting them through

shaker plates.

• Lift and drop each spiral baffle to check that all baffles are free to move in their respective tubes.

12.6.3 Secondary Heat Exchanger

12.6.4 Fan

There are two dif ferent t ypes of spiral baffle fitted to the secondary heat exchanger.

The spiral baffles fitted to the right hand side have a 2½ turn spiral and are dif ferent to those on the lef t hand side which have 4½ turn spiral.

Whenever these are removed, it is important that they are refitted in the correct side of the secondary heat exchanger.

With the hinged hopper lid open, top access cover and heat exchanger removed (as per Section 12.6.2)

• Clean the secondary heat exchanger as follows:

• Remove all of the stainless steel spirals from the secondar y heat

exchanger tubes. Refer to Figure 12-5.

NOTE

Figure 12-6: - Location of fan

• With the hinged hopper lid open, top access cover and heat exchanger cover removed (as per Section 12.6.2), clean the fan.

• Using a small wire brush, clean any ash deposits from the fan blades and mounting plate.

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.

Check and clean the wash system jets to ensure all ash deposits

•

and other debris is removed.

• Refit the heat exchanger cover to the top of the heat exchanger(s) and secure with the nuts previously removed. Do not over tighten.

• Reconnect air inlet hoses.

• Re-connect water supply hose to connection on wash system

manifold. Refer to Figure 12-2.

CAUTION

Figure 12-5: Secondary heat exchanger spirals

• Clean down any ash inside tubes, using a suitable pipe brush, into the base of the condensing heat exchanger below.

• Clean all ash deposits from top chamber of secondary heat exchanger (above tubes) using brush and vacuum.

• Clean and check condition of all spiral baffles. Replace if necessary.

• Re-fit baffles into heat exchanger tubes, such that all the top edges of the baffles are running ‘front to back’. Refer to Figure 11-9.

Figure 12-7: Removal of fan

Section 12: ServicingPage 56

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12.6.5 Combustion Chamber

Ensure the electrical supply to the boiler is isolated at the fused spur before proceeding.

Shut off the isolator.

• Fit the multi-purpose tool (provided with the boiler) into slot in door catch. Refer to Figure 11-5.

• Lift the tool handle to release the door catch and fully open the combustion chamber door of the boiler. Refer to Figure 11-6.

• Using the multi-purpose tool supplied with the boiler, carefully remove ash pan from combustion chamber. Refer to Figure 12-9.

WARNING

Figure 12-8: Carrying ash pan

Figure 12-10: Vertical combustion chamber baffle

Figure 12-9: Ash pan removal

Extreme care is required when emptying the ash pan as smouldering ash could be present and cause serious damage to persons or proper ty. Ensure the ash is disposed of in a safe manner.

•

When carrying the ash pan use both the multi-purpose tool and the ash pan carrying handle (also provided with the boiler). Refer to Figure 12-8.

• Remove both the horizontal and vertical baffles from the rear of the combustion chamber and inspect them. Refer to Figures 12-10 and 12-11.

• Clean off any remaining deposits using a brush and vacuum.

• Before re-fitting the baffles, remove all ash deposits from all the

internal combustion chamber surfaces using a vacuum.

• Clean any ash deposits from the inner face of the combustion chamber door.

• Re-fit the baffles to the combustion chamber.

CAUTION

Figure 12-11: Horizontal combustion chamber baffle

Section 12: Servicing Page 57

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12.7 Burner

12.7.1 Dismantling the Burner

• Remove the flame pot from the top of the burner. Refer to Figure 12-15.

Ensure the electrical supply to the boiler is isolated at the fused spur before proceeding.

To clean the burner thoroughly it is necessar y to dismantle it using the following procedure:

• Fully open the combustion chamber door (as per Section 12.6.5).

• Clean any ash deposits from the external surfaces of the burner.

• Using the multi-purpose tool supplied with the boiler, rotate the

brazier catch (on the front of the burner) 90° anticlockwise to release it from the upper front of the burner housing. Refer to Figure 12-12.

WARNING

Figure 12-15: Removal of flame pot

• Using the multi-purpose tool supplied with the boiler, remove the wire cotter pin that attaches the brazier assembly to the brazier cleaning shaft. Refer to Figure 12-16.

Figure 12-12: Brazier catch

• Hinge down and remove the brazier front plate from the burner. Refer to Figure 12-13.

Figure 12-13: Removal of brazier front plate

• Using the multi-purpose tool supplied with the boiler, remove the brazier base plate from the lower front of the burner housing. Refer to Figure 12-14.

Figure 12-16: Cotter pin removal

• Remove the brazier assembly from the burner. Pull to the right (until it touches combustion chamber wall) and then remove it from the front. Refer to Figures 12-17 and 12-18.

Do NOT attempt to force the brazier assembly open without removing the wire cotter pin from the brazier cleaning shaft Failure to follow this guidance will result in damage to cleaning actuator, cleaning mechanism or brazier.

WARNING

Figure 12-14: Removal of brazier base plate

Section 12: ServicingPage 58

Page 59

Figure 12-17: Brazier assembly removal to side

The flange on one side of the octagonal pot is narrower than the other seven sides. Refer to Figure 12-19. This side MUST be located on the left hand side or the pot will not fit into the burner housing.

Re-fit the brazier base plate into the lower front of the burner

•

housing using the multi-purpose tool supplied with the boiler

• Re-fit the brazier front plate onto the lower front of the burner housing. Secure in place by engaging the brazier catch into the catch plate on the upper front face of the burner housing. Rotate catch 90° clockwise to ensure it is fully engaged in the catch plate using the multi-purpose tool supplied with the boiler.

• Finally, remove any remaining deposits of ash from the bottom of the combustion chamber and then re-fit the ash pan in the base of the combustion chamber.

NOTE

Figure 12-18: Brazier assembly removal

12.7.2 Cleaning the Burner

Once dismantled, clean the burner as follows:

• Clean and inspect the burner housing (inside the combustion chamber).

• Remove all ash deposits and check that all openings and air holes are clear.

• Clean and inspect the brazier assembly, flame pot (refer to Figure 12-19), brazier base plate and brazier front plate.

The boiler will perform an automatic brazier cleaning operation when power to the boiler is re-connected.

12.7.3 Photocell

Remove the photocell from the mount on the left side of the heat exchanger. Check and clean the photocell. Replace if damaged. Refer to Figure 12-20.

NOTE

Figure 12-20: Photocell location

12.8 Ignition Element

Location flange

Figure 12-19: Flame pot flange

• Remove all ash and clinker deposits from these parts using a wire brush and, where necessary, a flat scraper. Check that all air holes are clear.

• Re-fit brazier assembly into the burner housing – locating the brazier cleaning shaft into the opening in the left side of the brazier assembly.

• Replace the wire cotter pin to secure the brazier assembly to the brazier cleaning shaft.

• Re-fit the flame pot into the top of the burner housing.

Remove and check the condition of the ignition heater element.

To remove; first remove steel clip holding grommet in place. Grasp the black grommet and pull the element from the mounting tube (on the left side of the heat exchanger). Do NOT pull on the element power cable. Refer to Figure 12-21.

Figure 12-21: Ignition element location

Section 12: Servicing Page 59

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Clean the inside of the element mounting tube using a suitable size of

35 - 40mm

tube brush.

Check and clean both ignition element and ceramic socket and ensure the ignition element if correctly fitted into the ceramic socket.

To ensure that the element is correctly positioned in the tube check the distance from the shoulder of the grommet to the element socket is 35 – 40mm. Adjust the position of the grommet as necessary. Refer to Figure 12-22.

Refit ignition element into mounting tube until grommet is fully pushed home.

Refit steel clip to secure grommet in place.

Figure 12-22: Correct ignition element position

12.9 Condensate Disposal System

12.9.1 Condensate Trap

The condensate trap, condensate outlet and disposal pipe MUST be checked on EVERY service and cleaned as necessary. Failure to regularly check and clean the condensate trap and disposal pipe may result in damage to the boiler and this will not be covered by the product guarantee.

The condensate must be checked and cleaned as necessary on every service.

To check/clean the trap:

• Disconnect the condensate disposal system from the outlet of the trap.

• Disconnect the trap from the boiler condensate outlet. Refer to Section 5.5 for condensate trap connection details.

• Check that the boiler condensate outlet is clear. Remove any blockage or ash build-up.

• Thoroughly clean out the trap to remove any deposits and re-fit to condensate disposal pipe.

• Reconnect trap to the boiler condensate outlet. Refer to Section

5.5 for condensate trap connection details.

NOTE

12.10 Boiler Settings

With the electrical power to the hopper and boiler switched on, and the boiler ON/STANDBY switch set to STANDBY, check that ALL boiler settings in the ‘parameter menu’ match those set on commissioning (i.e. as recorded on the Commissioning Report form), a copy of which was left with the householder/user.

Refer to Sections 9.6 and 9.7 for details on how to access and check these settings.

Reset the ‘Service’ period to zero as follows:

• Access the ‘Service Menu’ (refer to Section 9.6 for guidance)

• When in the ‘Service Menu’ - press button 2 to scroll down to

‘Reset Service Timers’ function

• Press button 4 to select ‘Reset Service Timers’ function

• Press button 4 to confirm

• Press button 3 twice to return to ‘Home Screen’

12.11 Hopper Lid Cut-out Switch

Check operation of the cut-out switch. Follow the procedure given in Section 11.4.

12.12 Combustion Checks

To ensure safe and ef ficient operation of the boiler, it is essential that the boiler combustion is re-checked and adjusted as necessary.

12.12.1 Combustion Chamber Draught

Check the combustion chamber draught. Follow the procedure given in Section 11.8.

11.12.2 Flue Gas Analysis

Check the %CO Section 11.9.

To ensure safe and ef ficient operation of the boiler it is important that boiler/burner is re-commissioning as detailed in Section 11.

in the flue gases. Follow the procedure given in

WARNING

12.9.2 Condensate Disposal Pipe

Before re-connecting discharge pipe to the trap outlet:

• Check entire length of disposal pipe, for any leaks or blockages.

• Thoroughly clean to remove any deposits or replace as neces-

sary.

• Dismantle and Check that any outlets to a gully or hopper are not obstructed. Remove any blockages.

12.9.3 Condensate Pump

If a condensate pump is fitted to the system, check:

• The condition of the holding tank. Thoroughly clean, if required, to remove any deposits.

• Operation of the overflow cut-out float switch.

• That the pump is operating correctly.

Section 12: ServicingPage 60

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13 Fault Finding

13.1 Fault Codes

The boiler control system monitors all aspects of the boiler operation and, should a fault occur, will display a fault message and fault code on the control panel LCD.

The fault messages and codes are as follows:

Fault message Err or code

Safety Relay Fault 1

Auger Monitor Fault 2

Failed Pellet Lighting 2

Ignition Monitor Fault 3

Safety Charge Pipe Stat 3

Overheat Thermostat 4

Servo Motor Blocked 8

Flue Fan Ignition Rate 10

Flue Fan Failed 11

Water Flow Switch 12

Fuel Low 13

Safety Shutdown 14

Door Open 15

Hopper Lid Open 16

Burner Fan Ignition Rate 17

Burner Fan Failed 18

False Flame 19

EN60730 Fault (PCB fault) 20

Safety Flap Open 21

Safety Flap Closed 22

APS Fault 23

Safety Monitor 24

Section 13: Fault Finding Page 61

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13.2 Fault Details

13.2.1 Failed Pellet Lighting

Section 13: Fault FindingPage 62

Page 63

13.2.2 Overheat Thermostat

Section 13: Fault Finding Page 63

Page 64

14 Spare Parts

14.1 Boiler Parts List

Item Description Grant UK product code Quantity

N/A Front door lock and keys VEC001 1

N/A Lid safety switch WPS88 1

N/A Front cleaning door safety switch WPS88 1

N/A Electrical isolation switch VEC002 1

N/A Display board (LED screen) VEC003 1

N/A On / of f switch VEC004 1

N/A Vecta PCB board VEC005 1

N/A Power unit for PCB board VEC006 1

N/A Lambda sensor VEC007 1

N/A Lambda sensor PCB board VEC008 1

N/A Complete heat exchanger cover complete with manifold VEC009 1

N/A Nozzle tube (for wash down) VEC010 1

N/A Nozzle holder (for wash down) VEC011 1

N/A Wash down flexible hose Special - please call Grant UK 1

N/A Primary heat exchanger spirals VEC012 8

N/A Secondary heat exchanger spirals (LHS - 4½ turns) VEC013 15

N/A Secondary heat exchanger spirals (RHS - 2½ turns) VEC014 15

N/A Shaker box gasket VEC015 1

N/A Photocell WPS09 1

N/A Photocell tube VEC016 1

N/A Ignition element WPS10A 1

N/A Ignition element tube VEC017 1

N/A Ash pan VEC018 1

N/A Carry handle Special - please call Grant UK 1

N/A Multi purpose tool VEC019 1

N/A Vertical combustion chamber baf fle VEC020 1

N/A Horizontal combustion chamber baffle VEC021 1

N/A Brazier front plate c/w catch VEC022 1

N/A Brazier base plate VEC023 1

N/A Complete brazier assembly VEC024 1

N/A Flame pot VEC025 1

N/A Air pressure switch VEC026 1

N/A Manual air vent VEC027 1

N/A High limit stat WPS107 1

N/A Temperature thermistor WPS25 1

N/A Solenoid coil and valve WPS76 1

N/A Flue fan motor VEC028 1

N/A Actuator board VEC029 1

N/A Fire damper motor (Belimo) VEC030 1

N/A Auger motor (SPG) Special - please call Grant UK 1

N/A Low fuel warning microswitch Special - please call Grant UK 1

N/A Low fuel diaphragm Special - please call Grant UK 1

N/A Linear motor (Lynex) VEC031 1

N/A Fuse (5 amp - fast acting glass) Special - please call Grant UK 1

Section 14: Spare Par tsPage 64

Page 65

14.2 Side Store Par ts List

Item Description Grant UK product code Quantity

N/A Auger motor (SPG) Special - please call Grant UK 1

N/A Low fuel warning microswitch Special - please call Grant UK 1

N/A Low fuel diaphragm Special - please call Grant UK 1

Section 14: Spare Par ts Page 65

Page 66

15 The Clean Air Act 1993 and Smoke Control Areas

The Clean Air Act 1993 and Smoke Control Areas

Under the Clean Air Act local authorities may declare the whole or part of the district of the authority to be a smoke control area. It is an offence to emit smoke from a chimney of a building, from a furnace or from any fixed boiler if located in a designated smoke control area. It is also an offence to acquire an “unauthorised fuel” for use within a smoke control area unless it is used in an “exempt” appliance (“exempted” from the controls which generally apply in the smoke control area).

The Secretary of State for Environment, Food and Rural Affairs has powers under the Act to authorise smokeless fuels or exempt appliances for use in smoke control areas in England. In Scotland and Wales this power rests with Ministers in the devolved administrations for those countries. Separate legislation, the Clean Air (Northern Ireland) Order 1981, applies in Northern Ireland. Therefore it is a requirement that fuels burnt or obtained for use in smoke control areas have been “authorised” in Regulations and that appliances used to burn solid fuel in those areas (other than “authorised” fuels) have been exempted by an Order made and signed by the Secretar y of State or Minister in the devolved administrations.

Further information on the requirements of the Clean Air Act can be found at www.gov.uk/smoke-control-area-rules

Your local authority is responsible for implementing the Clean Air Act 1993 including designation and supervision of smoke control areas and you can contact them for details of Clean Air Act requirements.

The Grant Vecta 4-16 Condensing Wood Pellet Boiler has been recommended as suitable for use in smoke control areas when burning EN Plus A1 pellets.

Section 15: The Clean Air Act and Smoke Control AreasPage 66

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16 Declaration of Conformity

EC Declaration of Conformity

In accordance with BS EN ISO/IEC 17050-1:2004

Grant Engineering (UK) Limited

We:

Hopton House

Of:

Hopton Industrial Estate Devizes SN10 2EU

Telephone: Fax: Email: Website:

Declare that: Equipment: Model Name/Number:

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. 92/42/EC Conforms with the requirements of the Boiler Efficiency Directive.

+44 (0)1380 736920

+44 (0)1380 736991

[email protected]

www.grantuk.com

Floor Standing Domestic Condensing Wood Pellet Boiler

Grant Vecta 4-16 Wood Pellet Boiler

Has been designed and manufactured to the following specifications:

EN60335-1:2012 Household and similar electrical appliances. Safety – General requirements. EN60335-2-102:2006+A1:2010 Household and similar electrical appliances. Safet y. Particular requirements for gas, oil and sold fuel

burning appliances having electrical connections. EN303-5:2012 Heating Boilers for solid fuels. Manually or automatically stoked. Nominal heat output up to 500kW.

I hereby declare that the equipment named above has been tested and found to comply with the relevant sections of the above referenced specifications. The unit complies with all essential requirements of the Directives.

Responsible Person: Position: Technical Manager Signature:

Date: 15th December 2016

Neil Sawers

Section 16: Declaration of Conformity Page 67

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17 Health and Safety Information

Under the Consumer Protection Act 1987 and Section 6 of the Health and safety at Work Act 1974, we are required to provide information on substances hazardous to health (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:

17.1 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.

17.2 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 skin.

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. Seek immediate medical attention.

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.

Skin:

Wipe off and wash with soap and water.

Inhalation:

Remove to fresh air.

Section 17: Health and Safety InformationPage 68

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18 Disposal and Recycling

General

Grant wood pellet boilers incorporate components manufactured from a variet y of different materials. The majorit y of these materials can be recycled whilst the smaller remainder cannot.

Materials that cannot be recycled must be disposed of according to local regulations using appropriate waste collection and/or disposal services.

Disassembly

There is little risk to those involved in the disassembly of this product. Please refer to and follow the Health and Safety Information given in the Installation & Servicing Instructions provided with the boiler.

For guidance on the disassembly of the boiler refer to the information given in the Servicing section of the Installation & Ser vicing Instructions provided with the boiler.

Recycling

Many of the materials used in Grant oil boilers can be recycled, these are listed in the table below:

Component Material

Outer casing panels Mild steel (polyester powder coated)

Primary heat exchanger and baffles Mild steel

Secondary heat exchanger Stainless steel

Secondary heat exchanger spirals Stainless steel

Pipework Copper

Burner body/brazier Stainless steel

Electrical wiring Copper / plastic

Thermostats Copper / plastic

Printed circuit boards Copper / plastic

Disposal

All materials other than those listed above must be disposed of responsibly as general waste

Section 18: Disposal and Recycling Page 69

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19 Guarantee

You are now the proud owner of a wood pellet boiler from Grant Engineering (UK) Limited, which has been designed to give years of reliable, trouble free, operation.

Grant Engineering (UK) Limited guarantees the manufacture of the boiler including all electrical and mechanical components for a period of twelve months from the date of installation

, provided that the boiler has been installed in full accordance with the installation and servicing instructions issued.

This will be extended to a total period of two years if the boiler is registered with Grant Engineering (UK) Limited within thir ty days of

installation

and it is serviced at regular intervals

. See main Terms and Conditions below.

Registering the product with Grant Engineering (UK) Limited

Please register your wood pellet boiler with Grant Engineering UK Limited within thirty days of installation grantuk.com, where you can register your boiler for a further

. To do so visit w ww.

twelve

months guarantee (giving t wo years from the date of installation).

This does not affect your statutory rights

If a fault or defect occurs within the manufacturer’s guarantee period

If your boiler should fail within the guarantee period, you must contact Grant Engineering (UK) Limited who will arrange for the repair under the terms of the guarantee, providing that the boiler has been correctly installed, commissioned and regularly ser viced by a competent person and the fault is not due to tampering, running out of fuel, the use of unapproved wood pellets, contamination, debris, system water contamination, misuse, trapped air or the failure of any external components not supplied by Grant Engineering (UK) Limited, e.g. motorised valve, etc.

This two year guarantee only applies if the boiler is registered with Grant Engineering (UK) Limited within thir ty days of installation

and is regularly ser viced3.

In the first instance

Contact your installer or commissioning engineer to ensure that the fault does not lie with the system components or any incorrect setting of the system controls that falls outside of the manufacturer’s guarantee other wise a service charge could result. Grant Engineering (UK) Limited will not be liable for any charges arising from this process.

If a fault covered by the manufacturer’s guarantee is found

Ask your installer to contact Grant Engineering (UK) Limited Ser vice Department on +44 (0)1380 736920 who will arrange for a competent service engineer to rectify the fault.

Remember - before you contact Grant Engineering (UK) Limited:

• Ensure the boiler has been installed, commissioned and ser viced by a competent person in accordance with the installation and servicing instructions.

• 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 installation and servicing instructions supplied with the boiler for guidance.

• Ensure the problem is not being caused by poor qualit y or incorrect pellets.

Free of charge repairs

During the two year guarantee period 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 installation and servicing instructions, it was registered with Grant Engineering (UK) Limited within thir ty days of installation of regular servicing is available

and details

The following documents must be made available to Grant Engineering (UK) Limited on request:

• Proof of purchase

• Commissioning Report Form

• Service documents

Chargeable repairs

A charge may be made (if necessary following testing of parts) if the cause of the breakdown is due to any fault(s) 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 guarantee’ below.

Extent of manufacturer’s guarantee:

The manufacturer’s guarantee does not cover the following:

• If the boiler has been installed over t wo years.

• If the boiler has not been installed, commissioned, or ser viced

by a competent person in accordance with the installation and servicing instructions.

• The serial number has been removed or made illegible.

• Fault(s) due to accidental damage, tampering, unauthorised

adjustment, neglect, misuse or operating the boiler contrary to the manufacturer’s installation and servicing instructions.

• Damage due to external causes such as bad weather conditions (flood, storms, lightning, frost, snow, ice), fire, explosion, accident or theft.

• Fault(s) due to incorrectly sized expansion vessel(s), incorrect vessel charge pressure or inadequate expansion on the system.

• Fault(s) caused by external electrics and ex ternal components not supplied by Grant Engineering (UK) Limited.

• 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 Engineering (UK) Limited).

• Removing any pellet store or hopper contamination or blockages in the pellet augers, pellet hopper or bulk pellet store.

• Removal of dust from the pellet augers, pellet hopper or bulk pellet store.

• Problems due to the flue system being incorrectly fitted or not installed to meet installation requirements.

Section 19: GuaranteePage 70

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• Boiler servicing, de-scaling or flushing.

• Cleaning out condensate traps/discharge pipework or thawing

frozen condensate pipework.

• Checking or replenishing system pressure.

• Electrical cables and plugs, heating system controls not supplied

by Grant Engineering (UK) Limited.

• Heating system components, such as radiators, pipes, fittings, pumps and valves not supplied by Grant Engineering (UK) Limited.

• Instances where the wood pellet boiler has been un-installed and re-installed in another location.

• Use of spare parts not authorised by Grant Engineering (UK) Limited.

• Consumable items including, but not limited to, gaskets, seals, etc.

IMPORTANT

Do not wait until your wood pellet supply runs out before you re-order.

Dust in the bottom of the pellet store or hopper may prevent the supply of pellets to the burner. It is impor tant that this is checked for and, if dust is present, removed on the regular service to prevent nuisance stoppage of the boiler.

Terms of manufacturer’s guarantee:

• The Company shall mean Grant Engineering (UK) Limited.

• The boiler must be installed by a competent installer and in full

accordance with the relevant Codes of Practice, Regulations and Legislation in force at the time of installation.

• The boiler is guaranteed for t wo years from the date of

installation completed

, providing that regular servicing has been

and the boiler registered with the Company within thirty days of installation. Any work undertaken must be authorised by the Company and carried out by a competent service engineer.

• The boiler must be installed by an engineer that has attended and passed a Grant Engineering (UK) Limited accredited training course.

• The shell (heat exchanger) of the wood pellet boiler is covered by a five year parts only guarantee from the date of installation

This is subject to the following:

• The boiler is operated correctly, in accordance with the

installation and servicing instructions.

• Proof is provided that the system has been flushed or

chemically cleaned where appropriate (refer to BS 7593) and that the required quantity of a suitable corrosion inhibitor added.

• Proof of regular ser vicing (including the checking of any

expansion vessels and pressure relief valves) must be provided if and when requested by the Company.

IMPORTANT Grant Engineering (UK) Limited strongly recommends that

a Grant Mag-One in-line magnetic filter/s (or equivalent

) is fitted in the heating system pipework. This should be installed and regularly ser viced in accordance with the filter manufacturer’s instructions.

• 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 installation and servicing instructions.

• The boiler is registered with the Company within thirty days of installation rights

. Failure to do so does not affect your statutory

• The balance of the guarantee is transferable providing the installation is serviced prior to the dwelling’s new owners taking up residence. Grant Engineering (UK) Limited must be informed of the new owner’s details.

• The 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.

• This guarantee applies to Grant Engineering (UK) Limited boilers purchased and installed on the UK mainland, Isle of Wight, Channel Islands and Scottish Isles only

. Provision of inguarantee cover elsewhere in the UK is subject to agreement with the Company.

• All claims under this guarantee must be made to the Company prior to any work being undertaken. Invoices for call out/repair work by any third party will not be accepted unless previously authorised by the Company.

• Proof of purchase and date of installation, commissioning and service documents must be provided on request.

• If a replacement boiler is supplied under the guarantee (due to a manufacturing fault) the product guarantee continues from the installation date of the original boiler, and not from the installation date of the replacement

• Breakdown/failure due to lime scale will not be covered by this guarantee.

• The replacement of a boiler under this guarantee does not include any consequential costs.

• The boiler must not be sited in a location where it may be subjected to frost.

• The ceramic ignition element is covered by a two year guarantee.

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 guarantee. Ask your installer for advice.

Foot notes:

1. Your statutory rights entitle you to a one year guarantee period only.

2. The UK mainland consists of England, Scotland and Wales only. Please note that for the purposes of this definition, Northern Ireland, Isle of Man and Scilly Isles are not considered part of the UK mainland.

3. Your wood pellet boiler must be regularly serviced as per the installation and servicing instructions, (even when the guarantee has expired) to prolong the lifespan and ensure it is operating safely and efficiently.

4. The guarantee period will commence from the date of installation, unless the installation date is more than six months from the date of purchase, in which case the guarantee period will commence six months from the date of purchase.

5. As measured by gauss. The Mag-One magnetic filter has a gauss measurement of 12000.

Version 1.0 - December 2014

Section 19: Guarantee Page 71

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Grant EnGinEErinG (UK) LimitEd

Hopton House, Hopton Industrial Estate, Devizes, Wiltshire, SN10 2EU

Tel: +44 (0)1380 736920 Fax: +44 (0)1380 736991

Email: [email protected] www.grantuk.com