Grant Spira 6-26 kW, Spira 9-36 kW User Instruction

Download

Page 1

IRL NO.012 Rev; 0 April 2011

USER INSTRUCTION

for

GRANT SPIRA 6-26 kW CONDENSING WOOD PELLET BOILER

GRANT SPIRA 9-36 kW CONDENSING WOOD PELLET BOILER

Leave the user manual with the householder.

This appliance is deemed a control service and specific regional statutory requirements

may be applicable.

Page 2

Contents Section Page

1 Introduction 3 2 About your boiler 3 3 About your Fuel 4 4 Cleaning and servicing you boiler 5 5 User controls 5 6 Burner display 6 7 Priming the auger 7 8 Lighting the boiler 7 9 Emptying the ash 8 10 If you boiler fails to light 9 11 Ventilation 10 12 Frost protection 10 13 Electricity supply 10 14 Sealed Central heating system 10 15 Visual guide to assess Wood pellet Quality 11 16 Service log 12

Page 3

1. Introduction

This guide is intended to assist and instruct the User in the operation of the Grant SPIRA Condensing Wood Pellet Boiler. A separate manual is available to Engineers for the installation, servicing and commissioning of the boiler.

The following special text formats are used in this manual of 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”

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

2. About your boiler.

Your Grant SPIRA wood pellet boiler should only be installed, commissioned and serviced by a FETAC registered Engineer. They are also required to have undergone specific product training by Grant Engineering (Ireland) Ltd.

When commissioned correctly, your Grant SPIRA condensing wood pellet boiler operates automatically as it is equipped with an automatic cleaning system. The ash pan will need to be emptied after each 3 tonnes of pellet consumption and serviced annually by a Service Engineer who has completed the Grant training course. Details of each service should be recorded in the Service Log in the back of this manual.

The burner is equipped with a brazier where the combustion of the wood pellets takes place within the boiler. The self cleaning device on the brazier and boiler activates after the auger run time has exceeded a predetermined set time. The auger run time for brazier and boiler cleaning is set in the burner menu. Both cleaning functions may be activated at different stages, this is normal.

As long as there are sufficient pellets in the hopper, the system is „calling‟ and the auger is charged then the boiler is fully automatic once switched on, providing central heating and also heating your domestic hot water if you have a cylinder fitted.

If your appliance is controlled by a remote programmer and/or a room thermostat, it will provide hot water and central heating during the periods as set on the programmer, when either the room thermostat and or the hot water thermostat are calling.

The system comes complete with an intermediate hopper. This hopper stores 110 kg (169 lt.) of wood pellets. The hopper is for indoor use only and should be positioned in a dry environment. As the hopper comes with castors, allow sufficient area in front of the hopper for removal during servicing. The hopper should be filled to the point where it is still possible to close the top door.

Do not adjust or modify the appliance in anyway as to do so could cause malfunction of the appliance, injury to persons or death or result in a potential fire hazard. Only allow a qualified Service Engineer who has completed the Grant training course should carry out any work on the appliance.

All national and local regulations and European Standards shall be complied with during the operation of the appliance.

Always ensure the front access door of the

combustion chamber is fully closed and latched

during operation.

Certain external surface of the boiler will be hot to

touch when in operation, due care is needed.

WARNING

CAUTION

NOTE

WARNING

Page 4

3. About your Fuel

Once your boiler has been commissioned the burner settings are adjusted for use with that fuel. Only use one of following wood pellet brands with the Grant Wood pellet boiler.

6mm „BNM Premium‟, 6mm „Balcas Brites‟

6mm „GWP‟ pellets. If the Commissioning Engineer has commissioned your boiler for use with an alternative fuel supplier (other than that listed above) check with Grant Engineering (Ireland) Limited as you may need to have the boiler recommissioned if you plan to change your fuel supplier. Each bulk pellet manufacturer has clear guidelines on the requirements of a bulk storage hopper used to store their pellets together with requirements on positioning, access, and minimum deliveries. Check with the pellet supplier /manufacturer you wish to use before installing your bulk hopper system.

This Grant SPIRA boiler is designed to run on wood pellets that meet the following criteria;

Key Parameter

Limits

Category as per prCEN/TS 14961:2004

Diameter

6mm

D06,

Average length

L<5 x diameter

Maximum length

40mm

Moisture Content

<10%

S0.05

Mechanical durability

>97.5%

DU 97.5

Amount of fines

<1.0%

F1.0

Additives

None

Nitrogen

< 0.3%

N0.3

Nett calorific value

Ca. 4.8 to 5.2 kWh/kg

Bulk density

Ca 650 kg/m3

Chlorine

< 0.03%

CL 0.03

Additives; Additives are used to improve the stability of the pellets. If manufactured correctly, and of a sufficiently low moisture content, quality

pellets will require no additives.

Ash; 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.

Average length: To provide a predictable flow of fuel into the burner, the recommended length of a pellet is deemed greater than 5mm and less than

5 times the diameter.

Bulk density; Bulk density is the ratio between the weight of the pellet and the amount of space they take up. A good quality pellet will have a

density of 650 kg/m3. 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 Pellets are made from compressed wood. As pellets rub together they can break down slightly, producing dust or fines. Too many

fines indicate a poor quality pellet and can impede pellet flow in addition to causing dust problems when delivering and storing the

pellets. Mechanical Durability This is a measure of how stable the pellet is and how likely it is to produce fines from normal handling. A high durability percentage

is an indicator of a good quality pellet. Moisture content Moisture affects the calorific value of the pellet. Low moisture content guarantees constant and predictable combustion efficiency.

Higher moisture contents can result in pellet breakdown. Net Calorific Value 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. Nitrogen High levels of nitrogen in the flue gases emissions can give rise to corrosion. Sulphur High levels of sulphur in the flue gases emissions can give rise to corrosion.

Page 5

4. Cleaning and Servicing your boiler.

To ensure the safe and trouble free operation of the boiler ensure the ash pan is emptied after each 3 tonne of pellets burnt as failure to do so could cause the boiler to malfunction.

Ensure the boiler is serviced annually. Only allow

a qualified Competent Service Engineer who has

completed the Grant Engineering Training course

on Wood pellet boilers to service your boiler.

Ensure the service details are recorded in the

Service log at the back of this book.

5. User Controls

The boiler control panel has the following controls that are designed for the user to operate.

Burner switch, interrupts the signal from a

remote programmer and/or a room thermostat. This switch should be left in the ON position during normal operation of the boiler.

CLEANING; Auto / Test. This switch is

normally in Auto mode which allows the controls automatically clean the boiler. In test mode the controls are bypassed allowing the Operator or Service Engineer to activate the cleaning of the boiler. The switch is spring loaded to return to the Auto mode after Test mode is released.

Overheat reset; A built in safety feature is

provided to prevent the temperature of the boiler overheating. This can be manually reset. If the re-setting is continually required contact your Service Engineer.

The burner control panel has the following controls that are designed for the user to operate.

Increases the boiler temperature set point

Decreases the boiler temperature set point

Resets any error.

NOTE

RESET

Page 6

6. Burner display

6.1 Set point

The set point is the temperature setting about which the modulation of the boiler output is activated.

5°C below the set point the boiler is in 100%

power mode.

5°C above the set point the boiler has

reached minimum output.

The set point is not the cut out temperature of the burner. The burner cut out temperature of the burner

is factory set in the burner menu‟s, but may have

been adjusted by the commissioning Engineer.

6.2 Boiler system temperature.

This is the temperature of the water in the boiler. Note;When the burner cuts out the temperature will continue to rise as the heat from the flame is transferred to the system water.

6.3 Burner function

The function the boiler is in when viewed, is scrolled across the bottom of the display screen. This can be any one of a number of functions depending on the mode the boiler is in when viewed.

Error messages are also displayed on this section of the screen.

6.4 Operating functions:

‘WAIT PRELOAD BRAZIER’ Initial loading of pellets into the brazier to enable combustion to start.

‘WAIT LIGHTING’ –IGNITION Period of time given for pellets to light.

‘PELLET BURNER FIRING’; Power 25-100% Flame is fully developed and boiler is operating on full power.

‘TURNING OFF BRAZIER’; Burn down period to remove any pellets remaining in the brazier.

‘WAIT POST PURGE’ Period of time after burn down is complete to ensure no unburnt pellets ignite.

‘BOILER WAIT THERMOSTAT’; Boiler is in standby awaiting a switched live input signal and/or the burner switch is in OFF mode.

6.5 Error messages;

FAILED PELLET LIGHTING SAFETY BOILER THERMOSTAT SERVO MOTOR BLOCKED PROBE FAULT SAFETY CHARGE PIPE THERMOSTAT AIR PRESSURE ERROR

For further details on Errors messages see section on „Boiler fails to light‟

6.6 Active Symbols

Active symbols: To the left of the burner display a range of symbols are shown. Once the symbol has a curser displayed beside it in the screen area then that item is active. The list of function symbols are as follows:

2 3

SET

RESET

SET 75°C

H2o 60°C

PELLET BU

Temperature set point (User adjustable)

increase temperature set point

decrease temperature set point

2 3

SET

RESET

SET 75°C

H2o 60°C

PELLET BU

Boiler system

water temperature

2 3

SET

RESET

SET 75°C

H2o 60°C

PELLET BU

BURNER FUNCTION

2 3

SET

RESET

SET 75°C

H2o 60°C

PELLET BU

Active symbols

= Boiler thermostat calling

= Burner fan operational = Pressure switch closed = Ignition element operational = Feed auger operational = Photocell lux reading >'Flame On' setting = n/a

= Error

Page 7

7. Priming the auger

1. Disconnect the 7 pin plug and 6 pin socket from the left-hand side of the burner.

2. Disconnect the pellet delivery hose from the burner and place in a container of at least 1 litre capacity as shown below.

3. Place the 7 pin plug into the 6 pin socket as shown below. The feed auger will now run continuously until the plug and socket are disconnected.

4. The auger will prime itself with wood pellets after a period of 15 to 20 minutes depending on the auger length. Once there is a continuous flow of pellets from the pellet delivery hose disconnect the plug and socket. The auger is now fully primed.

5. Refit the pellet delivery hose into the pellet delivery tube of the burner.

6. Refit the 7 pin socket and 6 pin plug into the original position on the side of the burner.

8. Lighting the boiler.

1. Ensure that system controls are calling for heat.

2. Switch the „Burner Standby/On‟ switch on the boiler control panel to the „On‟ position. The highlighted curser should now be displayed beside the thermostat symbol before the boiler can fire. If not check „Burner Standby/On‟ switch is in „on‟ position and all controls are calling.

If the burner On/Off switch is switched off at this stage the pellet feed will stop and the burner will run through the post purge sequence before pellet feed starts again.

Do not repeatedly switch on and off the burner at this stage as a build up of pellets in the brazier will occur resulting in poor combustion during lighting.

3. The flue fan will start and pellets will be delivered to the burner. The boiler will now light automatically after a short lighting period.

4. Set the HW and CH functions to Timed. The

boiler will now operate during the „on‟

periods set on the programmers.

= Boiler thermostat calling

NOTE

CAUTION

Page 8

9. Emptying the Ash

The interlock on the burner door disconnects the power to the burner to prevent firing when the door is opened. It does not extinguish the flame immediately. If the burner door is opened during the operation of the burner there can be a large uncontrollable flame emitted from the brazier.

After the burner has been switched off (either manually by the switch on the control panel,

the boiler stat’, or the switched live input) the

burner needs to burn-down the remaining pellets in the brazier. Do not AT ANY TIME open the front combustion chamber access

door until the burner display reads “WAIT

BOILER THERMOSTAT”

1. Switch the „Burner Standby / On‟ switch to standby.

2. Wait until the display screen function reads „WAIT PELLET THERMOSTAT‟

3. Disconnect the pellet delivery hose from the burner.

4. Open the front access cleaning door. Slide the ash pan forward. Remove any ash resting on the baffle above the ash pan as shown below.

5. Using the handles provided remove the ash pan from the boiler. Remove any remaining ash that may be left in the base of the boiler.

Extreme care is required when empting the ash

pan as smouldering ash could be present and can

cause serious damage to persons or property.

Ensure the ash is disposed of in a safe manner.

Servicing and replacement of parts must only be

carried out by a suitably qualified engineer who

has completed the Grant training course on wood

pellet boilers.

Details of every service should be entered in the

service log, in the boiler hand book.

Failure to maintain a clean flue may result in

the emission of flue gases into the dwelling

or damage from potential fire in the flue.

Thus it is important that your boiler is

serviced annually be a suitably qualified

engineer who has completed the Grant

training course on wood pellet boilers

WARNING

CAUTION

NOTE

CAUTION

Page 9

10. If your boiler fails to light.

If you boiler fails to light, make the following checks;

1. Check the „Burner Standby/On‟ switch is in the On position.

2. Check the remote programmer(s) is working and is in an „On‟ period.

3. On systems without a bulk hopper fitted; Check there is sufficient quantity of pellets in the intermediate hopper to engage the low level diaphragm in the rear of the hopper.

The curser should now be lit on the burner display beside the thermostat symbol, if not then recheck the programmer(s) and/or add more pellets to the hopper.

Error messages

10.1 Failed pellet lighting;

1. On systems with a bulk hopper fitted; If the

bulk and intermediate hopper is allowed to run out of pellets then the error message

„FAILED PELLET LIGHTING‟ will be

displayed on the burner screen. Once the hoppers have been filled the auger will need re-priming. See section 7 „Priming the Auger, and the error cancelled by pressing the reset button on the burner control panel.

2. Check auger is rotating

3. Check sufficient pellets being delivered to

the burner..

4. Check auger primed fully.

5. Check for dust or blockage in auger.

Pellets that contain excessive dust will prevent the auger from pulling the pellets out of the hopper. The hopper will need to be cleaned of any dust.

6. Check for clinker in the brazier. If present

check quality of pellets.

10.2 SAFETY BOILER THERMOSTAT;

1. The boiler is fitted with a safety overheat thermostat which will automatically switch off the boiler in the case of control malfunction causing overheating. If this occurs the error

message „SAFETY BOILER THERMOSTAT‟

is displayed on the burner screen. Remove

the plastic cap and press the „OVERHEAT

RESET‟ button, then replace the plastic cap.

2. Cancel the error message on the burner screen by pressing RESET on the burner controls. If the condition continually repeats contact your Service Engineer.

10.3 SERVO MOTOR BLOCKED

1. Switch the „Burner Standby / On‟ switch to standby.

2. Wait until the display screen function reads „WAIT PELLET THERMOSTAT‟

3. Disconnect the pellet delivery hose from the burner.

4. Open the front access cleaning door.

5. Check the brazier for solid clinker, remove if present.

6. To cancel the error message press reset on the burner control panel.

10.4 PROBE FAULT

Contact your Service Engineer

10.5 SAFETY CHARGE PIPE THERMOSTAT

1. Check pellet delivery tube is fitted correctly and not damaged in any way.

2. Check drain pipe from boiler is not blocked or frozen.

3. To cancel the error message press reset on the burner control panel.

4. If none of the above are applicable contact you service engineer.

10.6 AIR PRESSURE ERROR

Contact your Service Engineer.

Do not under any circumstances enter a wood

pellet hopper that has been in operation as if the

boiler has malfunctioned there may be a build-up

fumes within the enclosure.

= Boiler thermostat calling

NOTE

WARNING

Page 10

11. Ventilation

Do not attempt to „box in‟ the boiler or build a

compartment around it before contacting your Installer

Do not place any combustible material around or on the boiler or flue pipe.

Do not adjust or block any ventilation openings in the building that the boiler is located in.

12. Frost protection

Your installer may have fitted a frost thermostat. If not, and you are likely to be away for a short time leave the boiler on. For longer periods the boiler should be turned off and the system drained down.

Contact your service Engineer for draining and filling the system.

Grant recommend that a combined inhibitor be used in the primary water system.

13. Electricity supply

If the electricity supply fails, the boiler will not operate. It should relight after the supply is restored. However it may burn-down any smouldering pellets still present in the brazier before it starts the lighting sequence.

If a remote programmer is connected, it may retain the time settings for some time and may not have to be reset to the correct time of day when the supply is restored. Refer to the instructions supplied with your programmer for further details. It is recommended that you check the time settings after a power failure has occurred.

The electrical connections to the boiler must be

earthed.

14. Sealed Central Heating System

If your boiler is operating on sealed heating system, the installer will have adjusted the pressure in the system and should have told you (or set it on the pressure gauge) the system pressure when cold. This is normally between 0.5 and 1.0 bar, which will increase slightly when hot.

If the pressure (when cold) is below the set pressure mentioned above, you can re-pressurize the system. If this is frequently required, ask your Installer or service engineer to check the heating system for leaks and to check the expansion vessel air charge.

The boiler or system will be fitted with an automatic air vent to remove any air from the system. Any trapped air in the radiators should be removed by venting the radiators using the vent screw at the top of each radiator. Only vent a radiator if the top is cool and the bottom is hot.

Excessive venting will reduce the system pressure, so only vent when necessary and check the system pressure as mentioned above. Repressurise the system as necessary.

A sealed system should have a safety valve to release excess pressure. If water or steam is emitted from the end of the safety valve discharge pipe, switch off the boiler and contact your installer or Service Engineer.

NOTE

CAUTION

Page 11

15. Visual guide to assess Wood pellet Quality

Page 12

16. Service log

Service Engineer: ____________________

Date ; _____________________

Service carried out by Qualified Engineer service as per instruction and training by Grant Engineering (Ireland) Limited.