Grant Spira 6-26kW, Spira 9-36kW Installation, Commissioning And Servicing Instructions

- 1 -

IRL NO.011 Rev;3 July 2011

INSTALLATION, COMMISSIONING

AND

SERVICING INSTRUCTIONS

GRANT SPIRA 6-26 kW CONDENSING WOOD PELLET BOILER

GRANT SPIRA 9-36 kW CONDENSING WOOD PELLET BOILER

After installing the boiler leave these instructions with the Appliance.

Leave the user manual with the householder.

This appliance is deemed a controlled service and specific regional statutory requirements may be

applicable.

Index of Wood pellet Boiler installation manual

1. Introduction

1.1

How the wood pellet boiler operates

1.2

Boiler description

1.3

Boiler components

2. Technical data

2.1

Boiler & Hopper technical data

2.2

Boiler output data

2.3

Flue gas analysis

2.4

Boiler & hopper set up Dimensions

3. Pellet specification & storage

3.1

Pellet specification

3.2

Pellet storage

4. Installation information

4.1

Introduction

4.2

Boiler location

4.3

Regulations to comply with

4.4

Preparation for installation

4.5

Installing the boiler

4.6

Make the water connections

4.7

Fan box

4.8

Burner

4.9

Intermediate hopper

4.10

Pellet Feed Auger

5. Condensate disposal

5.1

General requirements

5.2

Connections

5.3

Pipe work

5.4

External pipework

5.5

Condensate soak away

5.6

Condensate trap

5.7

Inspection and cleaning of trap

6. Flue system & Air supply

6.1

Air supply

6.2

Flue position and clearances

6.3

Flue Components & assembly

7. Electrical

7.1

Connecting the power supply

7.2

Frost protection

8. Burner

8.1

Burner operation

8.2

Burner modes

8.3

Operational sequences

8.4

Burner display screen

8.5

Burner control buttons

8.6

Burner menu navigation chart

8.7

Burner menu description

9. Commissioning

9.1

Equipment required

9.2

Before switching on

9.3

Priming the pellet feed auger

9.4

Lighting the boiler

10. Boiler servicing

10.1

Checking before servicing

10.2

Cleaning the burner

10.3

Cleaning the boiler & Flue

11. Fault finding

11.1

Boiler won’t fire (no error message)

11.2

Blank display screen

11.3

Error messages

12 Spare parts.

13 Health & safety information.

14 Warranty.

15 Notes

Grant SPIRA Condensing Wood Pellet Boiler & Intermediate Hopper

This manual is intended to guide Engineers who have completed the Grant Wood Pellet Boiler Installer training course on the installation, commissioning and servicing of the Grant SPIRA Condensing Wood Pellet Boiler. A separate manual is available to guide users in the operation 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.

1.1 How the condensing wood pellet boiler operates

During the combustion process, hydrogen and oxygen combine to produce heat and water vapour. The water vapour produced is in the form of superheated steam in the heat exchanger. This superheated steam contains sensible heat (available heat) and latent (heat locked up in the flue gas). A conventional boiler cannot recover any of the latent heat and this energy is lost to the atmosphere through the flue.

The Grant SPIRA Condensing wood pellet boiler contains an extra (secondary) heat exchanger which is designed to recover the latent heat normally lost by a conventional boiler. It does this by cooling the flue gases to below 90°C thus

extracting more sensible heat and some of the latent heat. This is achieved by cooling the flue gases to their dew point.

To ensure maximum efficiency, the boiler return temperature should be 55°C or less (minimum of 40°C) at maximum operating temperature. This will enable the latent heat to be condensed out of the flue gases.

The boiler will achieve full load efficiency as follows; SPIRA 6-26 Full output = 97.4% Reduced output = 96.4% SPIRA 9-36 Full output = 93.1% Reduced output = 98.1% The Grant SPIRA condensing wood pellet boiler operate

extremely high efficiencies even when it is not in condensing mode and therefore is suitable for fitting to an existing heating system without alteration to the radiator sizes. The boiler is capable of a maximum flow temperature 80°C.

The burner is a drop feed burner. The output of the burner is determined by varying the feed and pause time of the pellet feed auger suppling pellets to the burner.

1.2 Boiler Description

When commissioned correctly, the Grant SPIRA condensing wood pellet range of boilers operate automatically as they are 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 Grant trained service Engineer. Details of each service should be recorded in the Service Log in the back of the User Operating Manual.

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.

The boiler is suitable for use on a sealed or open vented central heating system. All models are supplied with the control panel factory fitted. The burner, combined fan box & flue starter, pellet feed auger and hopper come separately and needs to be fitted by the installer. See section 4 for boiler installation.

WARNING

CAUTION

NOTE

CAUTION

1 Introduction

The boiler needs to be connected to a conventional flue system. There is no provision for connection to a balanced flue system as there is draft regulator fitted to the appliance.

The boiler is not designed specifically for operation on a system with a buffer tank/ thermal store, however when used on a system with a buffer tank/ thermal store there is no effect on the boiler performance.

The only flue system suitable for the Grant SPIRA condensing wood pellet boiler is the Grant „Black‟

insulated conventional flue system.

This 125mm (5”) „Black‟ flue system is suitable for both

models 6-26 & 9-36.

1.3 Boiler components

1.3.1 Burner. The burner is supplied separately and will need

to be mounted to the boiler on site. All burners are supplied at a factory default setting. During commissioning each burner parameter will need to be checked and adjusted if necessary as pellet feed auger angle, pellet size and flue sizes/length can have significant effect on the boiler performance. Refer to commissioning in section 9. The Burner is equipped with a self cleaning device to prevent a build up ash and clinker in the burner brazier. The burner output is determined by the feed / pause times of the pellet feed auger supplying the burner. See section 8 for full burner operation.

1.3.2 Boiler. The SPIRA condensing boiler is supplied with a combined primary and secondary heat-exchanger. The boiler is also equipped with a self cleaning system, of which the primary cleaning system comes fitted in the boiler and the secondary cleaning system needs to be fitted. See section 4. Boiler Installation.

1.3.3 Boiler controls. The temperature of the water leaving the boiler to heat the radiators and hot water cylinder is user adjustable by adjusting the set point on the burner menu see section 8. The boiler is fitted with an overheat thermostat (which allows it to be used on a sealed central heating system) which will automatically switch off the boiler if the temperature exceeds a pre-set temperature of 110°C. The control panel is fitted with a Burner ON/STAND-BY switch. This switch interrupts the switched live supply to the burner, it does not isolate the electrical supply to the burner. The control panel is also fitted with a cleaning switch, in the default position it allows the boiler cleaning system to perform automatically, when pressed it allows the cleaning system to

be manually tested. Only operate the cleaning switch when the boiler is in „WAIT BOILER THERMOSTAT‟. See figure 1.1

Fig. 1.1

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”

1.3.4 Pellet Feed Auger. The pellet feed auger is a hollow

spiral type. Its function is to deliver the pellets from the hopper to the burner. The output of the boiler is determined by varying the on/off periods of the pellet feed auger motor. All Grant hoppers are fitted with a fixed angle feed pellet feed auger at 45° to maintain consistent feed. Once the pellet feed auger angle is altered the input to the boiler is also altered.

1.3.5 Hopper. The system comes complete with an intermediate hopper. This hopper stores 120 kg (169 lt) of wood pellets with a refill capacity of 80 kg The hopper is for indoor use only and should be positioned in a dry environment. Position the hopper to the left side of the boiler only and on the same floor level as the boiler. The hopper is supplied with castors, allow sufficient area in front of the hopper for removal during servicing. The hopper comes

with „knock-out‟ to allow entry of pellets from a bulk hopper system, this knockout is positioned to ensure the pellets drop into the hopper and will de-activate the low level indicator. Making an alternate opening in the

intermediate hopper could effect the operation of the low level indicator. Always ensure that the door and top panel of the intermediate hopper are fitted to ensure no foreign debris enters the hopper. If a bulk system is fitted ensure the bulk auger does not stop the opening of the intermediate hopper access door.

NOTE

WARNING

2 Technical Data

2.1 Boiler & Hoper technical data

Model

Units

SPIRA

6-26

9-36

Water content

Litres

51.5

Weight boiler heat-exchanger

201

231

Weight of auger

8.35

Weight burner

25.5

Weight intermediate hopper (empty)

Weight intermediate hopper (full)

143

Weight fan box

Maximum heat Output

Btu/hr

88,700

122,800

Flow connection

1” B.S.P. (F)

1 1/4” B.S.P. (F)

Return connection

1” B.S.P. (F)

1 1/4” B.S.P. (F)

Waterside resistance ΔT = 10°C

mbar

26.0

Waterside resistance ΔT = 20°C

mbar

9.5

Mains water (cleaning system)

Litre/min

Minimum of 16

Condensate connection

1 ¼ ” B.S.P. Female

Conventional flue

125mm (5”) Black system

Combustion chamber draught requirement

mbar

0.10 to 0.15 (running)

Maximum static head m 25

Minimum circulating head m 1

Boiler temperature set point range

°C

55° to 80°

Boiler temperature cut out point

°C

65° to 80°

Minimum return temperature

°C

40°

Water system overheat cut-out temp.

°C

110°

Burn-back overheat cut-out

°C

60°

Electricity supply

230V ~50Hz

Max operating pressure -sealed system

bar

2.5 bar

Max operating pressure -open system

bar

2.5 bar

Maximum auger length (bulk hopper)

meter

3.0

Minimum flue length m 2.0

Maximum flue length m 8.0

Heating element rating

Watts

450

Intermediate auger motor power

Watts

Intermediate auger motor starting current

Amps

0.64

Intermediate auger motor running current

Amps

0.64

Intermediate auger speed

rpm

8.5

Flue fan motor power

Watts

Flue fan motor starting current

Amps

0.27

Flue fan motor running current

Amps

0.13

Cleaning solenoid power

Watts

Cleaning solenoid current

Amps

0.087

Burner fan motor power

Watts

Total burner start current

amp

2.5

Total burner run current

amp

0.60

2.2 Boiler output data

Settings in the table below are based on the boiler using the Grant fixed angle pellet feed auger at 45° and an auger motor fixed speed of 8.5 rpm using 6mm „BNM Premium ‟, 6mm „Balcas Brites‟ or 6mm „GWP‟ pellets.

For settings on other brand pellets contact Grant Engineering.

2.2.1 Burner settings

Model

Pellet

feed Auger angle

MAX flame

MIN flame

Burner setting

Heat Output

Heat Input

Burner setting

Heat Output

’TIME

LOAD

MAX

’TIME PAUSE’

Btu/h

Full

Eff.

Input

kg/hr

’TIME

PAUSE

MIN’

Btu/h

SPIRA

6-26

45°

0025

(2.5sec)

0025

(2.5sec)

26.3

89,735

27.1

92,510

97.4

5.70

0175

(17.5sec)

6.5

22,100

SPIRA

9-36

45°

0065

(6.5sec)

0025

(2.5 sec)

122,832

38.7

132,078

93.1

7.78

0250

(25sec)

30,700

1. * = Based on a calorific value of 4.81 kW/kg

2. Data given above is approximate only.

3. The above settings will have to be adjusted on site for correct operation of burner.

4. The installer must amend the boiler data label if the output is changed.

2.3 Flue Gas Analysis

Only use a calibrated flue gas analyser that has

a „Wood Pellet‟ fuel setting. Setting the fuel to

an alternative fuel will give incorrect readings.

To allow the boiler to be commissioned and serviced, the boiler is supplied with a test point in the top cleaning door. When this test point is used, note that the test point is for CO2 and smoke reading only. The boiler efficiency and flue gas analysis must be taken from the flue test point that is closest to the flue connection chamber on the top rear cleaning door. To gain access to this test point, remove the top panel from the boiler.

NOTE

Do not sample flue gases through the

draught stabilizer or within the flue as the

gases will have been diluted with air from the

draught regulator. Only use the test points in

the top rear access door

CAUTION

To obtain good combustion the minimum

„TIME LOAD MAX‟ setting should not be set

lower than 25 (2.5 seconds)

CAUTION

Fig 2.1

FLUE EXHAUST FAN

PLAN VIEW - BOILER & HOPPER

DRAUGHT REGULATOR

140

400

266

268

227

255

510

1021

1293

1538

103

254

SIDE VIEW - BOILER & HOPPER

FRONT VIEW - BOILER & HOPPER

REAR VIEW - BOILER & HOPPER

727

770

1012

172

275

413

BULK HOPPER INLET OPTION

1186

1635

CLEARANCE REQUIRED

FOR ACCESS TO

DRAUGHT STABILIZER &

REMOVE WASH MANIFOLD

225

150

MINIMUM NON-COMBUSTIBLE BASE AREA

- 125MM THICK

-SAME FLOOR LEVEL AS HOPPER BASE

150

Fig 2.2

FLUE EXHAUST FAN

PLAN VIEW - BOILER & HOPPER

DRAUGHT REGULATOR

140

400

266

268

227

255

510

1021

1293

1538

103

254

195

SIDE VIEW - BOILER & HOPPER

FRONT VIEW - BOILER & HOPPER

REAR VIEW - BOILER & HOPPER

727

770

1012

172

275

413

BULK HOPPER INLET OPTION

1186

1635

CLEARANCE REQUIRED

FOR ACCESS TO

DRAUGHT STABILIZER &

REMOVE WASH MANIFOLD

225

150

MINIMUM NON-COMBUSTIBLE BASE AREA

- 125MM THICK

-SAME FLOOR LEVEL AS HOPPER BASE

150

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

Key Parameter

Limits

Category as per prCEN/TS 14961:2004

Diameter

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 6 only. Fines Pellets are made from compressed wood. As pellets rub together they can break down slightly,

producing dust or fines. Too many fines indicate a poor quality pellet and can impede pellet 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.

3. Pellet Specification, Storage & Delivery

3.2 Pellet Storage

3.2.1 Intermediate Hopper & Pellet Feed Auger. The

appliance is supplied with an intermediate hopper and a 1.2 metre pellet feed auger to deliver the pellets from the hopper to the boiler. The intermediate hopper should only be fitted on the left-hand side of the boiler. Once commissioned the angle of the intermediate pellet feed auger should not be adjusted in any way as this will vary the input to the boiler. The intermediate hopper and pellet feed auger together with the boiler should be installed in an indoor area and should be protected from dampness. Both the boiler and the intermediate hoper should be situated on the same level. The intermediate hopper also has a system to control the pellet feed auger from a bulk hopper. See figure 7.4. The top rear panel of the intermediate hopper has a knock-out to allow the pellet delivery hose from the bulk hopper auger to enter the hopper.

Fig. 3.1

3.2.2 Bulk Hopper. It is advisable to fit a bulk hopper storage

unit to take advantage of the lower cost of bulk pellets.

The boiler can be fed directly from a bulk storage unit. If

a bulk storage unit is used directly, careful attention is

needed during commissioning as the angle and speed of

the pellet feed auger motor will determine the amount of

pellets delivered to the boiler. Contact Grant Engineering

for further details.

The use of an intermediate hopper between the bulk hopper and the boiler is advisable as any problems with a bulk pellet quality can be isolated and the intermediate hopper can be used as the main input to the boiler.

Only use a bulk storage unit that is

(a) Specifically designed to store wood pellets (b) Is waterproof. (c) Vented (d) Supplied with appropriate connections for delivery

which are within the drivers reach.

(e) Is electrically earthed.

The length of the pellet feed auger used to feed pellets from the bulk hopper should be limited to a maximum of 3 meters in length, as any longer can damage the pellets.

The use of a self constructed wood pellet storage facility should be preapproved by the fuel supplier before any pellets are delivered and should meet relevant building and fire regulations.

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

A storage unit should not be positioned where it would result in a fire risk.

Bulk hopper feeding intermediate hopper.

Fig. 3.2

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 a

bulk hopper system.

CAUTION

NOTE

Boiler operates.

4.1 Introduction

The appliance comes complete on one pallet, this consists of the boiler, burner, intermediate hopper (fitted with pellet feed auger) and combined fan box & flue starter (complete with exhaust fan and draught stabilizer packed inside the boiler). Check the packing list (supplied in the boiler) to ensure all items were delivered. The Grant SPIRA condensing wood pellet flue system comes separately and its configuration will depend on the installation requirements.

4.2 Boiler Location

The boiler must be installed in a damp free environment. Refer to section 2.4 for boiler and hopper clearances. These clearances are to allow for access during servicing. Also if fitting a bulk hopper system refer to section 3.2.2 as the location of the bulk hopper can influence the boiler location.

4.3 Regulations to comply with

Installation of a Grant wood pellet boiler and hopper must be in accordance the following recommendations;-

All National Building Regulations and any local

Byelaws which you must check with the local authority for the area.

Model and local Water Undertaking Byelaws.

The installation should also be in accordance with the latest edition of the following standard codes of Practice;

BS 715 Metal flue pipes, fittings, terminals and

accessories.

BS EN 12828:2003. Heating systems in buildings.

Design for water-based heating systems

BS EN 12831:2003. 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 Code of Practice for treatment of water in

heating systems.

BS 7671 Requirements for electrical installations,

IEE wiring regulations.

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

4.4 Preparation for installation

With the units on the pallet, remove all outer packaging from the units. Open the boiler front cleaning door and remove the ash-pan and all items from the combustion chamber.

Remove the packing list and check all items are present. Fit the ash-pan in place in the combustion chamber and close the front cleaning door.

4 Installation Information

4.5 Installing the boiler

The boiler and hopper must be positioned on a level, solid, non-combustible material of at least 125mm thick. It must also extend past the boiler and hopper by 225mm at the front and 150mm on the remaining sides. The boiler position must comply with clearances shown in section 2.4.

4.6 Make the water connections

Flow and return connections: The flow and return connection are as follows; SPIRA 6-26 = Flow 1” BSP Female Return 1” BSP Female SPIRA 9-36 = Flow 1” ¼ BSP Female Return 1” ¼ BSP Female All flow and return connections are at the rear of the boiler, refer to section 2.4 for dimensions.

Pipework connections

Fit the ½” drain cock to the bottom rear ½” BSP connection.

Fit the air vent assembly into the ½” connection on the rear of

the boiler (this is to vent the secondary unit only), the flow pipe from the boiler must be vented.

Condensate Connection; Refer to section 5 for details on condensate connections and disposals.

Wash system; The boiler is supplied with a cleaning system to wash the condensing unit of any ash build up in the tubes. A 15mm

(1/2”) compression connection is needed to supply mains

water to this pipe. A minimum flow of 16 litres of water per minute is required to maintain an adequate supply. The wash system has to be fitted from the right-hand side of the boiler. Ensure adequate clearance (400mm) for removal of the system during servicing. Refer to section 2.4 for clearance dimensions.

If using plastic piping for the heating system consult with

the manufacturer of the pipe before use on how best to

protect the piping from overheating.

If you then choose to use plastic piping after advice from

the pipe manufacture, fit a minimum of one meter of

copper on the flow and return from the boiler, do not

connect plastic piping directly to the boiler. Grant

Engineering do not accept any responsibility for any

damage, how so ever caused, to plastic piping or fittings.

4.7 Combined fan box & flue starter

Fit the combined fan box & flue starter to the flue outlet of the boiler using the M8 nuts and washers supplied. Ensure there is an adequate seal between the unit and the boiler. Fit the solenoid head (fitted to the lead from the fan box) to the solenoid valve on the wash system just fitted. Fit the plug from the flue fan /solenoid to the socket into the rear of the boiler as shown in figure 4.1.

Fig 4.1

4.8 Burner

Fit the burner to the front of the boiler door using the two M8 nuts that come fitted to the boiler. Ensure the burner gasket makes an adequate seal with the boiler. Fit the seven pin plug and socket into the side of the burner.

4.9 Intermediate hopper

Position the intermediate hopper on a firm level surface on the left-hand side of the boiler with the top access door facing forwards as per the dimensions shown in section 2.4. Failure to adhere to these measurements can cause blockage of the pellets in the pellet delivery hose or can prevent access for servicing at a later date. The hopper is supplied with castor wheels which allows the hopper be moved during servicing. Once in the correct position engage the brakes on the front casters to main this position.

4.10 Pellet feed Auger

The intermediate auger comes fitted to the Intermediate hopper. Fit the pellet delivery hose onto the pellet feed auger and the opposite end onto the burner feed tube. (The pellet delivery hose may need to be cut if too long). A lubricant such as Vaseline may be required to ensure the pellet delivery hose is easily fitted. Ensure the pellet delivery hose is not kinked in any way. Plug the 6 way plug from the pellet feed auger into the 6 way socket on side of the burner as shown in Fig 4.2.

WARNING

Fig 4.2

Ensure the pellet delivery hose forms an air tight seal

each end and that the pellet delivery hose is not damage.

Leakage of air could cause increased temperature in the

pellet delivery hose and result in the „SAFETY CHARGE

PIPE THERMISTOR‟ shutting down the burner.

WARNING

5.1 General Requirements

When in condensing mode the Grant SPIRA condensing wood pellet boilers produce condensate from the water vapour in the flue gases and the fuel. This condensate is slightly acidic with a ph value of around 3 (similar to vinegar); provision must be made for the safe and effective disposal of this condensate.

Condensate should be disposed of using an internal 4” gulley connected to a foul water system or alternatively or into a purpose built high capacity soakway.

All condensate disposal pipes must be fitted with a trap – whether they are connected internally or externally to a domestic waste system/soil stack or run externally to a gully, hopper or soakway.

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 should not be connected directly into rainwater downpipes or to waste/soil systems connected to septic tanks.

Condensate should not be discharged into „grey water‟ systems that re-use water used in the home (not including water from toilets).

It should be noted that connection of a condensate pipe to the drain may be subject to local building control.

5.3 Pipework

All condensate pipework must be adequately protected

against freezing, however if the condensate pipe is

frozen, water will build up and discharge through the

overflow on the trap.

Condensate disposal pipework must be plastic. Copper or steel pipe is not suitable and must not be used.

Condensate disposal pipes should have a minimum „nominal‟ diameter of 38mm (1 1/2”) plastic pipe.

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 internally into a waste system

or externally to a gulley (e.g. for boilers installed in a

basement), it will be necessary to use a condensate

pump. When fitting a condensate pump, a condensate

holding tank of at least 40 litres is required. This is to

ensure that when the boiler cleaning cycle has operated

the holding tank can collect the total volume of the

water used in the wash down and the condensate pump

can then discharge the waste effectively. A boiler

interlock should be fitted to shut off the boiler in the

event of a malfunction of the condensate pump.

When using a condensate pump and condensate

holding tank, the burner settings for „T18‟ / „TIME

CLEAN PERIOD‟ (time boiler cleaning in operation)

must not be set greater than 600 (60 seconds) and the

„T17‟ / „TIME CLEAN BOILER‟ (time between boiler

cleaning operations) must not be set less than 240

minutes, as modifying these times could result in larger

and more frequent wash down of the boiler which could

exceed the capabilities of the tank and condensate

pump.

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.

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 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.

CAUTION

NOTE

WARNING

5 Condensate Disposal

For a boiler installed in an unheated area such as an outhouse or garage, all condensate pipework should be considered as an „external‟.

5.5 Condensate Soakway

To keep external pipework to a minimum, locate the soak away as close as possible to the boiler but ensure it is at least 1 metre from building foundations and away from other services, for example gas, electricity or other services.

The condensate pipe may be run above or below ground level and can enter either the top or side of the soakway tube. Refer to figure 6.1

Ensure that the drainage holes in the soakway tube face away from the building.

Backfill the soakway tube and the hole around it with 10mm limestone chippings. Only use a soakway where the soil is porous and drains easily.

Fig 5.1

5.6 Condensate Trap

Grant SPIRA condensing boilers are supplied with a 1 ¼”

G.B female condensate connection on the rear of the boiler. Fit the 1 ¼” 316 fitting supplied into this connection on the boiler and fit the pipework and trap as shown in fig. 5.2. A

condensate discharge pipe with a minimum diameter of 38mm is required to be fitted to this connection. The condensate trap must be situated where it can be easily accessed for removal and cleaning. For added frost protection leave the overflow connection open.

Fig 5.2

5.7 Inspection and Cleaning of Trap

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

Failure to regularly check and clean the condensate

trap may result in damage to the boiler and will not be

covered by the product warranty.

NOTE

2.5° fall

600

800 (min)

400

CAUTION

The only flue system suitable for the Grant SPIRA Wood

pellet boiler is the Grant „Black‟ insulated conventional

flue system.

This 125mm 5” „Black‟ flue system is suitable for both

models 6-26 & 9-36. The use of a masonry chimney is

not permitted due to the condensate produced from the

boiler.

6.1 Air supply

The Grant wood pellet boiler draws air from the room in which the boiler is located. A sufficient permanent air supply to the boiler should be provided;

a. For proper combustion of fuel and effective

discharge of combustion products to the open air.

b. To supply enough free air to the draught stabilizer. A permanent air vent with a total free area of 550 mm2 per kW shall be provided for combustion along with 300 mm2 per kW to supply free air to the draught stabilizer. To achieve this, the following is the vent opening requirements.

Boiler model

Vent opening

Grant SPIRA 6-26

Wood pellet

221 cm2 (35 in2)

Grant SPIRA 9-36

Wood pellet

306 cm2 (48 in2)

If a bulk hopper is fitted internally refer to the manufacturer instructions for ventilation requirements.

6.2 Flue position and clearances

The Grant wood pellet boilers have high operating efficiencies and low flue gas temperature. Care should be

taken to ensure that only the „Black‟ system is used, as this

is the only flue system suitable for the range of Grant wood pellet boilers. The boiler flue cannot terminate into an existing brick or

clay lined chimney.

The flue must terminate as per the details shown in Fig.

6-1.

The flue must also discharge in a down draught free

area, i.e. at least 1 metre above the point of exit through the roof or 600mm above the apex of the roof. See fig

6.1 for further details.

No other appliance can be connected to the flue.

Clearances to combustible materials must be at least

75mm.

The condensate may be allowed to run back into the

boiler. A condensate drain at the base of the flue system is not required.

Fig 6.1

Point where flue passes through weather surface

(Note 1,2)

Clearance to flue outlet

At or within 600mm of the ridge

At least 600mm above the ridge

Elsewhere on a roof (whether pitched or flat)

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

a; at least 1000mm above the highest point of intersection of the chimney and the weather surface; or b; at least as high as the ridge

Below (on a pitched roof) or within 2300mm horizontally to an openable rooflight, dormer window or other opening (Note 3)

At least 1000mm above the top of the opening

Within 2300mm of an adjoining building, whether or not beyond the boundary (Note 3)

At least 600mm above the adjacent building.

Notes

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

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

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

Clearances recommended by Grant Engineering Limited in accordance with British Standards and Building Regulations. Also refer to section J of either the England and Wales or Irish building regulations for comprehensive details on flue systems.

NOTE

6 Flue system and Air Supply

6.3 Flue components & assembly

6.3.1 Combined fan box & flue starter. The boiler is

supplied with a combined fan box & flue starter connector that comes packed inside the boiler combustion chamber. The unit comes complete with exhaust flue fan, draught stabilizer and a connection to take the Grant „Black‟ flue system. The draught stabilizer must not be boxed or obstructed from operation in any way. Also fitted is a clean out hatch to allow removal of any ash that may have dropped down the flue system. The clean-out hatch should be fully closed during normal operation. See section 10 servicing. The flue connector is fitted with a neoprene gasket for connection to the boiler. The neoprene gasket is to accommodate a low temperature wet flue system that is achieved on the condensing boiler. The attached wiring harness is for flue fan along with the connection for the wash system. When fitting the flue system to the boiler the gasket seals supplied must be fitted to the flue inner liner at every joint. A condensate drain at the base of the flue is not required as the flue connector is designed to allow the condensate run back into the boiler.

6.3.2 Flue System. The „Black‟ flue system is a twin wall

fully insulated flue which reduces the possibility of freezing in the flue on condensing boilers. The flue also has a high corrosion resistance suitable for solid fuel.

No horizontal section should be used or no elbow

greater than 45° should be used as these can cause a

build up of ash and condensate in the flue. Also all flue

joints must have a seal fitted on each joint of the inner

liner.

Failure to maintain a clean flue can result in the

emission of flue gases into the dwelling or damage

from fire in the flue. See section 10.3 Cleaning the

Boiler & Flue

6.3.3 Joining components. The joint is locked by rotating

the upper section clockwise. To secure the joint, the locking band supplied with the female end of all components must be used. To allow alignment, there are no locating flutes on the female section of the elbow. For this reason these joints MUST be secured using the locking band. All flue joints must have a lip seal gasket fitted on the bead of the

projecting liner spigot of every joint. The lip seal should be fitted dry and lubrication applied to the internal of the socket into which it is to be assembled.

6.3.4 Adjustable length. An adjustable flue length allows adjustment from 75mm up to 250mm. Assembly is achieved by fitting the adjustable length over the proceeding pipe. Remove insulation as necessary and secure when desired length is achieved using joint band supplied. The adjustable section is not load-bearing, therefore adequate support must be provided immediately above.

6.3.5 Support components. The weight of a chimney system is considerable and requires independent support. No weight should be taken by the appliance. On internal systems the weight is held by using a support plate and clamp fixed on top of the first floor/ceiling joist. A fire-stop plate is also required fixed to the ceiling below. In a normal house, when passing through the second floor the only requirements is two fire-stop plates because the system is adequately supported at first floor level. Wall brackets and roof brackets are not load bearing and give lateral support only. Wall brackets should be fitted every 3m and at any offset to ensure the system is rigidly supported. Where the flue is free standing above the roof and its height exceeds 1.5m beyond the last support or the roof a guy wire bracket must be used and every 1.5m thereafter. Alternatively a height of up to 4m can be achieved unsupported with the use of an extended locking band at the joint immediately below every joint above the roof.

Adjustable Pipe 75 - 250mm-

Part no. WP/ADJ250

Internal diameter 125mm. External diameter 180mm

Complete with locking band. Telescopes over pipe below.

Minimum engagement should be half the diameter.

This component is NOT load-bearing.

WARNING

Ø125 Ø180

75 - 230

Straight Pipe

DN21009

Nominal

Length

Effective Length

Code Number

1000

960

WP/EXT1000

500

460

WP/EXT500

333

293

WP/EXT333

200

160

WP/EXT200

Internal diameter 125mm. External diameter 180mm

Locking band

Part no. WP01

Internal diameter 125mm. External diameter 180mm

This item is supplied with pipes, bends, tees and terminals

30° Bend

Part no. WP/30

Internal diameter 125mm. External diameter 180mm

45° Bend

Part no. WP/45

Internal diameter 125mm. External diameter 180mm

Ø125 Ø180

EFFECTIVE LENGTH

Ø125 Ø180

30°

Ø125 Ø180

45°

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Grant Spira 6-26kW, Spira 9-36kW Installation, Commissioning And Servicing Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual