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

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IRL NO.011 Rev;3 July 2011

INSTALLATION, COMMISSIONING

AND

SERVICING INSTRUCTIONS

GRANT SPIRA 6-26 kW CONDENSING WOOD PELLET BOILER

GRANT SPIRA 9-36 kW CONDENSING WOOD PELLET BOILER

After installing the boiler leave these instructions with the Appliance.

Leave the user manual with the householder.

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

applicable.

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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

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Grant SPIRA Condensing Wood Pellet Boiler & Intermediate Hopper

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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

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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

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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

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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

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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

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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

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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

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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

Page 12

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

Page 13

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

Page 14

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

Page 15

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

Page 16

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

Page 17

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

Page 18

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

Page 19

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°

Page 20

Double 30° Bend and straight pipe length

960 Eff pipe

1061

542

460 Eff pipe

628 B 292

293 Eff pipe

483 B 208

160 Eff pipe

368 B 142

Viton Seal

Part no. WP02

Internal diameter 125mm.

ø125mm Wall Band (50mm)

Internal/external Code WP/WB50

External diameter 180mm.

Roof Support

Code WP/RS

External diameter 180mm.

Fire stop plate

Code WP/FP

External diameter 180mm.

Ø125 Ø180

EFFECTIVE LENGTH

Page 21

Support plate

Code WP/SP

Diameter 180mm.

Support plate

Code WP/SP

External diameter 180mm.

Storm collar Code WP/SC

Diameter 180mm.

Angled Uniflash CodeWP/UF200

Diameter 180mm.

Straight Uniflash

Diameter 180mm.

Rain cap terminal Code WP/RC

Diameter 180mm.

Page 22

6.2 Typical flue installations details.

1000 MINIMUM

600 MINIMUM

30°

STRAIGHT PIPE 460

30° ELBOW

1500 MINIMUM

STRAIGHT PIPE 960

LIP SEAL & CLAMP

WALL BAND WALL BAND EXTENSION

600 MINIMUM

Page 23

The Grant Spira Condensing Wood Pellet boiler requires a 230/240 V ~50 Hz supply. If installed in the Republic of Ireland the wiring installation must comply with all ETCI rules, if installed in the UK the installation must comply with current IEE wiring regulations.

Refer to figure 7.1 to 7.4 for wiring diagrams.

The Grant wood pellet boiler and intermediate hopper

contains electrical switching equipment and must be

earthed; also any bulk hopper system fitted should also

be earthed.

The electrical supply to the appliance and bulk hopper (if fitted) must only have one common three pole isolator, providing complete electrical isolation for the permanent live, switched live and neutral.

The power supply cable should be at least 0.75mm2 PVC as specified in BS 6500, Table 16.

All the wiring and supplementary earth bonding external to the boiler must be in accordance with the current I.E.E. wiring regulations.

Any room thermostat or frost thermostat used with this boiler must be suitable for use on mains voltage.

In the event of an electrical fault after installation of the boiler, the following electrical system checks must be carried out.

Short circuit Polarity Earth continuity Resistance to earth

The Grant hopper has the facility to wire in an indicator lamp (not supplied), this is to indicate to the householder that the pellets in the hopper have reached its minimum level and the hopper needs to be topped up. The indicator lamp should be positioned so it can be easily viewed by the householder. See figure 7.3

If fitting a bulk hopper then the Grant hopper can control the feed auger from the bulk hopper to the Grant hopper. When using a bulk hopper to supply the Grant hopper then a low pellet indicator lamp can not be fitted to the Grant hopper. See figure 7.4

7.1 Connecting the power supply

The boiler requires a permanent mains supply and a switched live supply to control the boiler. Do not interrupt the permanent supply with any external controls. Refer to figure 7.3and 7.4 to determine the number of cores required for the cable supply and for typical control system wiring diagrams.

Before making any electrical connections to the hopper ensure the following;

a. The flue fan / solenoid plug is fitted to the rear panel

of the boiler.

b. The 7 pin plug and 7 pin socket is fitted to the left-

hand side of the burner.

c. The pellet feed auger plug is fitted to the side of the

burner.

The procedure for connecting the mains supply is as follows;

1. Remove the four screws on the rear of the Grant hopper to gain access to the wiring centre.

Fig 7.1

2. Remove the cable lead and socket from the hopper wiring centre and insert the socket into plug located on the top left-hand side of the boiler rear panel (when viewed from the front). Ensure the cable is routed so as to prevent damage.

WARNING

7 Electrical

Page 24

Fig 7.2

3. Make the electrical connection to suit either of the following.

-Grant hopper only and low pellet indicator lamp see figure 7.3.

-Grant hopper supplied by bulk hopper system see figure 7.4.

The electrical supply to the bulk feed auger will need a mains isolator to isolate the auger when

the hopper is empty of pellets.

4. Secure all cables fitted in the cable clamp and refit the panel cover.

7.2 Frost protection

For additional protection of either the entire heating system, or the boiler and localised pipework, it is recommended that a frost thermostat be installed; it is also recommended that it be used in conjunction with a pipe thermostat to avoid unnecessary and wasteful overheating of the property. The pipe thermostat should be located on the boiler return pipe, and set to operate at 25°C. Refer to fig 7.3 & 7.4 for connection details.

NOTE

Page 25

Fig 7.3

SOLENOID VALVE

FLUE FAN

G/Y

LIMIT THERMOSTAT

DOOR

ISOLATION

SWITCH

COM

SWITCHED LIVE

PERMANENT LIVE

BLK

G/Y

ON / OFF SWITCH

FEED AUGER MOTOR

G/Y

Relay

24 12

N L2

NL2

G/Y

BLK

G/Y

BOILER CLEANING MOTOR

SIX WAY FEMALE

2 core

0.75mm/sq black

insulation 1400mm

long

3 core

0.75mm/sq black

insulation

1700mm long

2 core

0.75mm/sq black

insulation

1600mm long

G/Y

ON / ON SWITCH MOMENTARY 1 SIDE

PLUG

SOCKET

PLUG

THERMISTOR

6B 5B

3A 2A

SEVEN WAY FEMALESEVEN WAY MALE

G/Y

6 5789

3 core

0.75mm/sq black

insulation

1450mm long

(no Earth)

3 core

0.75mm/sq black

insulation

1700mm long

3 core 0.75mm/sq

black insulation

1200mm long

BL -300mm

BL -400mm

BR -500mm

GY -500mm

GY -100mm

RD -320mm

BL -650mm

3 core 0.75mm/sq

white insulation

550mm long fir black

sleeves to inner

insulation

4 core 0.75mm/sq

white insulation

1300mm long

BLK

G/Y

3 core

0.75mm/sq white

insulation

950mm long

3 core 0.75mm/sq

white

insulation 13000mm long strip back outer

insulation 100mm

Colour code: BR - Brown, BL - Blue, RD - Red, G/Y - Green/Yellow, BLK-Black, OR - Orange, Y - Yellow

BLK

GRANT WOOD PELLET

6-26 & 9-36

BOILER WIRING DIAGRAM

SOCKET FROM

GRANT HOPPER

FAN BOX

ASSEMBLY

Page 26

NO.1 NO.2 NO.3

GRANT WOOD PELLET

6-26 & 9-36

BURNER WIRING DIAGRAM

FIGURE 7.4

Page 27

Figure 7.5 Figure 7.6

= INSTALLER WIRING

GRANT WOOD PELLET

INTERMEDIATE HOPPER

-INSTALLER WIRING OPTIONS

REMOVE RED LINK BETWEEN SL2 & L1

AND REFIT INTO SL1 & PL1

MAIN SUPPLY& SWITCHED LIVE

G/Y

LOW PELLET CUT-OUT WITH

WARNING LAMP

SUPPLY TO BOILER C/W SOCKET FOR

CONNECTING TO BACK OF BOILER

TO WARNING LAMP

Frost

thermostat

Pipe

Stat'

G/Y

SUPPLY TO BOILER C/W

SOCKET FOR CONNECTING TO

BACK OF BOILER

TO BULK HOPPER AUGER

Frost

thermostat

Pipe

Stat'

BULK HOPPER FEED

MAIN SUPPLY& SWITCHED LIVE

Supply to CH valve

Switched Live

Permanent Live

Supply to CH valve

with CH valve fitted connect

pipe stat' between L4 & L7

without CH valve fitted connect

pipe stat' between L4 & L5

LIMIT SWITCH

SL1 SL2

PL1 L1 L2

L5 L6 L7

SL1 SL2

PL1 L1 L2

L5 L6 L7

with CH valve fitted connect

pipe stat' between L4 & L7

without CH valve fitted connect

pipe stat' between L4 & L6

Permanent Live

Switched Live

BlkBrBl

G/Y

Blk

G/Y

Blk

Two

pole

isolator

switch

Page 28

8. Burner

8.1 Burner Operation

The burner controls the pellet feed auger, flue fan, boiler temperature and also the boiler and brazier cleaning systems. The burner comes with a display screen and six control buttons. These buttons are to access the menus and control the burner functions.

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 activates after the pellet feed auger run time has exceeded a predetermined set time. The pellet feed auger run time for brazier and boiler cleaning is set in the burner menu.

The temperature of the water within the boiler is controlled via a thermistor to the burner. The thermistor is inserted into the boiler water jacket and is used by the burner to control the modulation of the boiler output.

The boiler has a set point temperature. This is the target flow temperature from the boiler. As the temperature of the boiler increases and reaches the set point less 5°C the output of the boiler is reduced by one step. Each subsequent 1°C increase in boiler temperature reduces the output of the boiler by one modulation step until the temperature reaches the set point plus 5°C. At this point the boiler output is „MINIMUM FLAME‟ which is minimum output setting of the boiler. The percentage increase or decrease in power is calculated on the rate of temperature change. The sequence of operation is described in section 8.3.

8.2 Burner Operational Modes

„BOILER WAIT THERMOSTAT‟; (operation code 03) Boiler is in standby awaiting a switched live input signal and/or the

boiler temperature to drop below the „DELTA RESTART‟ temperature. („DELTA RESTART‟ is the temperature the

burner restarts after maximum temperature has been reached).

„WAIT PRELOAD BRAZIER‟ (operation code 40) Initial loading of pellets into the brazier to enable combustion to start.

Activated with a switched live input signal and/or

temperature drops below the „DELTA RESTART‟

temperature.

Deactivated after time exceeds „T08‟.

„WAIT LIGHTING‟ –IGNITION (operation code 41) Period of time given for pellets to light.

Activated after „Pre load‟ operation is complete. Deactivated once photocell lux reading exceeds

„FLAME ON‟ setting.

„WAIT LIGHTING‟–FLAME STABILIZATION (operation code

45) Period of time to allow flame stabilize after pellets have ignited.

Activated after ignition mode. Deactivated after time exceeds „T13‟

„WAIT LIGHTING‟ –LIGHTING FEED REDUCED (operation code 42) Period of time intermittent quantities of pellets supplied to the brazier to increase the flame.

Activated after -„WAIT LIGHTING‟ flame stabilization

mode.

Deactivated after time exceeds „T09‟.

„PELLET BURNER FIRING‟; Power 100% (operation code

13) Flame is fully developed and boiler is operating on full power.

Activated after –„WAIT LIGHTING‟ lighting feed

reduced mode

Deactivated after temperature is within „TEMP

DELTA‟ range.

„PELLET BURNER FIRING‟; Power (modulating) (operation code 13) Flame is reduced and boiler output is modulating.

Activated once the boiler temperature is within the

„TEMP DALTA‟ range.

Deactivated after temperature exceeds the „TEMP

DELTA‟ range.

„PELLET BURNER FIRING‟; Power (minimum) (operation code 13) Flame is reduced and boiler is at its minimum output.

Activated once the boiler temperature exceeds the

„TEMP DELTA‟ range.

Deactivated after the temperature exceeds „TEMP

OFF H2o.

„TURNING OFF BRAZIER‟; (Operation code 14). Burn down period to remove any pellets remaining in the brazier.

Activated once switched live input signal is switched

off or the boiler temperature exceeds „TEMP OFF

H2o‟ setting.

Deactivated once photocell lux reading has dropped

below the „FLAME ON‟ setting less.

„WAIT POST PURGE‟ (operation code 26) Period of time after burn down is complete to ensure no unburnt pellets ignite.

Activated after „TUNNING OFF BRAZIER‟ is

complete.

Deactivated after time exceeds „T22‟

Page 29

8.3 Burner operation sequence

8.4 Burner display screen

8.5 Burner control buttons

The burner has six control buttons, these perform the following tasks.

WAIT PRE LOAD BRAZIER

WAIT LIGHTING

(IGNITION)

WAIT LIGHTING

(FLAME STABILIZATION)

WAIT LIGHTING

(LIGHTING FEED REDUCED)

WAIT BOILER THERMOSTAT

PELLET BURNER FIRING

(MAX FLAME)

PELLET BURNER FIRING

(MODULATING)

PELLET BURNER FIRING

(MIN FLAME)

TURNING OFF BRAZIER

WAIT POST PURGE

TEMP > 'TEMP OFF H2o'

TEMP < 'TEMP DELTA' RANGE

TEMP > 'TEMP DELTA' RANGE

TEMP WITH-IN 'TEMP

DELTA' RANGE

TEMP < 'DELTA RESTART' TEMP & SWITCHED LIVE INPUT ON

TEMP IN 'TEMP DELTA' RANGE

T > 'T08' PRE LOAD TIME

LUX = 'FLAME ON'

T > 'T13' FLAME STABILIZATION

T > 'T09' LIGHTING CYCLE REDUCED

LUX < 'FLAME ON'

T > 'T22'

TEMP > 'DELTA RESTART' TEMP OR SWITCHED LIVE INPUT OFF

TEMP < 'DELTA RESTART' TEMP & SWITCHED LIVE INPUT ON

SWITCHED LIVE INPUT

OFF

WAIT BRAZIER

IS OPENING >>>>

WAIT BRAZIER

IS CLOSING >>>>

SWITCHED LIVE INPUT

OFF

SWITCHED LIVE INPUT

OFF

SWITCHED LIVE INPUT

OFF

SWITCHED LIVE INPUT

OFF

SWITCHED LIVE INPUT

OFF

WAIT CLEANING

BOILER

Auger run time > 'TIME CLEAN BRAZ'

Auger run time > 'TIME CLEAN BOILER

FLASH CLEANING = 1 Auger run time >

'TIME CLEAN BRAZ' &/or 'TIME CLEAN BOILER'

TURNING OFF BRAZIER

FLASH CLEANING = 0

Auger run time > 'TIME CLEAN BRAZ'

Auger run time > 'TIME CLEAN BOILER

WAIT PRE LOAD BRAZIER

(PRESSURE SWITCH CHECK)

PRESSURE SWITCH CHECK OK

BURNER POWER ACTIVATED

FLOW CHART OF OPERATION OF WOOD PELLET BOILER

2 3

SET

RESET

SET 75°C

H2o 60°C

PELLET BU

= Boiler thermostat calling

= Burner fan operational = Pressure switch closed

= Ignition element operational = Feed auger operational = Photocell lux reading >'Flame On' setting = n/a = Error

Active symbols

SET

Normal Mode; Increase temperature set point by 1°C

RESET

Button no. 1

Menu Mode; Scroll up.

Normal mode; Decrease temperature set point by 1°C

Button no. 2

Menu mode; Scroll down.

Button no. 3

Menu mode; Scroll forward.

Normal mode; Reset fault

Button no. 4

Menu mode; Scroll back.

Button no. 5

Menu mode; Decrease parameter value

Button no. 6

Menu mode; Increase parameter value.

Page 30

8.6 Burner menu navigation chart and factory default settings

LUX %

STEP AUTOMA

VIEW CLE BRAZ

VIEW CLE BOIL

T01 n/a

T02 n/a

T03 n/a

T04 n/a

T05

T07 n/a

T12 n/a

T14 n/a

T16

T24 n/a

FLAME ON

TEMP DELTA

TEMP OFF H2o

DELTA RESTART

TIME LOAD MAX

TIME PAUSE

TIME PAUSE MIN

TIME CLEAN BRAZ

TIME CLEAN BOILER

TIME CLEAN PERIOD

FLASH CLEANING

POWER LIGHTING

POWER TEST

LOAD DEFAULT

HOURS SERVICE

menu 1-4

INSTAL

FLAME OFF

FLAME % MIN

LANGUAGE

RESET SERVICE

= BURNER CONTROLS BUTTON

menu 2-4

menu 4-4

FAN

menu 3-4

INSTAL

CODE

SETUP

H2o

POWER PELLET

CLEAN

ITALIAN

ENGLISH

Time (MIN) between

cleanings -Brazier

T17

Time (MIN) between

cleanings -Boiler

T18

Time (SEC) -boiler

cleaning operation

T21

Time pause

min flame (SEC)

max flame (SEC)

time pause

T06

firing (SEC)

time load

T08

time (SEC)

pre-load

T09

reduced (SEC)

time lighting cycle

T10

lighting (SEC)

time load

T11

lighting (SEC)

time pause

T13

(SEC)

flame stabilization

2.5

65.0

120.

4.0

15.0

10.

240

60.

5°

80°

5°

2.5

240

500

100

T22

Time post

purge(SEC)

60.

TO RE-LOAD

FACTORY

SETTING

200

T19 n/a

MEnu MANUFACT

INSTAL

MANUFACT

INSTAL

VIEW

MANUFACT

USER

VIEW

PSW 0

INSTAL

PSW 0

INSTAL



CODE



TO STEP

BACK

SET

RESET

SET 75°C

H2o XX°C

PELLET BU



T20

Max time element

on (SEC)

360

6-26 =2.5 9-36 =6.5

6-26 =36 9-36 =43

T23

Flue fan delay(SEC)

T15

Time (SEC) Brazier

movement cycle

6-26 =17.5 9-36 =25.0

(T17)

(T18)

(T16)

T05

T06

T21

POWER MAXIMUM

POWER MINIMUM

SET POINT RANGE 55°- 75°C

Page 31

8.7 Burner menu

Using the main menu flow chart shown in fig. 8.6 navigate the menus using the buttons as described in section 8.5.

Each of the four main folders is described in further detail as follows;

„INSTAL‟, Installer folder, see section 8.3.1 „MANUFACT‟ manufacturer folder, see section 8.3.2 „VIEW‟ folder, see section 8.3.3 „USER‟ folder, see section 8.3.4

Press button „3‟ to open the menu settings. Once the menu

settings option is activated there are four folders to choose from as shown below.

8.7.1 „INSTAL‟ menu folder

„INSTAL‟ represents the Installer folder. It enables the installer access relevant parameters for adjustment during the installation / commissioning of the appliance. Only accessible with an access code.

The „INSTAL‟ folder has four sub folders;

menu 1-4, H2o menu 2-4, POWER PELLET menu 3-4, CLEAN menu 4-4, SETUP FAN

To access the parameters within the „INSTAL‟ folder from the main burner display, navigate as follows;

8.7.1.1 „menu 1-4- H2o‟. sub folder contains three parameters stored within this folder;

a) TEMP DELTA; Temperature range of modulation

each side of set point. Units -°Celsius. Default setting 6-26 & 9-36 = 5 (5°C)

b) TEMP OFF H2o; Temperature the burner‟ shuts

down. Units -°Celsius. Default setting 6-26 & 9-36 = 80 (80°C)

c) DELTA RESTART; Temperature drop before burner

re-starts. Units -°Celsius. Default setting 6-26 & 9-36 = 5 (5°C)

MEnu MANUFACT

INSTAL

MANUFACT

INSTAL

VIEW

MANUFACT

USER

VIEW



TO STEP

BACK

PSW 0

INSTAL

CODE



PSW 0

INSTAL

CODE



Installer folder; Enables the installer access

relevant parameters for adjustment during the installation / commissioning of the appliance. Accessible only with an access code. (See section 8.3.1)

Manufacturer folder; Enables the manufacturer set parameters required for a specific boiler range. Accessible only with an access code. (See section 8.3.2)

View folder; Displays the function or status of the boiler (See section 8.3.3)

User folder; Allows the user change the language (See section 8.3.3)



SET

RESET

SET 60°C

H2o 60°C

PELLET BU

MEnu MANUFACT

INSTAL

menu 1-4

INSTAL

menu 2-4

menu 4-4

FAN

menu 3-4

INSTAL

CODE

SETUP

H2o

POWER PELLET

CLEAN

MEnu MANUFACT

INSTAL

PSW 0

INSTAL



TO STEP

BACK

See section

8.3.1.1

See section

8.3.1.2

See section

8.3.1.3

See section

8.3.1.4

TO INCREASE

PARAMETER



TO DECREASE

PARAMETER



TO ACCEPT

PARAMETER

CHANGE

& EXIT



SET

RESET

SET 60°C

H2o 60°C PELLET BU

Page 32

Settings in the burner menu‟s below are based on the

boiler using the Grant fixed angle pellet feed auger at 45°

and a 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.

8.7.1.2 „menu 2-4- POWER PELLET‟. The parameters stored within this folder are;

a) TIME LOAD MAX; Time the pellet feed auger

operates to deliver pellets to the brazier when the burner is in max flame mode. Adjusting this time adjusts the boiler input in max flame, i.e. the larger the load time, the greater the input, alternatively the smaller the load time the lower the input (see table section 2.2.1). Units 000.0 seconds. Default setting 6-26 = 25 (2.5 seconds) Default setting 9-36 = 65 (6.5 seconds)

b) TIME PAUSE MAX; Time between pellet feed auger

operations when the burner is in max flame mode. Adjusting this time adjusts the boiler input in max flame, i.e. the larger the pause time, the lower the input, alternatively the smaller the pause time the higher the input (see table section 2.2.1). Units 000.0 seconds. Default setting 6-26 & 9-36 = 0025 (2.5 seconds)

c) TIME PAUSE MIN; Time between pellet feed auger

operations in min flame. Adjusting this time adjusts the boiler input in min flame, i.e. the larger the pause time, the lower the input, alternatively the smaller the pause time the higher the input (see table section 2.2.1). Units 000.0 seconds. Default setting 6-26 = 175 (17.5 seconds) Default setting 9-36 = 250 (25 seconds)

Adjusting this setting will also result in the input during the modulation period being adjusted as the modulation input is automatically calculated on the max/min & load/pause settings.

8.7.1.3 „menu 3-4- CLEAN‟

a) TIME CLEAN BRAZ; Total pellet feed auger run

time before burner brazier cleaning operation

activates. (If the burner shuts down immediately or waits for the next shut down is determined by „FLASH CLEANING‟ see 8.3.1.3 d.) Default setting 6-26 & 9-36 =240. (240 Minutes)

b) TIME CLEAN BOILER; Total pellet feed auger run

time before boiler cleaning operation activates. Default setting 6-26 & 9-36 =240. (240 Minutes)

c) TIME CLEAN PERIOD; Time period boiler cleaning

function is operational once „TIME CLEAN BOILER‟

has elapsed. Default setting 6-26 & 9-36 =60. (60 Seconds )

d) FLASH CLEANING; Commencement of brazier

cleaning. 1 = Interrupt burner firing, shut down and clean brazier when time grater than „TIME CLEAN BRAZ‟. 0 = At next burner shut-down, clean brazier when time grater than „TIME CLEAN BRAZ‟. Default setting 6-26 & 9-36 = 1

e) HOURS SERVICE; Time lapse period before the

burner screen displays „SERVICE‟. This is to

indicate a service is now due. Default setting 6-26 & 9-36 = 500 (500 hrs)

f) RESET SERVICE; To cancel the „SERVICE‟ display

on the burner screen after the boiler has been

serviced. Press button 3 („SET‟) follow by button 4

(„RESET)‟ five times to exit the menu.

8.7.1.4 „menu 4-4- SETUP FAN‟.

a) POWER MAXIMUM; Burner fan speed setting when

burner in „max‟ output mode. Default setting 6-26 = 36 Default setting 9-36 = 43

b) POWER MINIMUM; Burner fan speed setting when

burner in „min‟ output mode. Default setting 6-26 & 9-36 = 17

c) POWER LIGHTING; Burner fan speed setting when

burner in lighting mode. Default setting 6-26 & 9-36 = 26

d) POWER TEST; Used to simulate the burner fan

speed for test purposes only. Once the „POWER TEST‟ is cancelled from the screen the burner fan reverts to its required operational speed.

e) LOAD DEFAULT; Load factory default settings.

Press button 3 to activate factory default settings.

CAUTION

NOTE

Page 33

8.7.2 „MANUFACT‟ menu folder.

„MANUFACT‟ represents the manufacturer folder, it enables the manufacturer set parameters required for an individual boiler. This folder is only accessible with correct access code. If required the installer may require access to this folder to modify the boiler input setting. To access the parameters within the „MANUFACT‟ folder

from the main burner display, navigate as follows;

The „MANUFACT‟ menu folder has 27 parameter settings as

follows;

„T01‟ n/a

„T02‟ n/a

„T03‟ n/a

„T04‟ n/a „T05‟ TIME PAUSE MAX; Time between pellet feed auger

operations in max flame. Adjusting this time adjusts the boiler input in max flame, i.e. the larger the pause time, the lower the input, alternatively the smaller the pause time the higher the input (see table in section 2.2).

Units 000.0 seconds. Default setting 6-26 & 9-36 = 0025 (2.5 seconds)

„T06 ‟ TIME LOAD MAX; Time the pellet feed auger operates to deliver pellets to the brazier in max flame. Adjusting this time adjusts the boiler input in max flame, i.e. the larger the load time, the greater the input, alternatively the smaller the load time the lower the input (see table in section 2.2).

Units 000.0 seconds. Default setting 6-26 = 0025 (2.5 seconds) Default setting 9-36 = 0065 (6.5 seconds)

„T07‟n/a

„T08‟ PRELOAD TIME; Time the pellet feed auger runs during the lighting sequence to initially charge the brazier with pellets. If set too low there may be insuffient pellets to cover the element. If set too high it could cover the photocell and obscure the view of the photocell.

Units 000.0 seconds. Default setting 6-26 & 9-36= 0650 (65 seconds)

„T09‟ TIME LIGHTING FEED REDUCED; Period of time reduced charges of pellets are delivered to the brazier during light-up.

(„T11‟ x no of loads) +(„T10 x no. pauses) = „T09‟ Activated after pro-load, Deactivate once time has exceeded time setting for parameter „T09‟. If set too low the flame may not be sufficiently established resulting in the flame being smothered when the function changes to max flame feed. If set too high, pellets could burn away faster than the pellets were delivered.

Units 000.0 seconds. Default setting 6-26 & 9-36= 0120 (120 seconds)

„T10‟ TIME LOAD LIGHTING; Time the pellet feed auger operates to deliver reduced quantity pellets during „lighting feed reduced‟.

Units 000.0 seconds. Default setting 6-26 & 9-36 = 0040 (4 seconds)

„T11‟ TIME PAUSE LIGHTING; Time between pellet feed auger operations during „lighting feed reduced‟.

Units 000.0 seconds. Default setting 6-26 & 9-36= 0150 (15 seconds)

„T12‟ n/a

„T13‟ FLAME STABILIZATION; Time to allow flame

stabilize during lighting. Activated after ignition mode (once lux ≥‟FLAME ON‟ setting) Deactivate once time has exceeded time setting for parameter „T13‟. If set too low the flame may not be sufficiently established resulting in the flame being smothered when the function changes to „lighting flame reduced‟. If set too high, pellets could burn away resulting in not flame.

Units 0000 seconds. Default setting 6-26 & 9-36 = 0010 (10 seconds)

„T14‟ n/a

„T15‟ BRAZIER MOVEMENT CYCLE TIME; Time allowed

for the Brazier to complete one movement i.e. open or close. If the brazier blocks during cleaning, it automatically attempts one release (i.e. short reverse followed by forward movement) When a release is attempted the counter is reset to 0. If the blockage is not cleared and the brazier is jammed then after 200 seconds the error „SERVO MOTOR BLOCKED „ is displayed on the burner screen.

MANUFACT

INSTAL

T01

MEnu MANUFACT

INSTAL

MANUFACT

INSTAL

PSW 0

INSTAL



12

CODE



TO STEP

BACK

TO INCREASE

PARAMETER

 5

TO DECREASE

PARAMETER

 4

TO ACCEPT

PARAMETER

CHANGE

& EXIT



SET

RESET

SET 60°C

H2o 60°C PELLET BU

Page 34

Units 0000 seconds. Default setting 6-26 & 9-36 = 200 (200 seconds)

„T16‟ TIME CLEANING BRAZIER; Total pellet feed auger run time before burner brazier cleaning operation activates. Units 0000 minutes. Default setting 6-26 & 9-36 = 240 (240 minutes)

„T17‟ TIME CLEAN BOILER; Total pellet feed auger run time before boiler cleaning operation activates. Units 0000 minutes. Default setting 6-26 & 9-36= 240 (240 minutes)

„T18‟ TIME CLEAN BOILER; Time period boiler cleaning

function is operational once „TIME CLEAN BOILER‟ has

elapsed. Units 0000 seconds. Default setting 6-26 & 9-36= 60 (60 seconds)

„T19‟ n/a

„T20‟ MAXIMUM TIME ELEMENT ON‟ The maximum time allowed for the element to remain on. If the photocell

does not read 5 lux within this time, then „FAILED

PELLET LIGHTING IS DISPLAYED‟

Default setting 6-26 & 9-36=360 (360 Seconds)

„T21‟ TIME PAUSE MIN; Time between pellet feed auger operations in min flame. Adjusting this time adjusts the boiler input in min flame, i.e. the larger the pause time, the lower the input, alternatively the smaller the pause time the higher the input.

Units 000.0 seconds. Default setting 6-26 = 175 (17.5 seconds) Default setting 9-36 = 250 (25.0 seconds)

„T22‟ POST VENTILATION; Time burner fan runs once „TURNING OFF BRAZIER‟ function is complete (i.e. lux < Turning off brazier‟ setting). Deactivate once time has

exceeded time setting for parameter „T22‟.

Units 0000 seconds. Default setting 6-26 & 9-36= 60 (60 seconds)

„T23‟ Delayed start on the flue fan start.

Units 0000 seconds. Default setting 6-26 & 9-36= 0 (0 seconds)

„T24‟ Default setting 6-26 & 9-36= 10 (required for modulation –do not adjust).

„FLAME ON‟ Flame lux reading to;

a. Activate countdown of T13 to switch off ignition

element during lighting.

b. Deactivate the „Turning off brazier‟ function

when the burner is shutting down.

Default setting 6-26 & 9-36 = 2 (2 Lux)

„FLAME OFF‟ ; In “PELLET BURNER FIRING” mode if the flame Lux value is less than the „FLAME OFF‟ setting for 15 seconds, then error „FAILED PELLET LIGHTING‟ is displayed and the burner. The burner fan continues to run.

Default setting 6-26 & 9-36 = 1 (1 Lux)

„FLAME % MIN‟ When combined with the „FLAME OFF‟ setting is the Lux valve required before the fan changes to high speed in „WAIT LIGHTING MODE‟

Default setting 6-26 & 9-36 = 4 (4 Lux)

8.7.3 VIEW menu folder.

„VIEW‟ folder displays the function or status of the boiler.

To access the menu displays within the „VIEW‟ folder from

the main burner display, navigate as follows;

The „VIEW‟ menu folder has 4 readout displays as follows;

a. LUX % -Light illumination measured by the

Photocell. Readout is instantaneous.

b. STEP AUTO; Each boiler function is allocated a two

digit number. This menu displays the function the

VIEW

MANUFACT

MEnu MANUFACT

INSTAL

MANUFACT

INSTAL

VIEW

MANUFACT



TO STEP

BACK



LUX %



TO INCREASE

PARAMETER

 5

TO DECREASE

PARAMETER

 4

TO ACCEPT

PARAMETER

CHANGE

& EXIT



SET

RESET

SET 60°C

H2o 60°C

PELLET BU

Page 35

boiler is in when viewing. List of functions are as follows;

03 -WAIT BOILER THERMOSTAT 13 -PELLET BURNER FIRING 14 -TURNING OFF BRAZIER 26 -POST PURGE 29 -AIR PRESSURE ERROR 33 -FAILED PELLET LIGHTING 40 -PRE-LOAD 41 WAIT LIGHTING (IGNITION) 42 WAIT LIGHTING (LIGHTING FEED REDUCED) 45 WAIT LIGHTING (FLAME STABILIZATION) 34 -SERVO MOTOR BLOCKED 15 - BRAZIER IS MOVING FORWARD 15 – BRAZIER IS MOVING BACK 47 – PROBE FAULT 46 – SAFETY CHARGE PIPE THERMOSTAT 46 – SAFETY BOILER THERMOSTAT

c. VIEW CLE BRAZ Total pellet feed auger run time

since brazier last cleaned. When ≥ „„T16‟ brazier cleaning operation will commence. Resets after each brazier clean.

d. VIEW CLE BOILER Total pellet feed auger run time

since boiler last cleaned. When ≥ „„T17‟ boiler cleaning operation will commence. Resets after each boiler clean.

8.7.4 USER menu folder.

„USER‟ folder; allows the user change the language on the burner display.

To access the menu displays within the „USER‟ folder from the main burner display, navigate as follows;

The language options are Italian or English. Once exited, the language selection shown on screen becomes the displayed language.

USER

VIEW

MEnu MANUFACT

INSTAL

MANUFACT

INSTAL

VIEW

MANUFACT

USER

VIEW



TO STEP

BACK



LANGUAGE

ITALIAN

ENGLISH



TO INCREASE

PARAMETER

 5

TO DECREASE

PARAMETER

 4

TO ACCEPT

PARAMETER

CHANGE

& EXIT



SET

RESET

SET 60°C

H2o 60°C

PELLET BU

Page 36

9. Commissioning

It is important that the following commissioning

procedure is carried out to ensure safe and efficient operation of the boiler.

9.1 Equipment required

To carry out a complete and comprehensive

commissioning of the Grant wood pellet boiler

the following equipment is required. Draught meter. Flue gas analyser –with a specific “wood pellet”

setting. Container of at least 1 litre capacity.

9.2 Before switching on

1. Open front access cleaning door and check ash pan is empty and positioned on the base of the combustion chamber, check the baffle (located in the top of the combustion chamber) is secured correctly on fixing brackets. Close the front access cleaning door.

Fig. 9.1

2. Check boiler flow and return are adequately vented. Check boiler and heating system has been vented (and pressurised if sealed system).Check the wash down manifold has been fitted and connected to an uninterrupted main water supply with all valves open.

3. Remove boiler top panel and boiler top access doors. Check that the spiral baffles in both the primary and secondary heat-exchangers are in place.

4. Test the boiler cleaning function by operating the momentary „CLEANING‟ „TEST‟ switch on the boiler control panel.

(a) Check the wash system (located under the top

rear access door) is spraying water directly into each flue gas tube of the unit. If the water jets are not spraying directly into the flue gas tubes adjust the orientation of the wash pipe using the screw in the right-hand side panel (above the wash pipe on the right-hand side panel.)

Jets spraying correctly

Fig. 9.2

Jets spraying incorrectly

Fig. 9.3

(b) Check the shaker unit (located under the top

front access door) is operating freely and that the spirals are moving up and down with an intermittent sudden vertical motion.

5. Refit the top access cleaning doors in position and tighten nuts.

6. Check the draught stabilizer is unobstructed and the stopper is in the fully open position.

Fig. 9.4

7. Check the quality of the wood pellets to be used (see section 3 Pellet specification and storage). Do not use wood pellets that have not being approved By Grant Engineering (IRL) Ltd. for use with this boiler.

Page 37

8. Check the pellet feed auger is fully inserted into the Grant hopper and the bolt fitted in the pellet feed auger fixing flange. Check the hopper is empty of all objects,

Fig. 9.5

9. Fill the Grant Intermediate hopper with approved wood pellets.

10. Isolate the electrical power to the appliance and remove the boiler control panel cover. Check the overheat thermostat probe and thermistor bulb is fully inserted in the boiler waterway pocket. (To view pocket, remove control panel cover). Also check the condition of cable and capillary, i.e. not damaged, broken or kinked. Refit the control panel cover.

11. Set the burner On/Standby switch to On. Check that all system controls are calling for heat.

12. The burner comes pre-set as shown in table

2.2.1. To confirm the burner output, check „TIME

LOAD MAX‟, „TIME PAUSE‟ & „TIME PAUSE

MIN‟ SETTINGS is correct. See section 8 for

access to the burner menu.

The data table shown in section 2.2.1 is when

using a Grant Intermediate Hopper only. When using a different hopper to feed the boiler directly contact Grant Engineering (IRL) Ltd for advice.

9.3 Priming the pellet feed auger

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

Fig. 9.6

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

Fig. 9.7

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

Fig. 9.8

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

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

NOTE

Page 38

Ensure the pellet delivery hose forms an air tight

seal each end and that the hose is not damage. Leakage of air could cause increased temperature in the pellet delivery hose and result in the burn-back thermistor shutting down the burner .

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

9.4 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 flue fan will start and pellets will be delivered to the burner.

If the burner STANDBY/ON 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 boiler should now be operational. See section 8.3 for lighting, running and shut down sequence of operation.

4. Check the flue fan is operational.

5. Check the combustion chamber draught when the burner operation mode is „POWER 100%‟ only by inserting the draft meter probe into the test point located to the left of the burner on the combustion chamber door.

Fig. 9.9

A draught reading of between 0.1 & 0.15 mbar should

be achieved. To adjust the combustion chamber draft move position of weights on draft regulator and add/remove if necessary as follows.

To increase draft – move weight away from

damper or add extra weights (if necessary.)

To decrease draft –move weight closer to

damper or remove weights (if necessary.)

6. Insert combustion analyser probe into rear test point on top rear access door (secondary

heat exchanger).

Fig. 9.10

7. When the burner is in MAX flame (Power 100%) operation, adjust the CO2 to achieve a mean peak reading of between 10 & 12% CO2 over a minimum of five minute period. To adjust the CO2 in „MAX flame (Power 100%) access the

burner sub menu „SETUP FAN‟ and adjust

„POWER MAXIMUM‟. To increase the CO2

value, reduce the „POWER MAXIMUM‟ value. To reduce the CO2 value increase the „POWER MAXIMUM VALUE‟ .

WARNING

NOTE

WARNING

Page 39

8. Also record the combustion analysis details from the combustion analyser and record the details on the commissioning sheet.

9. When the „Burner display reads „WAIT PELLET THERMOSTAT‟, remove the burner burn-back thermistor from the pellet feed tube. The Burner display should read „SAFETY CHARGE PIPE THERMOSTAT‟ once the burn-back thermistor is disconnected. Refit the thermistor then press reset the burner will be operational.

Fig. 9.11

10. When the boiler is in „WAIT BOILER THERMOSTAT‟ mode check the burner door interlock is operating by opening the combustion chamber door. The burner led display should then be switched off, closing the door should power up the display. This confirms that the door interlock is operating.

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.

11. Check the condition of the pellet delivery hose and ensure it forms an air tight seal each end. Check for damage and replace if necessary. A damaged pellet delivery hose can allow a back draft through the boiler resulting in burner displaying error „SAFETY CHARGE PIPE THERMOSTAT‟.

12. If a condensate pump is fitted, check that a condensate holding tank of at least 40 litres is also fitted. 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. Also check that the burner settings „T18‟ (TIME-BOILER

CLEANING OPERATION) is not set greater than 600 (60 seconds) and that „T17‟ (TIME (MIN) BETWEEN CLEANINGS) is not 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.

WARNING

Page 40

10. Boiler Servicing

To ensure a safe and efficient operation of the boiler the ash pan must be emptied after each 3 tonne of pellets is used and serviced after each 6 tonne of pellets is used.

The burner is programmed to display „SERVICE‟ on the burner display screen once a pre-determined pellet feed auger run time is achieved. The interval of the display is programmed by the commissioning engineer based on the pellet feed auger feed rate and the time taken to delivery 6 tonne to the boiler.

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.

Before starting any work on the boiler, or pellet

supply please read the health and safety

information given in section 14.

10.1 Checks before servicing

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

2. If the boiler is used on a sealed central heating system, check the system pressure, check the operation of the pressure relief valve and check the expansion vessel air charge. The expansion vessel air charge should be 1.0 bar when the system pressure is zero.

3. Check the burner parameters setting correspond with the commissioning sheet attached to the boiler.

4. Ensure all connections and fittings are sound. Remake any joints and check tightness of any fitting that may be leaking.

5. Refill, vent and re-pressurise the system as necessary.

6. Check that any ventilation openings are adequate and are clear. See section 6.1.

7. Operate the manual boiler cleaning system for at least 60 seconds to ensure the boiler is cleaned down. This is achieved by holding

the boiler cleaning switch in „TEST‟ mode.

Only operate when the burner is not firing.

Before servicing, set the burner switch to

„Standby‟ and after the burner has shut down and

displays „WAIT PELLET THERMOSTAT‟ isolate the

electricity supply by disconnecting the mains

socket fitted in the rear of the boiler as shown in

fig 10.1 below

Fig 10.1

10.2 Cleaning the burner

1. Disconnect the seven pin plug & socket and the six pin socket from the side of the burner. Disconnect the pellet delivery hose to the burner and open the front access cleaning door.

WARNING

NOTE

WARNING

Page 41

Fig 10.2

2. Clean out the brazier and remove all ash ensuring all air holes are free.

3. Remove the burner cover by loosening the two M5 screws each side of the burner and lifting off the cover.

4. Remove the M8 nut each side of the burner and withdraw the burner from the boiler. Remove the burner hood by loosening the two M5 bolts (highlighted below) each side of the brazier. Slide the hood away from the burner and lift up.

Fig 10.3

After a period of time the end wall of the brazier

hood may distort or show minor cracks. This does

not affect the operation of the burner. The hood should only be changed if there is considerably

deterioration.

5. Open the brazier manually by pulling up on the red slider of the electromechanical motor and at the same time pulling on the end wall of the brazier as shown in fig 10.4 below. Remove any ash from within the brazier. Close the brazier manually by pulling up on the red slider of the electromechanical motor and at the same time pushing on the end wall of the brazier.

Fig 10.4

Do not to force the brazier end wall without

disengaging the servo motor release switch.

Failure to release servo motor release switch

WILL damage servo motor gears.

6. Check the clearance of the brazier using the

„Grant‟ clearance gauge. Insert the gauge into

the brazier as shown in fig 10.5. The gauge should slide in using manual force only.

Fig 10.5

If the gauge does not fit or the clearance is too great;

a. Loosen the two M5 nuts (highlighted above)

each side of the brazier b. Insert the gauge as shown in fig 10.5. c. With the gauge in place lightly tighten the M5

screws using minimum force. d. Ensure the base of the brazier is fully down

by inserting a steel strip between the brazier

chassis and the „Flame plate‟ and lightly

NOTE

WARNING

Page 42

tapping each side of the brazier as shown in

fig 10.6, remove the steel strip when finished. e. Tighten the screws each side. f. Remove gauge.

Fig 10.6

(b) Check the condition of the heat-shield hood and

replace if necessary.

Fig 10.7

there is a build-up of debris remove the burner fan and clean the fan blades and fan housing.

(d) Remove, check and clean the photocell.

Replace if damaged. Ensure the photocell clamp is fitted 25mm from end as shown in fig

10.8.

Fig 10.8

(e) Remove and check the condition of the heating

element. Replace if damaged.

(f) Also check the pellet feed pipe, clean out if

necessary.

(g) If the burner was removed from the boiler

check the condition of the burner gasket and replace the gasket if necessary. Refit the burner and tightening the M8 nut each side.

(h) Refit the burner cover and tighten the two M5

screws each side.

10.3 Cleaning the Boiler & Flue

Fig 10.8

1. Remove the boiler top panel, remove both top access cleaning covers.

2. Remove the mild steel spirals (from the chamber at the front of the boiler), examine condition and clean down or replace if necessary. Remove any ash on the chamber walls and from underneath the spiral hangers. Refit spirals in position.

3. Remove the wash system manifold from the rear chamber of the boiler, clean thoroughly ensuring all jets are clear and rinse the inside of the wash system thoroughly to ensure all debris is removed.

4. Remove the stainless steel spirals (from the chamber at the rear of the boiler), examine condition and clean down or replace if necessary. Remove any ash on the chamber walls and from the rear flue gas duct.

5. Refit the wash system manifold in place, but do not tighten at this stage. (The system manifold

Page 43

needs to be aligned once the unit is powered up).

6. Remove the flue inspection plate and examine flue condition. Clean the flue by sweeping it clean. Chemical cleaners are not recommended.

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.

7. Remove the draught stabilizer from the combined fan box & flue starter. Open the clean out hatch. Clean out the combined fan box & flue starter and the base of the flue (through the opening left by the by-pass slider). Check fan blades and fan blade chamber, clean if necessary by removing the fan.

When cleaning the fan blades ensure a

thorough cleaning is carried out as an uneven cleaning will result in the fan being off balance and could possible damage the

fan.

8. Reposition the draught by-pass slider to original position and refit the draught stabilizer.

9. Remove and clean the baffle (located in the top of the combustion chamber).

Fig 10.9

10. Remove the ash pan (using the ash pan handles supplied with the boiler) and dispose of the ash safely.

Extreme care is required when empting the

ash pan as smouldering ash could be present and cause serious damage to

persons of property. Ensure the ash is

disposed of in a safe manner.

11. Clean down the combustion chamber and the combustion chamber door fully.

12. Check the baffle condition and replace if necessary. Refit the baffle in position ensuring it is seated correctly on the fixing brackets.

13. Refit the ash pan in the base of the combustion chamber.

14. Grease the front cleaning door latch mechanism and close the door.

15. Remove the boiler control panel cover to gain access to the boiler cleaning mechanism. Grease the cam edge using high temperature grease. Refit the boiler control panel. Also remove the M8 grub screw located on the shaft of the cleaning mechanism (within the top front chamber) and recharge the reservoir with high temperature grease, refit the M8 grub-screw do not tighten.

16. Power up the boiler by inserting the main connection into the back of the boiler as shown in fig 10.10.

Fig 10.10

17. Manually operate the boiler cleaning system by holding down the „TEST‟ switch on the boiler control panel.

I. Align the spray from the wash manifold jets

with the pipes in the rear chamber of the boiler, check all jets are clear. Tighten the M5 screw located on the fixing flange to maintain the position of the manifold.

II. Check the shaker unit (located under the

top front access door) is operating freely and that the spirals are moving up and down with an intermittent sudden vertical motion. (If there is no sudden vertical motion, isolate the power as shown in fig

10.1 and check the condition of the spring located in the rear of the control panel replace if necessary).

18. Check the condition of the top access cleaning covers and replace gaskets and seals if necessary. Refit the top access cleaning covers and the boiler top panel.

WARNING

CAUTION

Page 44

19. Disconnect the drain trap located on the condensate drain system from the back of the boiler. Clean thoroughly and re-fit.

20. Check the condition of the pellet delivery hose and ensure it forms an air tight seal each end. Check for damage and replace if necessary. A damaged pellet delivery hose can allow a back draft through the boiler resulting in burner

displaying error „SAFETY CHARGE PIPE

THERMOSTAT‟.

21. On the burner menus reset the service time by pressing the SET button (3) when the burner display shows RESET SERVICE. See section

8.6.

To ensure safe and efficient operation of the boiler it is important that re-commissioning is carried out, refer to Commissioning instructions 9.4 Lighting the boiler‟.

WARNING

Page 45

11 Fault finding

11.1 Boiler won‟t fire (no error message)

Notes;

1. When the switched live supply to the burner is activated, the burner display shows a cursor highlighted

beside the boiler thermostat symbol, as shown below.

2. Depending on the type of installation, insufficient pellets in the intermediate hopper will result in either of the

following; a. Intermediate hopper controlling a bulk hopper feed system will not use the low level cut out system, the

burner will display error message „FAILED PELLET LIGHTING‟ when the intermediate hopper has insufficient pellets.

b. Intermediate hopper using the low level cut out system will switch the boiler to standby mode and the

burner will display „WAIT BOILER THERMOSTAT‟ when the intermediate hopper has insufficient pellets.

3. Refer to diagram in section 7.1.2.

4. Refer to section 7 Electrical.

YES

NO FAULT

-BOILER

WAITING FOR

SYSTEM TEMP.

TO DROP

CURSER BESIDE

THERMOSTAT

SYMBOL OF

BURNER DISPLAY

'BURNER' SWITCH

IN THE 'ON' MODE

OF THE BOILER

CONTROL PANEL

= PRIMARY FAULT = SECONDARY FOLLOW ON CHECKS

2 3

SET

RESET

SET 80°C

H2o 60°C

WAIT BOILE

WAIT BOILER THERMOSTAT

note 1

POSITION

'BURNER' SWITCH

IN 'ON' MODE

YES

FILL HOPPER

SUFFICIENT

QUANTITY OF

PELLETS IN

HOPPER

YES

TIMER AND OR

ROOM STAT

CALLING

ACTIVATE

TIMER AND OR

ROOM STAT

YES

CHECK POWER

TO L2 OF

SUPPLY LEAD IN

REAR OF BOILER

CHECK

SWITCHED LIVE

SUPPLY TO

BOILER

(& HOPPER)

YES

CHECK

CONTINUITY BETWEEN T1 & T2 OF BURNER

PLUG NO. ?

CHECK POWER ACROSS BOILER ON/OFF SWITCH

YES

CHECK POWER

AT 21 & 24 OF

BOILER RELAY

WITH COIL

ENERGIZED

REPLACE

SWITCH

REPLACE

RELAY

note 2 note 3

note 4

H2o TEMP>SET

POINT MINUS

DELTA RESTART

TEMP.

YES

Page 46

11.2 Boiler won‟t fire (Blank screen)

Notes;

1. The burner door is fitted with a safety interlock. Once the door is opened all power is disconnected to the burner.

2. See diagram shown in section 7.1.

3. See diagram shown in section 9.3.1

Diagram showing burner door interlock

Diagram showing the fuse holder located within the burner PCB enclosure.

Fuse type F5AL250V

YES

BURNER DOOR

CHECK

BURNER

DOOR CLOSED

CHECK POWER

TO L1 OF

SUPPLY LEAD IN

REAR OF BOILER

CHECK

ELECTRICITY

SUPPLY TO

BOILER

2 3

SET

RESET

BLANK SCREEN

YES

FIT PLUGS

YES

CHECK POWER

TO L1 OF PLUG ?

IN BURNER

CHECK DOOR

MICRO-SWITCH

OPERATIONAL

CHECK BURNER

FUSE FOR

CONTINUITY

REPLACE

BURNER FUSE

YES

CHECK RIBBON

CABLE FITTED

TO BACK OF

DISPLAY

YES

REPLACE

BURNER PCB

REFIT RIBBON

CABLE

REFIT PCB &

REPLACE

DISPLAY UNIT

REPLACE

FAULTY DOOR

SWITCH

CHECK BURNER

PLUG

CONNECTIONS

CORRECT

note 2

note 3 note 3

note 4

note 5

note 1

= PRIMARY FAULT = SECONDARY FOLLOW ON CHECKS

Page 47

11.3 Error messages

When a fault occurs with the burner, the burner display screen displays a block to the right of the error symbol as shown below. The lower area of the text screen also displays a message of the fault that occurred.

List of possible error messages;

FAILED PELLET LIGHTING, Step Auto function -33 See section 11.1 SERVO MOTOR BLOCKED, Step Auto function -34 See section 11.2 SAFETY CHARGE PIPE THERMOSTAT, Step Auto function -46 See section 11.3 SAFETY BOILER THERMOSTAT, Step Auto function -46 See section 11.4 PROBE FAULT, Step Auto function -47 See section 11.5 AIR PRESSURE ERROR, Step Auto function -29 See section 11.6

2 3

SET

RESET

SET 60°C

H2o 60°C

FAILED PEL

FAILED PELLET LIGHTING

Error symbol

Page 48

11.3.1 FAILED PELLET LIGHTING

Notes;

1. Depending on the type of installation insufficient pellets in the intermediate hopper will result in either of the following;

A. Intermediate hopper controlling a bulk hopper feed system will not use the low level cut out system, the burner

will display error message „FAILED PELLET LIGHTING‟ when the intermediate hopper has insufficient pellets.

B. Intermediate hopper using the low level cut out system will switch the boiler to standby mode and the burner

will display „WAIT BOILER THERMOSTAT‟ when the intermediate hopper has insufficient pellets..

2. Clinker is classed as solidified ash containing sand particles that the burner cleaning system is unable to remove. Clinker is caused by using unsuitable pellets.

3. Refer to section 8.7.1.3a. menu folder „TIME CLEAN BRAZ‟

4. The ignition element is operational in Functions 40, 41 & 45. see section 8.7.3.b.

5. Check continuity across the ignition element when the element is disconnected.

6. Refer to section 8.7.2 „MANUFACT‟ menu folder.

7. When in function „41‟ (ignition), if after a time of „T20‟ & photocell Lux valve doesn‟t get to 5 lux, then the error message „FAILED PELLET LIGHTING‟ is displayed. Max „T20‟ = 750 See section 9.4.10, how to check preload.

8. See section 8.7.2, how to adjust the „preload‟ setting.

9. „T13‟ is the „FLAME STABILIZATION‟ period. This is the period allowed for the flame to establish. Too short a time prevents the flame from developing or too long a period allows the flame burn-up the fuel. Ideal time is 2

minutes or a „T13‟ setting of 20. If the flame drops below 5 lux in this function then error message „FAILED PELLET LIGHTING‟ is displayed.

10. See section 8.7.3.a VIEW menu folder. To display the photocell value view „LUX %‟.

NO NO

CHECK PELLETS

DELIVERED TO

BURNER

YES

FILL HOPPER

PRIME AUGER

CHECK AUGER

ROTATING

CHECK AUGER

MOTOR

POWER &

COUPLING

SUFFICIENT

QUANTITY OF

PELLETS IN

HOPPER

CHECK HOPPER

OUTLET FOR

DUST OR

BLOCKAGE

YES

CLEAN OUT

HOPPER AND

PRIME AUGER

CHECK (40)

PRE-LOAD

PARAMETER

CORRECT

YES

CHECK AUGER

PRIMED

FULLY

YES

RE-PRIME

AUGER

ADJUST

PRE-LOAD

PARAMETER 'T08'

UN-BURNT

PELLETS

IN THE

BRAZIER

YES

CLINKER IN

BRAZIER

YES

CLEAN BRAZIER &

CHECK PELLET

QUALITY, ADJUST

BRAZIER

CLEANING TIME

CHECK IGNITION ELEMENT

OPERATIONAL

CHANGE

ELEMENT

YES

CHECK (41) 'WAIT LIGHTING' IGNITION MODE

LUX GET TO 5

CHECK

'T20' = 750

CHECK (45)

'FLAME

STABILIZATION'

SETTING 'T13' = 20

RESET

'T20' TO 750

RESET

'T13' TO 20

YES YES

CHECK (42) 'LIGHTING CYCLE REDUCED' MODE

LUX DROP BELOW 5

YES

CHECK

'T09' = 120

'T10' = 40

'T11' = 200

CHECK PRO-LOAD

CHARGE QUANTITY CORRECT

INCREASE PRE-LOAD

CHARGE QUANTITY

YES

CHECK

IGNITION ELEMENT

OR PHOTOCELL

FAULTY

YES

REPLACE

FAULTY

COMPONENT

= PRIMARY FAULT = SECONDARY FOLLOW ON CHECKS

2 3

SET

RESET

SET 60°C

H2o 60°C

FAILED PEL

Error symbol

FAILED PELLET LIGHTING

RESET

'T09' = 120

'T10' = 40

'T11' = 200

note 2

note 1

note 3 note 5

note 2

note 6 note 7

note 5

note 8

note 9

note 11note 10

note 4

Page 49

11.3.2 SERVO MOTOR BLOCKED

Notes;

1. Refer to section 10.2.3 opening the brazier manually.

2. Refer to section 10.2.5 setting the brazier.

3. Set „T16‟ (time cleaning brazier) to 0, fire-up the boiler immediately switch off the boiler On/Off switch on the control panel. The brazier cleaning operation will now commence. Ensure „T16‟ is reset to its original setting or else the brazier operation will be activated after each lighting operation.

4. The stroke of the servo motor is factory set and should not be adjusted. Check with Grant Engineering for correct setting.

5. The total cleaning time for the brazier should be between 4 and 5 minutes.

Do not to force the brazier end wall

without first disengaging the servo motor release switch.

Failure to release servo motor release switch

will damage servo motor gears.

YES

OPEN BURNER

DOOR, CHECK

BRAZIER FOR

BLOCKAGE

YES

MANUALLY OPEN

BRAZIER, CHECK IS

BRAZIER SIZED

CLEAR BLOCKAGE AND CLOSE BURNER

DOOR

CHECK BRAZIER

CLEARANCE

CORRECT

YES

RESET BRAZIER

CLEARANCE

CHECK BRAZIER FOR DISTORTION

OR DAMAGE

REPLACE

DAMAGED PARTS

& RESET BRAZIER

CLEARANCE

CHECK SERVO

MOTOR

OPERATION

CORRECT

CHECK SERVO

MOTOR

CONTROLS SET

CORRECT

RESET

CONTROLS

YES

CHECK IS

CLEANING CYCLE

OPERATION TIME

> 5min

YES

REPLACE SERVO

MOTOR

YES

2 3

SET

RESET

SET 60°C

H2o 60°C

SERVO MO

Error symbol

SERVO MOTOR BLOCKED

= PRIMARY FAULT = SECONDARY FOLLOW ON CHECKS

note 1

note 2 note 2

note 4

note 5note 3

WARNING

Page 50

11.3.3 SAFETY CHARGE PIPE

Notes;

1. Refer to diagram shown in 9.4.10.

2. Leakage of air could cause increased temperature in the pellet delivery hose and result in the burn- back thermistor shutting down the burner .

3. Refer to section 9.4.5.

4. Refer to section 6.1.

5. Refer to section 10.3.3

6. Refer to section 8.6. and 8.7.2 p & q

DOES PRESSING

BURNER REST

CANCEL ERROR

(when temp. drops)

DOES REMAKE FEED

PIPE THERMISTOR

CONNECTION &

PRESS RESET

CANCEL ERROR

CHECK FEED

PIPE

THERMISTOR FOR

DAMAGE

REPLACE FEED

PIPE

THERMISTOR

YES

IS COMBUSTION

CHAMBER DRAFT

CORRECT

IS THE CORRECT

FLUE FITTED OR

IS THE FLUE

BLOCKED

IS CONDENSATE

TRAP/PIPE

BLOCKED/ FROZEN

YES

CLEAN

CONDENSATE

TRAP/PIPE

YES

MODIFY FLUE

& OR

CLEAR FLUE

BLOCKAGE

IS THE ASH PAN OVER-FLOWING

CLEAN OUT ASH

PAN AND BOILER

IS THE WASH

CLEANING SYSTEM

WORKING WHEN CLEANING TEST

SWITCH ACTIVATED

YES

RESET

'T17' & OR 'T18'

IS CLEANING

SYSTEM

PARAMETERS

'T17' & 'T18' SET

CORRECT

CHECK WATER

MAINS ON

YES

CHECK SOLENOID

OPERATING

CORRECTLY

YES

CHECK JETS

BLOCKED

IN CLEANING

MANIFOLD

CHECK CLEANING

MOTOR

OPERATION

IS ROOM

VENTILATION

ADEQUATE

YES

INCREASE

VENTILATION

2 3

SET

RESET

SET 60°C

H2o 60°C

SAFETY CH

Error symbol

SAFETY CHARGE PIPE

Error symbol

YES

note 1

note 3

note 4

IS THE SHAKER

CLEANING SYSTEM

WORKING WHEN CLEANING TEST

SWITCH ACTIVATED

note 5

note 6

= PRIMARY FAULT = SECONDARY FOLLOW ON CHECKS

YES

IS THE FLUE FAN

OPERATIONAL

YES

RECTIFY FLUE FAN FAULT / BLOCKAGE

PELLET FEED

TUBE DAMAGED

YES

REPLACE PELLET

FEED TUBE

PELLET FEED

TUBE AIR TIGHT

EACH END

REPLACE PELLET

FEED TUBE

note 2note 2

Page 51

11.3.4 SAFETY BOILER THERMOSTAT

Notes;

1. The pocket is located within the boiler control panel. Remove control panel outer cover to gain access.

2. Ensure the heating thermistor is retained in the heating pocket using the clip supplied.

3. Continuity can be checked between T1 & T2 of the seven way male connector plug fitted to the side of the burner.

4. The boiler comes complete with an air vent to vent the secondary heat-exchanger. The primary heatexchanger needs to be vented on the heating flow pipe. Check flow is adequately vented.

11.3.5 PROBE FAILURE THERMISTOR

Notes;

1. See diagram 9.3.1

11.3.6 AIR PRESSURE ERROR

CHECK HEATING

THERMISTOR

FITTED IN

POCKET

YES

NO NO

YES

REFIT HEATING

THERMISTOR AND

RESET

OVERHEAT

RESET

OVERHEAT STAT

CHECK

CONTINUITY

REPLACE

OVERHEAT

STAT'

IS BOILER

VENTED

CORRECTLY

VENT BOILER

2 3

SET

RESET

SET 60°C

H2o 60°C

SAFETY BO

Error symbol

SAFETY BOILER THERMOSTAT (OVERHEAT)

note 1

note 2

note 3

note 4

= PRIMARY FAULT = SECONDARY FOLLOW ON CHECKS

CHECK BURNER

PLUG

CONNECTIONS

CORRECT

YES

REMAKE

CONNECTION

CHECK HEATING

THERMISTOR FOR

DAMAGE

YES

REPLACE

THERMISTOR

CHECK HEATING

THERMISTOR

CONNECTION ON

BURNER PCB

2 3

SET

RESET

SET 60°C

H2o 60°C

PROBE FAI

Error symbol

PROBE FAILURE THERMISTOR

note 1

= PRIMARY FAULT = SECONDARY FOLLOW ON CHECKS

Page 52

Note 1. Before the „PRE-LOAD‟ operation commences and during the LIGHTING FEED REDUCED period, the burner controls check that burner fan has enough air pressure generated to close the air pressure switch. If during these operations the pressure switch is not closed then the warning „AIR PRESSURE ERROR‟ is displayed on the burner screen. Note 2. During the ‟PELLET BURNER FIRING‟ operation the burner controls checks that the burner fan speed is correct. (It does not check if the fan is generating enough air pressure). If during the ‟PELLET BURNER FIRING‟ operation the burner fan speed is not correct then the warning „AIR PRESSURE ERROR‟ is displayed on the burner screen. Note 3. Check the condition of the air supply tube to the pressure switch, replace if necessary. Note 4. Using a digital manometer (set for positive pressure) connected as shown below. Check the burner fan is generating a minimum air pressure of 0.8mbar to activate the air pressure switch.

FIRE BOILER,

CHECK FOR

FAULT DURING

LIGHTING

SEQUENCE

YES

RESET ERROR

MESSAGE BY

PRESSING

'RESET' ON

BURNER DISPLAY

2 3

SET

RESET

SET 60°C

H2o 60°C

AIR PRESS

Error symbol

AIR PRESSURE ERROR

= PRIMARY FAULT = SECONDARY FOLLOW ON CHECKS

YES

CHECK BURNER

FAN IS

OPERATIONAL &

NOT BLOCKED

YES

CHECK PRESSURE

SWITCH

OPERATION &

CONDITION OF AIR

SUPPLY TUBE

CHECK BURNER

FAN IS

OPERATIONAL &

NOT BLOCKED

CLEAR

BLOCKAGE

AND/OR REPLACE

FAN

CHECK BURNER

FAN PRESSURE IS

CORRECT

REPLACE

BURNER FAN

-CORRECT FAN PRESSURE

ACHIEVED

REPLACE MAIN

BURNER PCB

note 1

note 3

note 2

note 4

Page 53

12 Spare parts

12.1 Burner Burner controls –Exploded view

Fig 12.1

Page 54

Burner Brazier –Exploded view

Fig 12.2

Page 55

Burner parts list

Item

Description

Part No.

Quantity

6-26

9-36

Pressure switch

WP111 1 1

Primary printed circuit board c/w enclosure

WP112 1 1

Burner fan

WP03 1 1

Servomotor

WP04 1 1

LED display unit c/w enclosure

WP05 1 1

Mounting bracket set (LED display)

WP06 1 1

Electrical connector 7 way female

WP07 1 1

Electrical connector 7 way male

WP08 1 1

Photocell

WP09 1 1

Ignition element

WP10 1 1

Pellet feed tube thermistor

WP11 1 1

Pellet feed tube thermistor cover

WP12 1 1

Pellet feed tube

WP13 1 1

Pellet feed tube gasket

WP14 1 1

Burner mounting gasket

WP15 1 1

Ignition element housing

WP16 1 1

Photocell tube

WP17 1 1

Electrical connector 6 way male

WP18 1 1

Brazier chassis

WP19 1 1

M6 washer

WP20 8 8

M6 nut

WP21 8 8

Ignition element mounting plate

WP22 1 1

Photocell back plate

WP23 1 1

Burner fan gasket

WP24 1 1

Boiler water thermistor

WP25 1 1

Controls chassis left gable

WP26 1 1

Controls chassis back-plate & base

WP27 1 1

Main burner cover

WP28 1 1

29a

Flame hood 6-26

WP29A 1 -

29b

Flame hood 9-36

WP29B - 1

Brazier flame plate set

WP130 1 1

M6 x 15 Coach bolt

WP31 8 8

32a

Grate enclosure (6-26)

WP32A 1 -

32b

Grate enclosure (26-26)

WP32B - 1

33a

Brazier base assembly 6-26

WP33A 1 -

33b

Brazier base assembly 9-36

WP33B - 1

Page 56

12.2 Boiler Exploded view

Fig 12.3 SPIRA 6-26 boiler displayed

Boiler parts list

Page 57

Item

Description

Part No.

Quantity

6-26

9-36

Rear lower panel

WP34 1 1

5 way mains connection –male fixed

WP 35 1 1

Rear upper panel

WP36 1 1

5 way mains connection –female detachable

WP37 1 1

5 way flue fan / cleaning solenoid connection –male detachable

WP38 1 1

5 way flue fan /cleaning solenoid connection – female fixed

WP39 1 1

Flue fan sealing gasket

WP40 1 1

Fan box

WP41 1 1

Cleaning door sealing gasket –secondary 6-26

WP42 1 -

Cleaning door sealing gasket –secondary 26-26

WP43 - 1

Cleaning door –secondary 6-26

WP44 1 -

Cleaning door –secondary 26-26

WP145 - 1

Flue fan

WP46 1 1

Air vent

MPCBS29 1 1

Air vent manifold

WP48 1 1

22mm Secondary to primary pipe 6-26

WP49 1 -

22mm Secondary to primary pipe 9-36

WP50 - 1

Return assembly 6-26

WP51 1 -

Return assembly 9-36

WP52 - 1

1” BSP Flow pipe 6-26

WP53 1 -

1 ¼” BSP Flow pipe 9-36

WP54 - 1

Draught Stabilizer

WP55 1 1

Fan box/secondary gasket

WP56 1 1

Secondary heat-exchanger spiral baffle

WP57

Cleaning door sealing gasket –Primary 6-26

WP58 1 -

Cleaning door sealing gasket –Primary 9-36

WP59 - 1

Secondary heat-exchanger 6-26

WP60 1 -

Secondary heat-exchanger 9-36

WP61 - 1

Shaker arm assembly 6-26

WP62 1 -

Shaker arm assembly 9-36

WP63 - 1

Spring anchor -fixed

WP64 1 1

Shaker chamber 6-26

WP65 1 -

Shaker chamber 9-36

WP66 - 1

Primary/secondary gasket

WP67 1 1

Top panel 6-26

WP68 1 -

Top panel 9-36

WP69 - 1

Cleaning pipe manifold 6-26

WP70 1 -

Cleaning pipe manifold 9-36

WP71 - 1

Cleaning door-shaker chamber 6-26

WP72 1 -

Cleaning door-shaker chamber 9-36

WP73 - 1

Fibre rope -shaker chamber door 6-26

WP74 1 -

Fibre rope -shaker chamber door 9-36

WP75 - 1

Solenoid valve

WP76 1 1

Secondary heat-exchanger spiral baffle

WP77

Spiral hanger 6-26

WP78 1 -

Spiral hanger 9-36

WP79 - 1

Shaker assembly mounting flange

WP80 1 1

Spring anchor -movable

WP81 1 1

Cleaning mechanism spring

WP82 1 1

Right side panel 6-26

WP83 1 -

Right side panel 9-36

WP84 - 1

Cleaning mechanism cam

WP85 1 1

Cleaning motor mounting flange

WP86 1 1

Cleaning mechanism motor

WP87 1 1

Door interlock

WP88 1 1

Shaker chamber mounting gasket 6-26

WP89 1 -

Shaker chamber mounting gasket 9-36

WP90 - 1

Left side panel 6-26

WP91 1 -

Left side panel 9-36

WP92 - 1

Brass fitting 1”BSP x 22mm 311

WP93 1 -

Brass fitting 1 1/4”BSP x 28mm 311

WP94 - 1

Primary heat-exchanger 6-26

WP95 1 -

Primary heat-exchanger 9-36

WP96 - 1

Combustion chamber baffle 6-26

WP97 1 -

Combustion chamber baffle 9-36

WP98 - 1

Ash pan handles

WP99 2 2

Ash pan 6-26

WP100 1 -

Ash pan 9-36

WP101 - 1

Combustion chamber cleaning door rope

WP102 1 1

Combustion chamber cleaning door

WP103 1 1

Combustion chamber cleaning door panel

WP104 1 1

Front panel

WP105 1 1

Combustion chamber cleaning door handle

WP106 1 1

On/Off switch

EFBS22 1 1

Limit stat‟

WP107 1 1

Momentary switch (double pole on/on)

WP108 1 1

Control panel chassis

WP109 1 1

Relay

MPCBS72X 1 1

Control panel cover

WP110 1 1

Plug (not show)

Plug (not shown)

Items not indexed are specific to the 9-36 model.

12.3 Intermediate Hopper -Exploded view (rear)

Page 58

Fig. 12.4

Intermediate Hopper parts list

Page 59

Item

Description

Part No.

Quantity

6-26 & 9-36

Castor Wheel (c/w brake)

WP146

Caster wheel flange

WP147

Right side panel

WP148

Pellet feed Auger shield

WP149

Base

WP150

Front panel

WP151

Grid

WP152

Top front panel

WP153

Door hinge

WP154

Top rear panel

WP155

Left side panel

WP156

Castor Wheel

WP157

Rubber diaphragm flange

WP158

Rubber diaphragm

WP159

Wiring centre

WP160

Pellet damper

WP161

Rear panel

WP162

Wiring centre access cover

WP163

Low level limit switch

WP164

Limit switch bracket

WP165

Page 60

13. Health and Safety Information

Under the Consumer Protection Act 1987 and section 6 of the Health & 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;

13.1 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. 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.

13.2 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. See immediate medical attention.

Skin –Wipe off and wash with soap and water. Inhalation –Remove to fresh air.

Page 61

14. Warranty

1. The company shall mean Grant Engineering (Ireland) Limited.

2. The boiler is guaranteed for a period of 12 months from the date of purchase, providing that; a. The boiler is commissioned & installed by an engineer who has completed the Grant Wood pellet training

course on wood pellet boilers and is an SEAI registered installer. b. Any work undertaken is authorised by the Company and carried out by an approved service agent. c. The boiler is run on approve 6mm wood pellets as described in section 2.3 & section 3 of this manual.

3. The primary and secondary heat-exchangers of the wood pellet boiler manufactured by Grant Engineering (Ireland) Limited are guaranteed for a period of 5 years from the date of installation. All other components except consumables are guaranteed for a period of 1 year.

4. The guarantee starts from the date of purchase.

5.The guarantee does not cover breakdowns caused by incorrect installation, neglect, misuse, accident or failure to operate this boiler in accordance with the manufacturer‟s instructions.

6. This guarantee is non transferable unless sanctioned by the company.

7. The company will endeavour to provide prompt service in the unlikely event of a problem occurring, but cannot be held responsible for any consequence of delay however caused.

8. This guarantee does not cover labour handling or shipping.

9. This guarantee applies to boilers installed on the island of Ireland both North and South. Provision for warranty cover elsewhere is subject to agreement with Grant Engineering (Ireland) Limited.

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

11. Grant Engineering do not accept any responsibility for damage, how so ever caused, to plastic piping or fittings used on the heating system.

Page 62

15. Notes

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EC Declaration of Conformity

We Grant Engineering (Ireland) Limited under our sole responsibility declare that the Grant Spira Wood pellet boiler as listed below complies with the requirements of the

The Low Voltage Directive (LVD) 2006/95/EC

Standard used; EN60335-1 2002

The Electromagnetic Compatibility Directive 2004/108/EC

Standard used; EN 55014 -1: 2007

Product Category; Floor Standing Domestic Condensing Wood pellet boiler

Model; Grant Spira 6-26 Wood Pellet Boiler

Grant Spira 9-36 Wood Pellet Boiler