Grant Spira Series, Spira 5-18, Spira 6-26, Spira 9-36 User, Installation And Servicing Instructions

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Grant Spira

5-18kW, 6-26kW and 9-36kW Condensing Wood Pellet Boiler

User, Installation and Servicing Instructions

UK | DOC 0042 | Rev 2.0 | October 2015

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Important Note

Important Note for Installers

After installing the boiler leave these instructions with the appliance. This appliance is deemed a controlled service and specific regional statutory requirements may be applicable.

GRANT ENGINEERING (UK) LIMITED

Hopton House, Hopton Industrial Estate, Devizes Wiltshire SN10 2EU

Tel: +44 (0)1380 736920 Fax: +44 (0)1380 736991 Email: [email protected] www.grantuk.com

This manual is accurate at the date of printing but will be superseded and should be disregarded if specifications and/or appearances are changed in the interests of continued product improvement. All good sold are subject to our official Conditions of Sale, a copy of which may be obtained on application.

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User Instructions - contents

For the Installation and Servicing Instructions, please refer to page 20.

1 Introduction 4

2 About your Boiler 4

2.1 General 4

2.2 Pellet Hoppers 4

2.3 Bulk Pellet Stores 4

2.4 Boiler Operation 5

2.5 Cleaning 5

3 About your Fuel 5

4 Boiler Controls 7

4.1 Boiler Control Panel 7

5 Burner Control Panel 8

5.1 Burner Control Panel 8

5.2 Error Messages 9

5.3 Service Indicator 9

5.4 Active Symbols 9

6 Pellet Feed Thermostat 10

7 Priming the Auger 10

8 Lighting the Boiler 11

9 If you Boiler Fails to Light 12

10 Emptying the Ash Pan 14

11 Cleaning and Servicing your Boiler 16

12 Ventilation 16

13 Electricity Supply 16

14 Sealed Central Heating system 16

15 Frost Protection 17

16 Corrosion and Protection 17

17 Service Log 18

This appliance can be used by children aged from 8 years and above and persons with reduced physical, sensory or mental capabilities or lack of experience and knowledge if they have been given supervision or instruction concerning use of the appliance in a safe way and understand the hazards involved. Children shall not play with the appliance. Cleaning and user maintenance shall not be made by children without supervision.

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1 Introduction

This guide is intended to assist and instruct the user in the operation of the Grant Spira Condensing Wood Pellet Boiler.

A separate manual is available to the installer for the installation, servicing and commissioning of the boiler.

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

WARNING

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

CAUTION

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

NOTE

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

2 About your Boiler

2.1 General

Your Grant Spira wood pellet boiler should only be installed, commissioned and serviced by a Grant Accredited Installer who has undergone specific product training by Grant Engineering (UK) Ltd.

If you have a Grant Spira 5-18, 6-26 or 9-36, your boiler basically consists of two parts:

• The boiler itself, with the burner mounted on the front

• The pellet hopper, with the pellet feed auger protruding from the front of the hopper casing

The hopper may be either a 110kg or 200kg capacity unit and will be located on either the left or right hand side of the boiler.

Check with your installer for the actual capacity of pellet hopper you have with your boiler.

Alternatively, if you have a Grant Spira 11-44, 12-52, 15-62 or 18-72, your boiler will basically consist of three par ts:

• Two boilers, each with the burner mounted on the front

• The pellet hopper, with two pellet feed augers protruding from the front of the hopper casing

In this case the hopper will have a 140kg capacity and will be located between the two boilers.

CAUTION All Grant Spira boilers and pellet hoppers are designed for indoor use only and MUST be positioned in a dry environment.

2.2 Pellet Hoppers

The pellet hopper is mounted on castors (with the front castors lockable) to allow it to be easily moved when required. Allow sufficient area in front of the hopper for it to be moved out and away from the boiler(s) for servicing.

The electrical connections to the boiler(s) are all made to the 4-way electrical plug on one of the three factor y-fitted ‘flying leads’ at the rear of the pellet hopper.

All Grant pellet hoppers are fitted with a contents switch. Refer to Figure 2-1.

This automatically detects when the level of pellets in the hopper falls to a pre-set minimum value.

The minimum quantity of pellets required to restart the boiler is 20kg for the single boiler hoppers and 30kg for the double boiler hoppers.

If you have a bulk pellet store (refer to Section 2.3), the contents switch automatically triggers the operation of either the bulk store auger or Grant SpiraVAC system, whichever is fitted, to deliver pellets from the bulk pellet store into the pellet hopper beside the boiler.

When there is no bulk store (but the pellet hopper only), the contents switch stops the burner operating when the minimum pellet level is reached. In this case, topping up the hopper with more pellets will automatically operate the contents switch and the burner will restart, as long as there is a demand from the heating controls (room thermostat, etc.) for the boiler to run.

CAUTION

Always ensure that the door on the top of the pellet hopper is closed after filling to ensure no foreign debris enters the hopper. The hopper should only be filled to the point where it is still possible to close the top door.

Figure 2-1: Contents switch in the base of the pellet hopper

2.3 Bulk Pellet Stores

You may also have a bulk pellet store, located either inside or outside the building. If so, check with you installer for the capacity of the bulk pellet store.

If you have a bulk pellet store you will have either a bulk store auger, or a Grant SpiraVAC vacuum system, to move the pellets from the bulk store to the pellet hopper as and when required. Check with your installer regarding which system you have fitted. If you have the Grant SpiraVAC system, please refer to the instructions provided with that system for details of its operation.

NOTE If you have a bulk pellet store it is essential that you routinely check the level of pellets in the store and arrange for a delivery of pellets before the store is empty.

Where a bulk store is fitted; if the bulk store and pellet hopper are both allowed to run out of pellets then the error message ‘FAILED

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PELLET LIGHTING’ will be displayed on the burner control panel screen. Once the bulk store has been refilled with pellets, the bulk store auger (if fitted) will need to be re-primed before the pellet hopper is automatically filled from the bulk store.

If a Grant SpiraVAC vacuum system is fitted refer to the Instructions supplied with the system to restart the pellet supply to the pellet hopper.

Once the pellet hopper is filled, the pellet hopper auger will also need to be re-primed. Refer to Section 7 of these instructions.

Once this has been done press the reset button on the burner control panel to cancel the error message and restart the boiler.

2.4 Boiler Operation

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 that contains heat that is locked up in the flue gases. A conventional boiler cannot recover any of this heat and this energy is lost to the atmosphere through the flue.

Your Grant Spira condensing wood pellet boiler contains an extra (secondary) heat exchanger which is designed to recover much of the heat normally lost by a conventional boiler through the flue system. It does this by cooling the flue gases and extracting more heat from them, pre-heating the cooler water returning to the boiler from your heating system.

Even when not operating in a condensing mode, this additional heat exchanger ensures that your Grant Spira boiler will still operate at an extremely high efficiency.

The burner output is determined by the delivery rate of the pellets via the pellet feed auger (on the pellet hopper). This is automatically controlled by the burner control system. During commissioning the burner control parameters should have been checked and adjusted as necessary by your Installer.

WARNING Do not adjust or modify the appliance in any way as to do so could cause malfunction of the appliance, injury to persons or death or result in a potential fire hazard.

Only an Grant trained installer, who has completed the Grant training course, should carry out any work on the appliance.

Once commissioned by a Grant trained installer, your Grant Spira boiler will operate automatically to provide heating and domestic hot water (if you have a hot water cylinder fitted), as long as:

• There are sufficient pellets of the correct type in the pellet hopper. Refer to Section 3.

• The pellet auger is fully primed. Refer to Section 7.

• The heating system controls are set to ON and ‘calling’, i.e. the programmer and room thermostat are on.

• The burner ON/STANDBY switch on the boiler control panel is set to ON. Refer to Section 4.

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

WARNING Always ensure the front access door of the combustion chamber is fully closed and latched during operation.

Certain external surfaces of the boiler will be hot to touch when in operation, due care is needed.

2.5 Cleaning

The burner incorporates a brazier, located within the boiler combustion chamber, where the combustion of the wood pellets takes place. This brazier is fitted with a self-cleaning system to prevent a build-up of ash and clinker. This operates automatically after a preset period has elapsed.

The boiler has two heat exchangers, the primary and secondary (condensing), and each is fitted with a self-cleaning system to keep the heat exchanger tubes clear of ash build-up. As with the brazier cleaning system, these are operated automatically after a pre-set period has elapsed.

CAUTION

Even with the automatic cleaning systems, it is vitally important that the boiler ash pan is regularly emptied and the boiler regularly serviced. Refer to Sections 10 and 11 of these instructions for further information on the cleaning and servicing of your boiler.

3 About your Fuel

You Grant Spira boiler is designed to run only on 6mm diameter EN Plus Grade A1 wood pellets (conforming to EN14961-2).

Under no circumstances should any other form of biomass fuel be used with this boiler.

WARNING ONLY EN Plus Grade A1 (EN14961-2) wood pellets MUST be used with your Grant Spira boiler. These pellets must be bark and sand free AND previously tested by Grant BEFORE being used in your Spira boiler.

Failure to use pellets that meet the conditions above will invalidate the product guarantee. If you are in any doubt over which pellets are suitable please contact Grant for assistance.

For your guidance, below are examples of both the correct grade of pellets to be used and poor quality pellets that must not be used in your Grant Spira boiler.

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Figure 3-1: Correct grade of pellets

Figure 3-2: Poor quality pellets

Meets EN Plus Grade A1.

Correct diameter and length with no dust and minimum bark content.

Pellets not pressed correctly causing them to easily disintegrate.

DO NOT USE!

The auger will be unable to consistently deliver these pellets from the hopper to the burner, resulting in pellet lighting problems.

Too much bark content.

DO NOT USE!

These will cause excessive sand in the ash resulting in clinker blocking air holes, poor combustion and jamming of the brazier cleaning system.

Figure 3-3: Pellets too dark in colour

Figure 3-4: Pellets too short in length

Figure 3-5: Pellets with high dust content

DO NOT USE!

The auger will not be able deliver these pellets at the correct rate to the burner, affecting the input (and output) of the boiler and the combustion.

DO NOT USE!

The auger will not be able deliver these pellets from the hopper to the burner, resulting in pellet lighting problems.

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4 Boiler Controls

Figure 4-1:Boiler Control Panel

4.1 Boiler Control Panel

The boiler control panel is located at the top of the boiler. This control panel is fitted with three controls, as follows:

• BURNER ON/STANDBY switch:

To switch off the burner when required, by interrupting the signal from the heating system controls, i.e. the remote programmer and room thermostat.

This switch MUST be left in the ON position during normal operation of the boiler.

WARNING This switch does NOT isolate the electrical supply to the burner.

WARNING After the burner has been switched off (either manually using the burner ON/STANDBY switch on the control panel, automatically by the boiler temperature control, or the heating system controls) the burner needs to burn-down the remaining pellets in the brazier.

Do not open the front combustion chamber access door until “WAIT BOILER THERMOSTAT” is showing on the burner control panel display.

• OVERHEAT thermostat:

This is a built-in safety device to automatically shut down the boiler if it overheats. If this device should operate, it can be manually reset once the boiler has cooled down.

Switch the burner ON/STANDBY switch to ‘STANDBY’ and allow the boiler to cool down.

Then unscrew the plastic cap and press the reset button. If this overheat thermostat continually trips there may be a fault and you should contact your Installer.

• CLEANING AUTO/TEST switch:

When pressed and held in the TEST position, it allows the installer or Grant service engineer to manually operate and test the automatic cleaning systems in both heat exchangers. When released, it will automatically return to the default AUTO position to allow the boiler cleaning system to perform automatically.

Only operate the cleaning switch when the boiler is not operating and ‘WAIT BOILER THERMOSTAT’ is showing on the burner control panel display.

NOTE The Cleaning Auto/Test switch does NOT operate the brazier cleaning system.

Do not open the front combustion chamber access door until ‘WAIT BOILER THERMOSTAT’ is showing on the burner control panel display.

If the burner door is opened during the operation of the burner there can be a large uncontrollable flame from the brazier.

NOTE Avoid repeated opening and closing of the boiler door as this will cause the automatic cleaning of the boiler and burner to be delayed. This can cause excessive ash build-up within the boiler and burner that may result in nuisance faults occurring.

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5 Burner Control Panel

5.1 Burner Control Panel

The burner control panel is located on the upper front part of the red burner cover.

This control panel is used by the Installer or Grant Service Engineer to check and set the burner and boiler settings during commissioning or servicing.

The burner control panel display shows the following information:

Temperature Set Point

The set point is set by the Installer, during commissioning, using either button 1 or 2 (as shown below) within the range 55°C to 75°C.

Refer to Figure 5-1.

Typically it will be set to 70-75°C. This is the ‘target’ temperature setting about which the modulation of the boiler output will operate.

• 5°C below the set point, the boiler is in 100% power mode.

• 5°C above the set point, the boiler has reached minimum output.

The set point is NOT the temperature at which the burner stops. The maximum boiler temperature at which the burner will cut out is factory set in the burner control settings. This can, if required, be adjusted by the installer or Grant service engineer.

Figure 5-1: Burner control panel display - temperature set point

Boiler System Water Temperature

This is the temperature of the water in the boiler. Refer to Figure 5-2.

Figure 5-2: Burner control panel display - boiler system water temperature

NOTE When the burner cuts out, the temperature will continue to rise as the heat from the flame is transferred to the system water in the boiler.

Burner Operating Modes

Figure 5-3: Burner control panel display - burner operating mode indication

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At any point during the start-up, running and shutting down of the burner, the burner operational mode is shown scrolling across the bottom of the display screen. This can be one of several modes, depending on the operation of the boiler at the time it is viewed, as follows:

• WAIT BOILER THERMOSTAT: boiler is in standby mode awaiting either a signal from the heating system controls and/or for the

burner ON/STANDBY switch to be set to ON to start the boiler, OR the temperature to fall to the Restart Temperature (5°C below the set temperature)

• WAIT PRELOAD BRAZIER: initial loading of pellets into the burner brazier to enable the burner to be lit.

• WAIT LIGHTING: period of time taken for the pellets to light, for the flame to stabilise and then for small amounts of pellets to be

added to build up the flame in the brazier.

• PELLET BURNER FIRING – Power 100%: flame is fully developed and boiler is operating on full power.

• PELLET BURNER FIRING – Power 99% - 25%: boiler output is being modulated down.

• PELLET BURNER FIRING – Power 25%: boiler is operating at minimum output.

• TURNING OFF BRAZIER: burn-down period to remove any pellets remaining in the brazier.

• WAIT POST PURGE: period of time after burn-down is complete to ensure no unburnt pellets ignite.

5.2 Error Messages

The burner control panel display can also indicate that a fault has occurred with the boiler. In the event of a fault, one of the following error (fault) messages may be seen scrolling across the bottom of the display screen:

• FAILED PELLET LIGHTING

• SERVO MOTOR BLOCKED

• PROBE FAULT

• AIR PRESSURE ERROR

5.3 Service Indicator

The burner will indicate when a service is required by showing the word ‘SERVICE’ on the control panel display. This will occur after a preset period (400 hours of pellet auger running time) has elapsed. This equates to the consumption of 4.8 tonnes of pellets.

The boiler must be serviced either annually, or when you see the ‘SERVICE’ message on the burner control panel display, whichever comes first. Contact you Grant Approved Installer and arrange for your boiler to be serviced.

5.4 Active Symbols

There are eight symbols on the left hand side of the burner control panel display.

These are the ‘active symbols’ that, when they have a cursor displayed next to them in the screen area, indicate what functions the burner is operating at any point when the boiler is running.

Figure 5-4: Burner control panel display – active symbols

The function indicated by each of these ‘Active Symbols’ is as follows:

Symbol Function

Heating demand (from heating system controls)

Burner fan operational

Air pressure switch closed

Ignition element operational

Pellet feed auger operational

Flame on

Not applicable

Fault

Table 5-5: Active symbols

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6 Pellet Feed Tube Thermostat

This is a built-in safety device, mounted on the pellet feed tube (on the top of the burner) to automatically shut down the burner if the temperature on the pellet feed tube (between the pellet auger and the burner) exceeds a safe level.

If this device should operate, it can be manually reset once the boiler and pellet feed tube has cooled down.

To reset:

• Isolate the electrical supply to the boiler (set the switch on the fused spur to off).

• Remove the red burner cover by loosening the four M5 screws (two on each side

of the cover) and lifting it off the burner. The thermostat is located on the pellet feed tube. Refer to Figure 6-1.

• Disconnect the lead from the thermostat terminals. Refer to Figure 6-2.

• Press the reset button located between the two terminals.

• Reconnect the lead. Ensure it is fully pushed on to thermostat terminals.

• Finally, refit the burner cover and tighten the four screws.

• Reconnect the electrical supply to the boiler and check operation.

NOTE There is no power present on the two thermostat terminals when the lead has been disconnected, so there is no risk of electrocution when resetting the thermostat.

Figure 6-1: Location of pellet feed tube thermostat

7 Priming the Auger

The pellet feed auger on the pellet hopper MUST be fully primed BEFORE attempting to start the boiler. The auger should be initially primed by the Installer as part of the commissioning process.

If for any reason the auger needs to be re-primed, this is a simple process using the following procedure:

Step 1

First set the burner ON/STANDBY switch to the STANDBY position.

Step 2

Disconnect the pellet feed auger 6-way plug (3) from the upper socket on the left side of the burner. Refer to Figure 7-1.

Step 3

Disconnect the 7-way plug (1) from the socket on the left side of the burner. Refer to Figure 7-2.

Step 4

Disconnect the pellet delivery hose from the pellet feed tube (on the burner) and place the open end into a DRY container of at least 1 litre capacity. Refer to Figure 7-3.

Figure 6-2: Disconnect lead from pellet tube thermostat

Figure 7-1: Remove plug 3 from burner

Figure 7-2: Remove plug 1 from burner

Step 5

Insert the 6-way plug (3) into the 7-way plug (1). Refer to Figure 7-4. It is not possible to connect these two plugs incorrectly as they will only fit together one way. When these plugs are connected the pellet feed auger will run continuously.

Step 6

Leave the auger running until there is a continuous flow of pellets from the pellet delivery hose. This may take 15 to 20 minutes. The pellet feed auger is now fully primed.

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Step 7

Disconnect the two plugs from each other and the auger will stop.

Refit the pellet delivery hose onto the pellet feed tube of the burner.

WARNING Ensure that the pellet delivery hose forms an air tight seal each end and that the hose is not damaged. Leakage of air could cause increased temperature in the pellet delivery hose and result in the pellet feed tube thermostat shutting down the burner.

Step 8

Re-fit both the 6-way and then 7-way plugs to their corresponding sockets on the left side of the burner. Ensure that both plugs are fully pushed home until the small catch on each plug clicks into place.

Step 9

Make sure that the boiler pellet hopper is correctly located against the side of the boiler with the front edge aligned with the top front edge of the boiler. Refer to Figure 7-5.

Step 10

Finally, set the burner ON/STANDBY switch to the ON position.

8 Lighting your Boiler

To start your boiler:

• First ensure that the electrical supply to the hopper and boiler is switched on.

• Check that the heating system controls are operating and are ‘calling’ for

heat. There should be a cursor next to the ‘Heating Demand’ symbol on the burner display. Refer to Section 5.4 – Active Symbols.

• Set the burner ON/STANDBY switch to ON. The flue fan will start and pellets

will be delivered to the burner for it to start.

NOTE If the burner ON/STANDBY switch is switched to STANDBY at this stage the pellet feed will continue, and then the burner will go through the ‘WAIT BOILER LIGHTING’ phase and light.

It will then immediately go to ‘TURNING OFF BRAZIER’ followed by ‘WAIT POST PURGE’ and then stop.

This process will take several minutes to complete before the boiler can be re-started.

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

• Set the heating (CH) and hot water (HW) functions on your programmer to ‘Timed’. The boiler will now operate during the ‘on’ periods set on the programmer.

CAUTION Do not repeatedly switch the ON/STANDBY 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.

Figure 7-3: Pellet tube ready for priming the pellet auger

Figure 7-4: Connect plugs together

Figure 7-5: Correct alignment of hopper to boiler.

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9 If your Boiler Fails to Light

If you experience a problem with your boiler, it may be due to something quite simple and by making a few checks you can quickly rectify it for yourself. If your boiler fails to light, please follow the procedure given below, starting with STEP 1:

STEP 1

STEP 2

STEP 3

Is the burner control panel display blank? NO - go to STEP 2

YES – Check the following:

• Is the electrical supply to boiler and heating system controls switched on at fused spur?

• Has the fuse in the fused spur blown?

• Are all the plugs at the rear of the hopper, the rear of the boiler and the side of the burner fitted

correctly?

• Is the combustion chamber door closed and the catch fully engaged?

• Has the boiler overheat thermostat tripped? Remove cap to check. If yes, press the reset button.

Refer to Section 4. If this does not rectify the problem, contact your Installer.

• Has the pellet feed tube thermostat tripped? Reset the thermostat. Refer to Section 6 – Pellet Feed

Tube Thermostat for details. If this does not rectify the problem, contact your Installer.

If, after checking the above, there is still a problem then contact your Installer for assistance.

Is one of the four ERROR MESSAGES scrolling across the bottom of the burner control panel display? YES – go to STEP 4

NO – go to STEP 3

Is there a cursor next to the ‘Heating Demand’ symbol on the burner display? YES – Check the temperatures on the burner display.

• Is the H2O value on the display higher than the set point temperature value plus 5°C. If so, there is

NO fault but the boiler is waiting for the system temperature to drop before firing again.

NO – Check the following:

• Is the burner STANDBY/ON switch set to the ON position? If not, then set it to ON.

• Is there a sufficient quantity of pellets in the pellet hopper? If not, top up the hopper with pellets.

• Are the heating system controls (programmer, room thermostat, etc.) ‘calling’ for heat? If not, set

controls to call for heat.

STEP 4

If, after checking the above, there is still a problem then contact your Installer for assistance.

Which one of the four ERROR MESSAGES is scrolling across the bottom of the burner control panel display?

• FAILED PELLET LIGHTING – go to STEP 5

• SERVO MOTOR BLOCKED – go to STEP 6

• PROBE FAULT – go to STEP 7

• AIR PRESSURE ERROR – go to STEP 8

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STEP 5

STEP 6

FAILED PELLET LIGHTING is scrolling across the bottom of the burner control panel display.

Check the following:

• Is there a sufficient quantity of pellets in the pellet hopper? If not, top up the hopper.

• Is the pellet auger fully primed? If not, prime the auger. Refer to Section 7.

• If there is a bulk pellet store, Are there pellets in the bulk store? Refer to Section 2 – Bulk pellet stores.

• Is the bulk store auger (if fitted) fully primed? Refer to Section 2 – Bulk pellet stores.

• If a Grant SpiraVAC vacuum system is fitted, is it delivering pellets to the pellet hopper? Refer to

Instructions supplied with the SpiraVAC system.

• Are pellets being delivered to the burner by the pellet hopper auger? If not, check the following:

a) Is the auger rotating? If not, check if the auger power supply lead is correctly plugged in to the burner. If it is still not rotating then contact your Installer. b) Is there a build-up of dust in the bottom of the hopper? If so, this dust MUST be removed from the hopper and auger, and the auger then must be re-primed. Refer to Section 7.

NOTE

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

• With the burner STANDBY/ON switch set to the STANDBY position, remove the pellet feed tube from

the burner and open the combustion chamber door.

• Is the brazier blocked with ash/clinker? If yes, is the correct grade of pellets being used? If not, empty

the hopper and refill with correct grade of pellet.

If, after checking the above, there is still a problem then contact your Installer for assistance.

SERVO MOTOR BLOCKED is scrolling across the bottom of the burner control panel display.

Check the following:

• With the burner STANDBY/ON switch set to the STANDBY position, remove the pellet feed tube from

the burner and open the combustion chamber door.

• Is the brazier blocked with ash/clinker? If yes, remove the blockage and close the combustion

chamber door. Reset the STANDBY/ON switch to ON and wait for the cleaning process to be completed.

If, after checking the above, there is still a problem then contact your Installer for assistance.

STEP 7

PROBE FAULT is scrolling across the bottom of the burner control panel display.

Check the following:

• Are the three plugs correctly fitted to the left side of the burner?

• Press the RESET button on burner control panel to clear error message.

If, after checking the above, there is still a problem then contact your Installer for assistance.

STEP 8

AIR PRESSURE ERROR is scrolling across the bottom of the burner control panel display.

Check the following:

• Press the RESET button on the burner control panel to clear error message.

If there is still a problem then contact your Installer for assistance.

WARNING

Do not under any circumstances enter a bulk pellet store or pellet hopper that has been in operation as there may be a build-up of fumes within the enclosure if the boiler has malfunctioned.

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10 Emptying the Ash Pan

It is essential that the ash pan (located inside the boiler combustion chamber) is periodically emptied.

This simple task must be carried out by the user at MONTHLY intervals for the FIRST THREE MONTHS after the boiler is installed.

After that the ash pan should be emptied regularly, on at least a MONTHLY basis, or as indicated by the amount of ash found during the first three months.

NOTE

The amount of ash produced varies between the different pellet brands and this will affect the frequency of cleaning and maintenance required.

To remove and empty the ash pan you will need the following items (supplied with the boiler):

• The removable door handle – to open the combustion

chamber door. Refer to Figure 10-1.

• The ash pan carrying handles – to remove and carry the ash

pan when hot. Refer to Figure 10-2.

To remove and empty the ash, follow the procedure below:

Figure 10-1: Removable door handle

Figure 10-2: Carrying handles

Step 1

Set the burner STANDBY/ON switch to ‘STANDBY’.

Step 2

If the boiler is running at the time, wait for it to complete the burner shut-down sequence, i.e. until the burner control panel display screen reads ‘WAIT PELLET THERMOSTAT’.

Do not AT ANY TIME open the front combustion chamber access door until the burner display reads “WAIT BOILER THERMOSTAT”

Step 3

Allow the burner to cool down, for a period of at least 30 minutes.

Step 4

Disconnect the pellet delivery hose from the pellet feed tube on the burner. Refer to Figure 10-3.

Figure 10-3: Disconnect pellet hose from burner

Step 5

Fit the removable door handle into the slot in the door catch. Refer to Figure 10-4.

Figure 10-4: Fitting the removable door handle

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Step 6

Lift the handle to disengage the catch and fully open the combustion chamber door. Refer to Figure 10-5.

Figure 10-5: Opening combustion chamber door

WARNING The interlock on the combustion chamber door automatically disconnects the power supply to the burner if the door is opened.

IT DOES NOT IMMEDIATELY EXTINGUISH THE BURNER FLAME.

If the burner door is opened during the operation of the burner there can be a large uncontrollable flame from the brazier.

Step 7

Hook one of the two carrying handles (supplied with the boiler) under the front edge of the ash pan and carefully pull the ash pan forward by about 300mm (12inches). Refer to Figure 10-6.

Step 8

Brush/scrape any ash resting on the burner into the ash pan below.

Step 9

Using both of the carrying handles, one at the front and the other at the back, carefully lift the ash pan out of the boiler. Refer to Figure 10-7.

Figure 10-6: Removal of ash pan from boiler

Figure 10-7: Lifting ash pan using carrying handles

Figure 10-5: Opening combustion chamber door

Do NOT use the centre cross bar of the ash pan as a carrying handle.

Step 10

Safely dispose of the ash.

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

Step 11

Remove any remaining ash that may be left in the base of the boiler before putting the ash pan back into the combustion chamber.

Step 12

Close the combustion chamber door and ensure that the door catch is fully engaged. Remove the door handle and keep in a safe place for future use, along with the carrying handles.

Figure 10-6: Removal of ash pan from boiler

Figure 10-7: Lifting ash pan using carrying handles

Page 16

11 Cleaning and Servicing your Boiler

The boiler MUST be serviced either ANNUALLY or when a service is indicated on the burner control panel display, whichever comes FIRST. Refer to Section 5.

Servicing should only be carried out by a Grant trained installer or Grant service engineer, and details of each service should be recorded in the Service Log in Section 17 of these User Instructions.

CAUTION Failure to regularly service the boiler will invalidate the terms of the Grant product guarantee.

Failure to maintain a clean flue may result in the release of flue gases into the dwelling or damage from potential fire in the flue. It is therefore essential that your flue is inspected annually and cleaned as necessary by either a Grant trained installer or a suitably qualified chimney sweep.

12 Ventilation

As an ‘open flued’ appliance, your Grant Spira boiler draws the air it requires for combustion from the room in which it is located. In turn, this air comes from outside via a permanently open air vent (or vents) correctly sized to meet the air requirements of your boiler.

WARNING Any permanently open combustion air vents in the room containing the boiler MUST NOT be blocked off or obstructed in any way. Do not attempt to ‘box in’ the boiler, or build a compartment around it, without contacting your installer first for guidance.

Do NOT place any combustible material against, around or on the boiler or flue pipe.

Current Building Regulations require that a Carbon Monoxide alarm (conforming to BS EN 50291:2001) must be fitted in the room where the boiler is located.

This should be positioned between 1 and 3metres horizontally from the boiler either: a) On the ceiling, at least 300mm from any wall

b) On a wall as high up as possible (above any windows or doors) at least 150mm from the ceiling.

13 Electricity Supply

If the electricity supply fails, the boiler will cease to operate. It should automatically relight when the electrical supply is restored. However, it may first burn off any smouldering pellets still present in the brazier before starting the lighting sequence again.

If a remote programmer is connected to your boiler, it may have a ‘battery back-up’ of some kind that will retain the on/off time settings you previously entered. It may also resume operation with the correct time of day and thus require no re-setting of time and on/off settings when the supply is restored. Refer to the instructions supplied with your programmer for further details. It is recommended that you check that the on/off and time settings after a power failure has occurred.

WARNING The electricity connections to the boiler must be earthed.

14 Sealed Heating System

If your boiler is operating on a sealed heating system, the installer will have adjusted the pressure in the system and should have told you (or set it on the pressure gauge) the system pressure when cold. This is normally between 0.5 and 1.0 bar, which will increase slightly when hot. If the pressure (when cold) is below the set pressure mentioned above, you can re-pressurize the system. If this is frequently required, ask your Installer or service engineer to check the heating system for leaks and to check the expansion vessel air charge.

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

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

Re-pressurise the system as necessary.

The sealed system is fitted with a safety valve to release excess pressure from the system. If water or steam is emitted from the end of the safety valve discharge pipe, switch off the boiler and contact your Installer for assistance.

Page 17

15 Frost Protection

Your installer may have fitted a frost thermostat. If not, and you are likely to be away for a short time, leave the boiler on with the room thermostat set at a low setting. For longer periods, the boiler should be turned off and the system drained down. Contact your Installer for draining and re-filling the system. Alternatively, a suitable anti-freeze may have been added to the heating system water. Check with your installer.

16 Corrosion Protection

In order to prevent corrosion within your heating system and boiler, your installer should have flushed the system and added a suitable corrosion inhibitor.

NOTE

The Grant Guarantee on the boiler shell (heat exchanger) requires that the heating system is flushed or chemically cleaned, following installation, and the required quantity of corrosion inhibitor is added to the heating system water.

Grant strongly recommends that an in-line magnetic filter (either a Grant Mag-One or equivalent*) is fitted in the heating system pipework.

This should be installed and regularly serviced in accordance with the filter manufacturer’s instructions.

*The Grant Mag-One magnetic filter has a Gauss measurement of 12000.

Page 18

17 Service Log

Heating System

System pressure – check/top up

Pressure relief valve operation - check

Expansion vessel charge pressure – check

Magnetic filter – inspect/clean

Corrosion inhibitor in system – check

Flue System

Flue terminal – check condition

Flue system – check clean

Draught stabilizer – check operation

Smoke test (Smoke test II Part J. Section E15)

Combustion ventilation – check

Boiler

Temperature probe – check

Overheat thermostat – check

Primary heat exchanger – inspect/clean

Secondary heat exchanger – inspect/clean

Wash system – inspect/clean

Combustion chamber – inspect/clean

Fan – inspect/clean

Shaker mechanism - grease

Shaker system – check operation

Condensate trap – inspect/clean

Condensate discharge pipe – inspect/clean

Burner

Brazier – dismantle/clean

Photocell – inspect/clean

Ignition element – inspect/clean

Boiler settings – check

Safety devices

Hopper lid switch – check operation

Combustion door switch – check operation

Pellet Hopper

Check for dust build-up

Auger – check for blockages

Combustion

Combustion chamber draught – check/adjust

Flue gas analysis – check/adjust

Customer handover

Service Date

Service Company

Service 1 Service 2 Service 3 Service 4 Service 5

Signature

Page 19

This page is intentionally left blank

Page 20

Installation and Servicing Instructions - contents

1 Introduction 21

1.1 How the Condensing 22 Wood Pellet Boiler Operates

1.2 Boiler Description 22

1.3 Boiler Models 22

1.4 Boiler Components 23

1.5 Boiler Cleaning and 24 Servicing

1.6 Removable Door Catch 24 Handle

2 Technical data 25

2.1 Boiler and Hopper 25 Technical Data

2.2 Boiler Input and 26 Output Data

2.3 Flue Gas Analysis 26

2.4 Boiler and Hopper 27 Dimensions and Clearances

3 Pellet Specification, 30 Storage and Delivery

3.1 Pellet Specification 30

3.3 Biomass Suppliers List 30

3.2 Pellet Storage 31

4 Installation information 33

4.1 Introduction 33

4.2 Boiler Location 33

4.3 Preparation for Installation 33

4.4 Installing the Boiler 33

4.5 Regulations 33

4.6 Heating System Design 33 Considerations

4.7 Pipework Materials 33

4.8 Pipe Connections 34

4.9 Wash System 34

4.10 Fan Box and Flue Starter 34

4.11 Pellet Feed Tube 35

4.12 Pellet Hoppers 36

4.13 Pellet Feed Auger 36

4.14 Before you Commission 36

4.15 Completion 36

6 Sealed Systems 39

6.1 Sealed System 39 Requirements

6.2 Filling the Sealed System 40

6.3 Venting the Pump 40

6.4 Pressure Relief (Safety) 40 Valve Operation

7 Flue System and 41 Air Supply

7.1 Air Supply 41

7.2 Flue Terminal Position and 41 Clearances

7.3 Flue System Specification 43

7.4 Flue System Assembly 43

7.5 Flue Testing 46

7.6 Flue Notice Plate 46

7.7 Carbon Monoxide Alarm 46

7.8 Typical Flue Systems 47

7.9 Flue Component Dimensions 48

7.10 Flue System Components 49

7.11 Flexible Flue Liner 51

8 Electrical 52

8.1 General Requirements 52

8.2 Hopper Electrical 52 Connections

8.3 Boiler/Hopper Plug 53 Connections

8.4 Heating System Controls 54

8.5 Connecting the Power 54 Supply

8.6 Wiring Diagrams 55

9 Burner 61

9.1 Burner Operation 61

9.2 Burner Operating Modes 61

9.3 Burner Operating Sequence 62

9.4 Burner Display Screen 63

9.5 Burner Control Buttons 63

9.6 Burner Menu Navigation 64 Chart and Factory Default Settings

9.7 Burner Menu 65

10.10 Flue Gas Analysis 72

10.11 Customer Handover 73

10.12 Commissioning Report Form 73

10.13 Commissioning Check List 73

11 Servicing 74

11.1 General 74

11.2 Checks Before Servicing 74

11.3 Heating System 74

11.4 Flue System 75

11.5 Combustion Ventilation 75

11.6 Boiler 75

11.7 Burner Brazier 77

11.8 Burner Components 78

11.9 Refitting the Burner 79

11.10 Condensate Disposal 79 System

11.11 Cleaning Function Test 79

11.12 Burner Settings 80

11.13 Safety Device Checks 80

11.14 Combustion Checks 80

12 Fault Finding 81

12.1 General 81

12.2 Normal Screen Display 82

12.3 No Screen Display 83

12.4 Boiler Overheat Thermostat 85

12.5 Pellet Feed Tube Thermostat 87

12.6 Failed Pellet Lighting 89

12.7 Servo Motor Blocked 91

12.8 Probe Fault 92

12.9 Air Pressure Error 93

13 Spare Parts 95

13.1 Boiler 95

13.2 Boiler Parts List 96

13.3 Burner 98

13.4 Burner Parts List 99

13.5 110kg Pellet Hopper 100

13.6 200kg Pellet Hopper 100

13.7 140kg Pellet Hopper 101

13.8 Pellet Hopper Parts List 101

5 Condensate disposal 37

5.1 General Requirements 37

5.2 Connections 37

5.3 Pipework 37

5.4 External Pipework 37

5.5 Condensate Trap 38

5.6 Inspection and Cleaning 38 of Trap

10 Commissioning 68

10.1 Equipment Required 68

10.2 Preliminary Inspection 68

10.3 Boiler 68

10.4 Pellet Hopper 69

10.5 Safety Device Checks 69

10.6 Burner Settings 70

10.7 Priming the Pellet Feed 70 Auger

10.8 Lighting the Boiler 71

10.9 Combustion Chamber 71 Draught

14 Clean Air Act and 102 Declaration of

Conformity

14.1 Clean Air Act 102

14.2 Declaration of Conformity 102

15 Health and Safety 103 Information

15.1 Insulation Materials 103

15.2 Sealant and Adhesive 103

16 Guarantee 104

Page 21

1 Introduction

Figure 1-1: Grant Spira Condensing Wood Pellet Boiler and Intermediate Hopper

This manual is intended to guide Installers who have completed the Grant Wood Pellet Boiler Installer training course on the installation, commissioning and servicing of the Grant 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 for the purposes listed:

WARNING

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

CAUTION

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

NOTE

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

Page 22

1.1 How the Condensing Wood Pellet Boiler Operates

On start up, the auger feeds the wood pellets from the hopper into the burner where they are lit by an ignition element. The burner output is modulated to achieve the set temperature by controlling the feed rate of pellets. The fan in the burner propels hot gases generated from the fuel into the Spira’s primary heat exchanger. The heat energy is then transferred to water from the central heating system, before being circulated around the property to radiators/underfloor heating. It is important to note that in noncondensing biomass boilers, up to 20% of the energy that is produced is lost to the atmosphere through waste gases exhausted by the flue system.

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

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

The boiler has been independently tested to BS EN303-5 and will achieve the following full load (nett) efficiencies when both the boiler and system are correctly set:

Model Nominal Reduced output output

Spira 5-18 95.5% 90.2%

Spira 6-26 97.4% 96.4%

Spira 9-36 93.1% 98.1%

To ensure maximum efficiency from the Grant Spira boiler, the boiler return temperature should be 55°C or less (but NOT less than 40°C) at maximum operating temperature. This will enable the latent heat to be condensed out of the flue gases.

The boiler is capable of a maximum flow temperature with a maximum set point of 75°C.

To achieve the required return temperature (55°C or less), it is recommended that the heating system is designed and balanced to operate with a temperature differential of 20°C between flow and return. The use of modulating circulating pumps and effective control systems should be considered.

Grant Spira condensing wood pellet boilers will still operate at extremely

high efficiencies even when not in condensing mode and are therefore suitable for fitting to an existing heating system without alteration to the radiator sizes.

1.2 Boiler Description

The Grant Spira boiler uses a drop feed type burner with modulated heat output. The burner output is determined by varying the feed and pause times of the pellet feed auger supplying pellets to the burner. See Section 9 for details of burner operation.

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

All models are supplied with the control panel and burner factory fitted. The fan box, pellet feed auger and hopper are supplied separately and are fitted by the installer. See Section 4 for boiler installation. The boiler needs to be connected to a conventional flue system. There is no provision for connection to a balanced flue system

Product code Model Description

WPS518 RH110 5-18 1 x 5-18kW boiler + 110kg right hand hopper

WPS518 LH110 5-18 1 x 5-18kW boiler + 110kg lef t hand hopper

WPS518 RH200 5-18 1 x 5-18kW boiler + 200kg right hand hopper

WPS518 LH200 5-18 1 x 5-18kW boiler + 200kg lef t hand hopper

WPS626 RH110 6-26 1 x 6-26 boiler + 110kg right hand hopper

WPS626 LH110 6-26 1 x 6-26 boiler + 110kg lef t hand hopper

WPS626 RH200 6-26 1 x 6-26 boiler + 200kg right hand hopper

WPS626 LH200 6-26 1 x 6-26 boiler + 200kg lef t hand hopper

WPS936 RH110 9-36 1 x 9-36 boiler + 110kg right hand hopper

WPS936 LH110 9-36 1 x 9-36 boiler + 110kg lef t hand hopper

WPS936 RH200 9-36 1 x 9-36 boiler + 200kg right hand hopper

WPS936 LH200 9-36 1 x 9-36 boiler + 200kg lef t hand hopper

WPS1144 11-44 1 x 5-18kW and 1 x 6-26kW boilers + 140kg double boiler

WPS1252 12-52 2 x 6-26kW boilers + 140kg double boiler hopper

WPS1562 15-62 1 x 6-26kW and 1 x 9-36kW boilers + 140kg double boiler

WPS1872 18-72 2 x 9-36kW boilers + 140kg double boiler hopper

as there is draught stabiliser 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 such a system there is no effect on the boiler performance.

NOTE

The only flue suitable for use with the Grant Spira condensing wood pellet boiler is the Grant Biomass twin-wall insulated conventional flue system.

This 125mm (5”) diameter flue system is suitable for the 5-18kW, 6-26kW and 9-36kW Spira models.

For the 44kW, 52kW, 62kW and 72kW double boiler installations each boiler must have a separate

flue system. Refer to Section 7.

1.3 Boiler Models

The Grant Spira condensing wood pellet boiler is available in sixteen different models:

hopper

Page 23

1.4 Boiler Components

1.4.1 Burner. The burner is supplied

factory-fitted to the boiler. All burners are supplied with factory default settings. During commissioning each burner parameter will need to be checked (see Section 9), and adjusted if necessary as the flue length can have a significant effect on the boiler performance. Refer to commissioning in Section 10.

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

All Spira boilers are fitted with a flame viewing window, located on the right hand side of the front combustion chamber door, just above the burner.

The burner output is determined by the feed / pause times of the pellet feed auger supplying the burner. See Section 9 for full burner operation details.

1.4.2 Boiler. The Spira condensing boiler is supplied with a combined primary and secondary heat-exchanger. Both heat exchangers are equipped with a self cleaning system.

1.4.3 Boiler controls. The set-point temperature of the boiler is user adjustable via two push buttons on the burner control panel - see Section 9.4 for details.

The boiler control panel (see Figure 1-2) is located at the top of the boiler and is fitted with three controls, as follows:

ON/STAND-BY switch – to switch off the burner when required, by interrupting the switched live supply to the burner. This switch does not isolate the electrical supply to the burner.

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

CLEANING switch - when pressed and held in the TEST position, it allows the cleaning system to be manually operated and tested. When released it will automatically return to the default AUTO position to allow the boiler cleaning system to perform automatically. Only operate the cleaning switch when the boiler is not operating

- when ‘WAIT BOILER THERMOSTAT’ is showing on the burner display screen.

NOTE

‘TEST’ does NOT operate the burner cleaning function, but only that of the two heat exchangers.

Figure 1-2: Boiler control panel

WARNING

After the burner has been switched off (either manually by the switch on the control panel, or automatically by the boiler control stat, or the heating system controls) the burner needs to burn-down the remaining pellets in the brazier. Do not open the front combustion chamber access door until the burner display reads “WAIT BOILER THERMOSTAT”.

1.4.4 Boiler Pellet Hoppers. All single

boilers (Spira 5-18, 6-26 and 9-36 models) come with a pellet hopper. Two sizes of hopper are available for use with single boilers, as follows:

• 110 kg hopper – for storing a maximum of 110kg (≈170 litres) of wood pellets

• 200kg hopper – for storing a maximum of 200kg (≈308 litres) of wood pellets.

There are two versions of both the 110kg and 200kg pellet hopper available for use with a single boiler:

Left hand hopper – to be positioned on the left hand side of the boiler.

Right hand hopper – to be positioned on the right hand side of the boiler.

NOTE

The hopper type must be specified when ordering.

Both hoppers are supplied with a single

1.2m pellet feed auger, to be fitted to the hopper on site by the installer.

All ‘double boiler’ installations (Spira 11-44, 12-52, 15-62 and 18-72 models) come with one ‘double’ hopper to feed both boilers with two 1.2m pellet feed augers.

This hopper is positioned between the two boilers and stores a maximum of 140 kg (≈215 litres).

All the Grant pellet hoppers are for indoor use only and must be positioned in a dry environment.

Hopper contents switch

All hoppers are fitted with a contents switch. This detects when the level of pellets in the hopper falls to a pre-set minimum value. If a bulk store is used, this triggers the operation of either a bulk store auger, or vacuum system, to delivery pellets from the bulk pellet store.

If no bulk store is used, the contents switch will stop the burner operating when the minimum pellet level is reached or low level warning light.

Topping up the hopper with more pellets will automatically operate the contents switch and the burner will restart (if there is a demand for the boiler to run).

The minimum quantity of pellets required to restart the boiler is 20kg for the single boiler hoppers and 30kg for the double boiler hoppers.

All boiler pellet hoppers are for indoor use only and MUST be positioned in a dry environment free from dampness. They must be located

on the same floor level as the boiler or boilers, they are supplying.

All hoppers are mounted on castors (with the two front castors lockable) to allow it to be easily moved when required. Allow sufficient area in front of the hopper for it to be moved out and away from the boiler(s) during servicing.

The electrical connections to the boiler(s) are all made to the 4-way electrical plug on one of the three factory-fitted ‘flying leads’ at the rear of the hopper. Refer to Section 8 for details.

Page 24

All hoppers are supplied with a rectangular blanking plate fitted on the top rear panel. This can be removed, as required, to allow the fitting of the Grant SpiraVac pellet feed system. Refer to installation instructions supplied with the Grant SpiraVac system for further details.

This blanking plate has a single round ‘knock-out’ to provide an entry into the hopper from an auger supplying pellets from a bulk hopper system. This knockout is positioned to ensure the pellets drop into the hopper and operate the hopper contents switch. Only this opening MUST be used as making another opening in the intermediate hopper could affect the operation of the contents switch.

Electrical connection for either a bulk auger or Grant SpiraVac system, if required, is made using the 6-way electrical plug and flying lead supplied factory-fitted at the rear of the hopper. Refer to Section 8 for connection details.

Always ensure that the door and top panel of the boiler hopper are fitted to ensure no foreign debris enters the hopper. If a bulk system with an auger is fitted, ensure that the bulk auger does not impede the opening of the hopper door.

1.4.5 Pellet Feed Auger. All Grant hoppers are supplied with either one or, on double boiler hoppers, two

1.2m pellet feed augers. These are set at a fixed angle of 45° to maintain a consistent feed. If the pellet feed auger angle is altered the input to the boiler will also be altered.

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. Refer to Section 3.2 for pellet feed data.

1.5 Boiler Cleaning and Servicing

Grant Spira condensing wood pellet boilers are equipped with an automatic cleaning system for each of the two heat exchangers and also for the burner brazier.

CAUTION

The ash pan (located inside the combustion chamber) will need to be periodically emptied. This simple task must be carried out by the user at MONTHLY intervals for the FIRST THREE MONTHS. Thereafter, the ash pan should be emptied regularly, on at least a monthly basis, or as indicated by the amount of ash found during the first three months. Two carrying handles are supplied with the boiler to allow removal of the ash pan when hot. Refer to Figure 1-3

Figure 1-3: Removable carry handles

WARNING

Care must be taken to avoid contact with hot surfaces.

Always wait for the boiler to cool down before opening the combustion chamber door and removing the ash pan.

The boiler MUST be serviced either ANNUALLY or when a service is indicated on the burner control panel display, whichever comes first. Servicing should only be carried out by a Grant UK trained Installer and details of each service should be recorded in the Service Log in the back of the user instructions.

NOTE

The amount of ash produced varies between the different pellet brands and this will affect the frequency of cleaning and maintenance required.

1.6 Removable Door Catch Handle

All Grant Spira boilers are supplied with a removable handle for the combustion chamber door catch. This must be removed when the door is shut. Refer to Figure 1-4.

To open the combustion chamber door:

• Fit the removable door handle into the slot in the door catch.

• Lift handle to disengage the catch and open the door.

When closing the combustion chamber door:

• Fully engage the door catch to remake the door cut-out switch.

• Remove the handle and keep in a safe place for future use.

Figure 1-4: Removable door catch handle

Page 25

2 Technical Data

2.1 Boiler and Hopper Technical Data

Units 5-18 6-26 9-36

Maximum heat output kW

Btu/h

Flow connection - 1” BSP (female) 1” BSP (female) 1¼” BSP (female)

Return connection - 1” BSP (female) 1” BSP (female) 1¼” BSP (female)

Water content litres 51.5 51.5 60

Minimum flow rate litres/hour 756 1 080 1 512

Water resistance ΔT = 10°C mbar 50

Water resistance ΔT = 20°C mbar 40

Mains water (cleaning system) bar 1 bar operating pressure

Minimum dynamic pressure bar 0.8

Maximum mains inlet water pressure kPa 800 (8 bar)

Minimum mains inlet water pressure kPa 100 (1 bar)

Condensate connection - 1¼” BSP (female)

Conventional flue - 125mm (5”) 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 75°C

Boiler temperature cut out point °C 65° to 80°C

Minimum return temperature °C 40°C

Water system overheat cut-out temperature °C 100°C

Burn-back overheat thermostat cut-out °C 90°C

Electrical supply - 230V~50Hz single phase

Max. operating pressure - sealed system / open system bar 2.0 bar

Max. operating pressure - pressure relief valve bar 2.5 bar

Maximum auger length (bulk hopper) metres 6.0

Maximum auger speed (bulk hopper) rpm 30

Minimum flue length metres 1.6

Maximum flue length metres 12.0

Heating element rating Watts 450

Intermediate auger motor power Watts 55

Intermediate auger motor starting current Amps 0.64

Intermediate auger motor running current Amps 0.64

Intermediate auger speed rpm 8.1

Flue fan motor power Watts 32

Flue fan motor starting current Amps 0.27

Flue fan motor running current Amps 0.13

Cleaning solenoid power Watts 10

Cleaning solenoid current Amps 0.087

Burner fan motor power Watts 56

Total burner start current Amps 2.5

Total burner run current Amps 0.60

61 400

88 700

122 800

Page 26

2.2 Boiler Input and Output Data

The settings in the table below are based on the boiler using the Grant fixed angle pellet feed auger at 45° with an auger motor fixed speed of 8.1 rpm.

Only EN Plus Grade A1 (BS EN ISO 17225-2) pellets MUST be used with the Grant Spira boilers. These pellets must be bark and sand free AND approved by Grant BEFORE being used in the Spira boilers. Failure to use approved pellets will invalidate the product guarantee.

2.2.1 Burner settings

All burner settings must be checked as part of commissioning and servicing. Refer to Section 9.6 for full details of the burner settings and how to access, check and, where necessary, how to adjust them.

Model

5-18 45° 0025

6-26 45° 0025

9-36 45° 0065

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

Pellet

feed auger angle

Burner setting Heat

TIME

LOAD

MAX

(2.5 sec)

(6.5 sec)

TIME

PAUSEkW(Btu/h)kW(Btu/h)

0048

(4.8 sec)

0025

(2.5 sec)

0025

(2.5 sec)36(122 832)

Boiler and Hopper Weights

Units 5-18 6-26 9-36

Weight boiler - less burner and fan box (empty) kg 201 201 231

Weight burner kg 25.5 25.5 25.5

Weight fan box kg 5 5 5

Total weight of boiler (empty) kg 232 232 262

Total weight of boiler (full) kg 283 283 322

Weight 110kg pellet hopper (empty) - incl. auger kg 41 41 41

Weight 110kg pellet hopper (full) - incl. auger kg 151 151 151

Weight 200kg pellet hopper (empty) - incl. auger kg 77 77 77

Weight 200kg pellet hopper (full) - incl. auger kg 277 277 277

Weight of auger kg 8 8 8

Weight 140kg double boiler hopper (empty) - incl. 2 augers

Weight 140kg double boiler hopper (full) - incl. 2 augers

MAX flame MIN flame

Draught CO

(in.wg)

(0.04-0.06)

output

17.8

(60 769)

26.3

(89 735)

Heat

input

18.6

(63 500)

27.1

(92 500)

38.7

(132 000)

Full eff.

95.5 3.87 0.1-0.15

97.4 5.70 0.1-0.15

93.1 7.78 0.1-0.15

Input

kg/

hr*

mbar

kg 42 42 42

kg 182 182 182

Burner

setting

% TIME

PAUSE

MIN

10-12 0220

10-12 0140

10-12 0250

(22.0 sec)

(14.0 sec)

(25 sec)9(30 700)

(19 050)

(22 100)

Heat

output

(Btu/h)

5.6

6.5

2.3 Flue Gas Analysis

As part of both the commissioning and servicing procedures, the CO of the flue gases must be checked. To enable this to be done, the boiler is supplied with a combustion test point in the top rear cleaning door. Refer to Figure 10-16.

To gain access to this test point, first remove the top casing panel from the boiler. The test point should be at the back left corner of the rear cleaning door. If it is located at the front right corner of the cleaning door, then remove the door and refit it with the test point in the correct position.

content

NOTE

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

CAUTION

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

CAUTION

Do not sample the flue gases through either the draught stabiliser, or from within the flue, as they will have been diluted with air entering through the draught stabiliser.

Only use the combustion test point in the top rear access door to check the CO

See Figure 10-16.

content of the flue gases.

Page 27

2.4 Boiler and Hopper Dimensions and Clearances

2.4.1 Single Boiler with Left Hand Hopper

Front view

Air vent

511

Wash system

255

1613

1417

1296

Side View

150

280

237

771

719

102

177

280

Flow connection

Return connection

Condensate drain

Rear view

Hopper wiring centre

150

Plan view

134

225

150

Figure 2-1: Boiler and hopper dimensions and clearances – single boiler with left hand hopper

Spira wood pellet boiler model

5-18 110kg left hand hopper 1056 518 513 177 96 661 1160 1120

5-18 200kg left hand hopper 1256 618 713 125 44 713 1160 1120

6-26 110kg left hand hopper 1056 518 513 177 96 661 1160 1120

6-26 200kg left hand hopper 1256 618 713 125 44 713 1160 1120

9-36 110kg left hand hopper 1056 518 513 277 196 661 1260 1220

9-36 200kg left hand hopper 1256 618 713 225 144 713 1260 1220

A B C D* E* F G* H

Dimensions

* If the measurement from the flue centre line to the rear wall is increased (shown as 134 in the plan view), then the dimensions D, E and G will have to be increased by the same increment. All units in millimetres.

Page 28

2.4.2 Single Boiler with Right Hand Hopper

511

255

1613

1417

1293

150

Side view

280

Plan view

150

Hopper wiring centre

Rear view

Front view

Flow connection

Return connection

458

Drain cock

361

277

Air vent

Wash system

719

400

134

771 237

225

Figure 2-2: Boiler and hopper dimensions and clearances – single boiler with right hand hopper

Spira wood pellet boiler model

5-18 110kg right hand hopper 1056 518 513 177 96 661 1160 1120

5-18 200kg right hand hopper 1256 618 713 125 44 713 1160 1120

6-26 110kg right hand hopper 1056 518 513 177 96 661 1160 1120

6-26 200kg right hand hopper 1256 618 713 125 44 713 1160 1120

9-36 110kg right hand hopper 1056 518 513 277 196 661 1260 1220

9-36 200kg right hand hopper 1256 618 713 225 144 713 1260 1220

A B C D E F G H

Dimensions

Page 29

2.4.3 Double Boiler with Central Hopper

1232

697

Front view

Air vent

237

771

719

Flow connection

Return connection

Condensate drain

Drain cock

Wash system

Hopper wiring centre

Flow connection

102 1231

177 1232

280 1232

280

2801232

Return connection

Drain cock

150400

Air vent

Rear view

Wash system

772 237

134

1565

1417

1296

Plan view

Side view

Figure 2-3: Boiler and hopper dimensions and clearances – double boiler with central hopper

Spira wood pellet boiler model

11-44 (5-18 and 6-26) with double hopper 1792 616 697 224 141 616 1160 1120

12-52 (2 x 6-26) with double hopper 1792 616 697 224 141 616 1160 1120

15-62 (6-26 and 9-36) with double hopper 1792 616 697 324 241 616 1260 1220

18-72 (2 x 9-36) with double hopper 1792 616 697 324 241 616 1260 1220

A B C D* E* F G* H

Dimensions

213

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3 Pellet Specification, Storage and Delivery

3.1 Pellet Specification

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

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

Origin and source 1.13 Stemwood

1.2.1 Chemically treated wood residues

Diameter (D) mm 6 ± 1

Length (L) 3.15 < L ≤ 40

Moisture (M) w-% ≤ 10

Ash (A) w-% dry ≤ 0.7

Mechanical durability (DU)

Fines (F)

Additivies

Net calorific value (Q) MJ/kg or ≥ 16.5

Bulk density (BD)

Chlorine (Cl) w-% dry ≤ 0.02

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

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 between 3.15 and 40mm.

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/m

Chlorine High levels of chlorine in the flue gases emissions can give rise to corrosion.

Diameter The most common diameter is 6mm with some 8mm also available. This boiler is designed for 6mm only.

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

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

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

Moisture content Moisture affects the calorific value of the pellet. Low moisture content guarantees constant and predictable combustion efficiency. Higher moisture contents can result in pellet breakdown.

Net Calorific Value This is the useful energy contained in a kilogram of fuel. This value is affected by the amount of non- combustible materials (ash) and the moisture content of the pellet. Typical values range from 4.8 kWh/kg to 5.2 kWh/kg.

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

w-% ≥ 97.5

w-% ≤ 1.0

w-% ≤ 2

Type and amount to be stated

kWh/kg ≥ 4.6

kg/m

≥ 600

Footnotes

Negligible levels of glue, grease and other timber production additives used in sawmills during production of timber and timber product from virgin wood are acceptable, if all chemical parameters of the pellets are clearly within the limits and/or concentrations are too small to be concerned with.

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

Type of additives to aid production, delivery or combustion.

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

3.2 Biomass Suppliers List

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

Recipients of the Domestic RHI will be obliged to source their fuel from suppliers on the BSL unless they are supplying themselves. To find an approved supplier in your area go to www.biomass-suppliers-list.service.gov.uk/find-a-fuel

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3.3 Pellet Storage

3.3.1 Pellet Hoppers and Pellet Feed Auger

All Grant Spira boilers are supplied with a pellet hopper. Refer to Section 1.4.4 for further details of the hoppers.

All Grant hoppers are supplied with either one or, on a double boiler hopper, two 1.2 m pellet feed augers, to deliver the pellets from the hopper to the boiler. Refer to Section 1.4.5.

The pellet hopper, along with the boiler (or boilers) it is supplying, MUST be installed in a dry indoor environment free from dampness. The hopper and boiler(s) must be located on the same floor level. The hopper must be located adjacent/between the boiler/s as shown in Section 2.

If a bulk hopper is to be used, there are two methods of transferring the pellets from the bulk store to the intermediate hopper: a) Via a bulk pellet feed auger b) Via the Grant SpiraVac vacuum pellet feed system

All boiler pellet hoppers are supplied to accept either of these two pellet supply systems, as required. Refer to Section

1.4.4 for further details on the hoppers.

The electrical connections to the boiler(s) are all made to the 4-way electrical plug on one of the three factory-fitted ‘flying leads’ at the rear of the hopper.

Electrical connection for either a bulk auger or Grant SpiraVac system, if required, is made using the 6-way electrical plug and flying lead supplied factory-fitted on the hopper. Refer to Section 8 for details.

3.3.2 Bulk Hopper

It is advisable to fit a bulk pellet store to take advantage of the lower cost of pellets purchased in bulk.

NOTE

The boiler must be switched off before the bulk pellet store is re-filled. The boiler must only be switched back on again after the filling is completed.

Figure 3-1: Bulk auger inlet in hopper

The pellet hopper (supplied with the boiler/s) must still be used, situated between the bulk hopper and the boiler, as the auger fitted to the hopper delivers the precise quantity of pellets required by the burner.

The pellet hopper also allows any problems with bulk pellet quality to be isolated and the intermediate hopper can be used temporarily as the source of pellets for the boiler.

NOTE

Each bulk pellet supplier 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.

The information given in this manual is for guidance purposes only and you should ALWAYS check with the pellet supplier you wish to use BEFORE installing a bulk storage system.

It is essential to only use a bulk storage unit that is:

a) Waterproof b) Specifically designed to store wood pellets c) Supplied with appropriate connections for pellet delivery, which are within the drivers reach d) Fitted with a vent connection (for dust extraction) during filling e) Permanently vented (if located outside) or unvented (if installed indoors) f) Fitted with a rubber arrester mat (or similar) to limit pellet damage during filling g) Is electrically earthed

A range of suitable bulk pellet stores are available from Grant UK. These are supplied either pre-assembled or flat packed for on-site assembly. Refer to assembly instructions supplied with each kit. For details of capacities and dimensions visit our website or contact Grant UK.

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

Page 32

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.

The store should be located on a suitable base (e.g. concrete) capable of supporting the weight of the store when full of pellets.

3.3.3 Bulk Pellet Feed Auger

When installing a bulk pellet store with a bulk pellet feed auger, consideration must be given to the position of the store in relation to the hopper as this will dictate the length of the auger.

The length of the pellet feed auger, supplying pellets from the bulk store, is limited to a maximum of 6 metres in length, as a longer auger can damage the pellets.

Grant UK offer a range of eight bulk pellet augers, from 2.5m to 6m in length in 0.5m steps, as given in the following table:

Product Bulk Auger Auger

Code Length m Weight kg

WPAUG25 2.5m 21.3

WPAUG3 3.0m 24.1

WPAUG35 3.5m 26.9

WPAUG4 4.0m 29.7

WPAUG45 4.5m 32.5

WPAUG5 5.0m 35.3

WPAUG55 5.5m 38.1

WPAUG6 6.0m 40.9

To determine the length of auger required the following factors must be determined:

• Difference in height between the

ground/floor level (on which the store will stand) and the floor level (on which the hopper will stand).

• Horizontal distance between the

back of the hopper and the store.

If the store is to be situated outside, this horizontal distance will be made up from:

• The distance from the rear of the

hopper to the inner face of the wall

• The thickness of the wall

• The distance to the store from the

outside face of the wall.

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4 Installation Information

4.1 Introduction

For the 5-18, 6-26 and 9-36 models, the appliance comes supplied on two pallets:

• Pallet 1 contains the intermediate hopper, auger and auger feed hose

• Pallet 2 contains the boiler, burner and accessory box.

For the 11-44, 12-52, 15-62 and 18-72 models (‘double boiler’ installations), the appliance comes supplied on two pallets:

• Pallet 1 contains the intermediate hopper, augers and auger feed hoses

• Pallet 2 contains both boilers, each with burner and accessory box.

An accessories box is packed with each boiler and this includes the following:

• Fan box (complete with exhaust fan, draught stabiliser and flue connection

• Inspection pipe (product code: WPB/IP)

• Condensate drain trap items

• Wash system manifold assembly (complete with bracket)

• Pellet feed tube (supplied in two parts)

• Pellet delivery hose

• Brazier clearance gauge plate

• AAV (complete with elbow and bush)

• 2.5 bar PRV

• Ash pan lifting handles

• Removable (door) handle

The Grant Biomass 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 Preparation for Installation

With the units on the pallet, remove all outer packaging from the units. Unpack the accessories box supplied with the boiler and check the packing list against all items present.

4.4 Installing the Boiler

The boiler and hopper must be positioned on a level, solid, noncombustible base of at least 125mm thick. This 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.

4.5 Regulations

Installation of a Grant Spira wood pellet boiler and hopper must be in accordance with the following recommendations:

• National Building Regulations and any local Bylaws which you must check with the local authority for the area, e.g. Approved Document J

• Model and local Water Undertaking Bylaws

• MCS Installer Standards, i.e. MIS 3004 (if applying for the Renewable Heat Incentive)

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

• BS EN 12828:2012. Heating

systems in buildings. Design for water-based heating systems

• BS EN 12831:2003. Heating

systems in buildings. Method for calculation of the design heat load.

• BS EN 14336: 2004. Heating

systems in buildings. Installation and commissioning of water based heating systems.

• BS 7593:2006 Code of Practice for

treatment of water in heating systems.

• BS 7671:2008 Requirements for

electrical installations, IET wiring regulations.

• ONORM M7137 standard should

be used as a guideline for DIY bulk storage units.

NOTE

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

WARNING

Before starting any work on the boiler or fuel supply please read the Health and Safety information given in Section 14.

4.6 Heating System Design Considerations

To achieve the maximum efficiency possible from the Grant Spira wood pellet boiler, the heating system should be designed to the following parameters:

Radiators

• Flow temperature 70°C

• Return temperature 50°C

• Differential 20°C

Size the radiators using a mean water temperature of 60°C.

Design system controls with programmable room thermostats, or use weather compensating controls, to maintain return temperatures below 55°C.

NOTE

The boiler should not be allowed to operate with a return temperature of less than 40°C when the system is up to operating temperature.

The use of a pipe thermostat is recommended to control the return water temperature when using weather compensating controls.

Underfloor Heating

• Flow temperature 50°C

• Return temperature 40°C

• Differential 10°C

In underfloor systems it is essential that the return temperature must be maintained at or above 40°C to prevent internal corrosion of the boiler water jacket.

4.7 Pipework Materials

Grant Spira boilers are compatible with both copper and plastic pipe. Where Plastic pipe is used it must be of the oxygen barrier type and be the correct class (to BS 7291 - Part 1:2010) for the application concerned.

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WARNING

On either sealed or open-vented systems; where plastic pipe is used a minimum of ONE metre of copper pipe MUST be connected between both the boiler flow and return connections and the plastic pipe. DO NOT CONNECT PLASTIC PIPE DIRECTLY TO THE BOILER. Grant UK do not accept any responsibility for any damage, however caused, to plastic piping or fittings.

Drain Cock:

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

The 1¼” BSP female condensate outlet connection is located at the rear of the boiler. Refer to Section 5 for details on condensate connection and disposal pipework.

NOTE

In hard water areas an anti-scale device should be fitted on the cold water supply to the wash system to prevent scale build-up in the manifold pipe and jets.

Sealed Systems

If plastic pipe is to be used, the installer must check with the plastic pipe manufacturer that the pipe to be used is suitable for the temperature and pressures concerned.

Plastic pipe must be Class S to BS 7291 - Part 1:2010.

WARNING

The system MUST incorporate a low-level pressure switch to shut off power to the boiler if the system pressure drops below 0.2 bar. A suitable low pressure switch kit is available to purchase from Grant UK (product code MPCBS62). refer to Figure 8-11 for the electrical connection details on this switch.

Underfloor Pipework

Plastic pipe may be used on underfloor floor systems where the plastic pipe is fitted after the thermostatic mixing valve.

Copper tube must be used for at least the first metre of flow and return primary pipework between the boiler and the underfloor mixing/blending valves.

4.8 Pipe Connections

Flow and return connections: The flow and return connection are at the rear of the boiler (see Section 2.4) and the sizes are as follows: Spira 5-18 Flow 1” BSP Female Return 1” BSP Female Spira 6-26 Flow 1” BSP Female Return 1” BSP Female Spira 9-36 Flow 1” ¼ BSP Female Return 1” ¼ BSP Female

4.9 Wash System

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

NOTE

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

This factory fitted wash system consists of two spray jets, mounted on the underside of the heat exchanger access cover. They are connected by a manifold pipe located on the upper side of the cover. Refer to Figure 4-1.

This manifold is fed with mains cold water via a solenoid valve located at the rear of the boiler.

This solenoid valve is supplied loose in the boiler components kit and must be fixed to the back panel of the boiler using the two self-tapping screws provided. Refer to Figure 4-2.

The valve is connected to the wash system manifold via flexible hose, supplied already fitted within the boiler casing. Connect one end of the hose to the outlet of the solenoid valve and the other to the inlet connection of the wash system manifold.

Connect the mains water supply to the 15mm compression inlet connection of the isolating/check valve, mounted on the solenoid valve inlet.

Figure 4-1: Spray jets (manifold omitted)

Figure 4-2: Solenoid valve self-tapping screws (wiring omitted)

4.10 Fan Box and Flue Starter

Fit the fan box to the flanged flue outlet on the back of the boiler so that the flue starter outlet is at the top.

Remove the nuts and washers from the four studs around the flanged flue outlet of the boiler. Refer to Figure 4-3.

Remove the access panel from the rear face of the fan box.

With the neoprene gasket in place on the fan box, locate the four studs through the corresponding holes in the gasket/fan box. Two of the studs pass through the flange at the base of the fan box. The other two are inside the fan box and are reached via the rear access opening.

Secure the fan box in position using the four nuts and washers previously removed.

When tightening these nuts, ensure that the fan box/flue starter section is vertical

Page 35

Figure 4-3: Fan box access panel

and the neoprene gasket is evenly compressed to give an adequate seal between the fan box and the flanged boiler outlet.

Replace the access panel on the rear face of the fan box and secure with the screws previously removed.

Fit the 5-way plug from the flue fan/ solenoid valve into the socket at the top right rear of the boiler. Ensure that the plug is fully pushed home. See Figure 4-4.

Figure 4-4: Flue fan/solenoid valve plug connection

Figure 4-5: Pellet feed auger fixing

4.11 Pellet Feed Tube

The 2-part pellet feed tube is supplied loose in the accessories box for fitting on site in either one of two possible positions, depending on the location of the pellet hopper. The pellet tube gasket and three fixing screws are supplied fitted to the burner.

With hopper located on the left side of the boiler - the pellet feed tube must

be fitted to point towards the left side. Refer to Figure 4-6.

Figure 4-6: Pellet feed tube - left-hand hopper

With hopper located on the right side of the boiler - the pellet feed tube

must be fitted to point towards the right side. Refer to Figure 4-7.

Figure 4-7: Pellet feed tube - righthand hopper

With hopper located between two boilers (in a ‘double boiler’ installation)

- the right hand boiler must have the pellet feed tube pointing to the left, and the left hand boiler must have the pellet feed tube pointing to the right.

To fit the pellet feed tube to the burner:

• First, remove the burner from the combustion chamber door

• Remove the red burner cover by loosening the four M5 screws (two on each side of the cover) and lifting it off the burner.

• Disconnect the plugs from the left side of the burner. Loosen the four screws (two on either side of the burner) and lift off the red burner cover.

• Whilst supporting the burner, unscrew and remove the two M8 burner securing nuts and washers, one each side of the burner.

• Carefully withdraw the burner from the combustion chamber door, taking care not to damage the burner door gasket, and place it on a suitable surface to work on it.

WARNING

Ensure the pellet delivery hose forms an air tight seal at each end and that the pellet delivery hose is not damaged. Leakage of air could cause increased temperature in the pellet delivery hose and result in the pellet feed tube (burn back) thermostat operating and shutting down the burner.

Then, fit the pellet feed tube:

• Using a 4mm Allen key, remove the three pellet tube fixing screws and locking washers. Take care not to drop them into the rectangular pellet feed opening in the top of the burner.

• Check the circular gasket is correctly positioned around the pellet feed opening and that the three cutouts in the gasket are aligned with the threaded holes in the burner.

• Position the flange of the pellet feed tube on the gasket.

• Align the holes in the flange with those in the gasket and burner such that the open end of the pellet feed tube points either to the

Page 36

right or left, as required.

• Re-fit the three screws and washers. Tighten them down evenly to secure the pellet feed tube to the burner.

• Fit the pellet feed tube thermostat lead on to the thermostat terminals.

• Fit the pellet feed tube.

With the gasket correctly located, re-fit the burner to the combustion chamber door:

• Carefully insert the burner brazier through the opening and locate the holes in the burner flange onto the M8 studs (on either side of the burner).

• Secure the burner to the door with the two M8 nuts previously removed.

• Re-connect the plugs to their corresponding sockets on the left side of the burner.

• Ensure that each plug is fully pushed home until the small catch clicks into place. Refer to Figure

4.8.

Figure 4-8: Auger plug connection

4.12 Pellet Hoppers

4.12.1 Single Boiler Installation

Position the pellet hopper on the same firm level surface as the boiler, on either the left-hand or right-hand side of the boiler (depending on hopper type used), with the top access door facing forwards. Refer to Figure 2-1 or 2-2 as required, for clearance dimensions and position.

4.12.2 Double boiler installation

Position the pellet hopper on the same firm level surface as, and in between, the two boilers, with the top access door facing forwards. Refer to Figure

2-3 for clearance dimensions and position.

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 castors which allows the hopper be moved during servicing. Once in the correct position, engage the brakes on the front castors to maintain this position.

4.13 Pellet Feed Auger

4.13.1 Single Boiler Hoppers

The pellet feed auger is supplied packed with the hopper but not factoryfitted to it.

To fit, unpack the hopper and auger. Remove the M5 screw fitted below the auger opening on the front of the hopper. Fit the end of the auger into opening in the front of the hopper as far as it will go and secure by fitting the M5 screw through the auger fixing flange and tighten. See Figure 4-5.

4.13.2 Double Boiler Hoppers

Both augers on the ‘double boiler’ Intermediate hoppers are supplied factory-fitted to the hopper.

To connect the hopper to the boiler, fit one end of the pellet delivery hose onto the pellet feed auger outlet and the other end onto the pellet feed tube. The pellet delivery hose may need to be cut if too long. A sachet of lubricant is supplied in the accessories carton; apply the lubricant to the joint to ensure the pellet delivery hose is easily fitted. Ensure the pellet delivery hose is not kinked in any way.

Fit the 6-way plug (No.3), from the pellet feed auger motor, into the corresponding 6-way socket on the left side of the burner. Ensure that the plug is fully pushed home until the small catch it clicks into place. See Figure

4-6. Refer to Section 8.3 for all boiler plug connections.

4.14 Before you Commission

To avoid the danger of dirt and foreign matter entering the boiler the complete heating system should be thoroughly flushed out – both before the boiler is connected and then again after the system has been heated and is still hot.

This is especially important where the boiler is to be installed on an old system.

For optimum performance after installation, the boiler and the associated heating system must be flushed in accordance with the guidelines given in BS 7593:2006 ‘Treatment of water in domestic hot water central heating systems’. This must involve the use of a proprietary cleaner, such as Betz Dearborn’s Sentinel x300 or x400, or Fernox Restorer. Full instructions are supplied with the products but for more details visit either www.sentinel-solutions.net for Betz Dearborn products or www. fernox.com for Fernox products.

After flushing the system, an inhibitor such as Sentinel X100 or Fernox MB-1 should be used in accordance with the guidelines given in BS 7593:2006 for long term protection against corrosion and scale.

Grant Engineering (UK) Limited strongly recommends that a Grant Mag One in-line magnetic filter/s (or equivalent*) is fitted in the heating system pipework. This should be installed and regularly serviced in accordance with the filter manufacturer’s instructions.

* As measured by gauss. The MagOne magnetic filter has a gauss measurement of 12000.

4.15 Completion

Please ensure that the Grant Spira Commissioning form (supplied with the boiler) is completed in full and that it is signed by the householder/user.

Leave the white copy with the user, retain the pink copy for your own records, and return the yellow copy to Grant UK. Refer to Section 10-12.

Ensure that these Instructions are handed over to the householder.

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5 Condensate Disposal

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. This condensate is slightly acidic with a pH value of around 6. Provision must be made for the safe and effective disposal of this condensate.

Condensate can be disposed using one of the following methods:

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

• Into an external gulley

MCS Product Certification Scheme Requirements for Biomass (MCS 008) state that: “

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

All condensate disposal pipes must be fitted with a trap whether they are

connected internally or externally to a domestic waste system/soil stack or run externally to a gully or hopper. Every Grant Spira boiler is supplied with a trap and this MUST be used. Refer to Section 5.5 for trap details.

”

5.2 Connections

Connections into a rainwater hopper, external drain or gulley should be terminated inside the hopper/drain/ gulley below the grid level but above the water level.

Condensate disposal pipes can be connected directly into waste/soil systems connected to septic tanks.

Condensate must not be discharged into ‘grey water’ systems that re-use water used in the home (not including water from toilets).

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

5.3 Pipework

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

suitable and must NOT be used.

All condensate disposal pipes connected to a Grant Spira boiler must have a minimum ‘nominal’ diameter of 38mm (1 ½”) plastic pipe.

Condensate disposal pipes should be kept as short as possible and the number of bends kept to a minimum.

Pipes should be adequately fixed to prevent sagging, i.e. at no more than

0.5 metre intervals.

Condensate disposal pipes must be fitted with a fall (away from the boiler) of at least 2.5° (≈45mm fall per metre run).

NOTE

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 using a condensate pump with a Grant Spira boiler, a condensate holding tank of at least 40 litres is required. This is to ensure that when the boiler cleaning cycle has operated the holding tank can collect the total volume of the water used in the wash system and the condensate pump can then discharge the waste water effectively.

A boiler interlock should be fitted to shut off the boiler in the event of a malfunction of the condensate pump.

WARNING

When using a condensate pump and holding tank, the burner settings for ‘TIME CLEAN PERIOD’ (time boiler cleaning is in operation) must not be set greater than 60 (60 seconds) and the ‘TIME CLEAN BOILER’ (time between boiler cleaning operations) must not be set less than 180 minutes, as modifying these times could result in larger and more frequent wash system of the boiler which could exceed the capabilities of the tank and condensate pump. Refer to Section 9 for further details of the burner settings.

5.4 External Pipework

Ideally, external pipework, or pipework in unheated areas, should be avoided. If unavoidable, external pipework should be kept as short as possible (less than 3 metres) and 38mm (1½”) waste pipe used to minimise the risk of ice blocking the pipe in freezing conditions.

The number of bends, fitting and joints on external pipes should be kept to a minimum to reduce the risk of trapping condensate.

NOTE

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

Page 38

5.5 Condensate Trap

Grant Spira condensing boilers are supplied with condensate trap. This trap must be used. No alternative trap should be used in place of the trap supplied with the boiler. The 1¼” BSP female condensate outlet connection is located at the rear of the boiler.

Fit the 1¼” 311 fitting (supplied) into this connection. Using the elbow and pipe (supplied), connect the trap to the condensate outlet on the boiler, as shown in Figure 5-1.

A condensate discharge pipe with a minimum diameter of 38mm (1½”) must be fitted to the outlet connection at the base of the trap.

In all cases the overflow pipe (see Figure 5-1) must be fitted to the trap and the end left open. This will protect the boiler from becoming blocked with condensate in the event of the condensate discharge pipe blocking or frozen.

CAUTION

If connecting the condensate discharge into a waste system or soil stack, either internally or externally, a second trap must be fitted in the condensate discharge pipe. This trap must provide the

required 75mm water seal. It must be located between the boiler condense trap and the connection to the soil stack, in a position accessible for checking and cleaning.

5.6 Inspection and Cleaning of Trap

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

CAUTION

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

Figure 5-1: Overflow pipe

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.

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6 Sealed Systems

5 6

6.1 Sealed System Requirements

1. Expansion vessel

2. Pressure gauge

3. Safety valve

4. Discharge

5. Filling loop

6. Double check valve

7. Automatic air vent

8. Thermostatic radiator valve

9. Automatic bypass valve

10. Drain tap

2 3

Static head of system

Figure 6-1: Sealed heating system components

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

The system must be provided with the following items:

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

• Pressure gauge.

• Pressure relief (safety) valve.

• Approved method for filling the system.

Expansion vessel

The expansion vessel can be fitted in either the return or flow pipework in any of the recommended positions as shown in Figure 6-1. To reduce the operating temperature of the expansion vessel, position it below the pipe to which it is connected.

The expansion vessel may be positioned away from the system,

* 3 port valve (alternative to 2 zone valves)

providing the connecting pipe is not less than 13 mm diameter. If the expansion vessel is connected via a flexible hose, care must be taken to ensure that the hose is not twisted.

Pressure Gauge

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

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

Safety Valve

The safety valve (provided with the boiler) is set to operate at 2.5bar. It

NOTE

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

should be fitted in the flow pipework near to the boiler.

The pipework between the safety valve and boiler must be unrestricted, i.e. no valves. The safety valve should be connected to a discharge pipe which will allow the discharge to be seen, but cannot cause injury to persons or damage to property.

Filling Loop

Provision should be made to replace water lost from the system. This can be done manually (where allowed by the local water undertaking) using an approved filling loop arrangement incorporating a double check valve assembly. The filling loop must be isolated and disconnected after filling the system.

Heating System

The maximum set point temperature for the central heating water is 75°C. Refer to Section 1.1.

Page 40

An automatic air vent should be fitted to the highest point of the system.

If thermostatic radiator valves are fitted to all radiators, a system by-pass must be fitted. The by-pass must be an automatic type.

All fittings used in the system must be able to withstand pressures up to 3 bar. Radiator valves must comply with the requirements of BS 2767:1991.

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

NOTE

The air charge pressure may be checked using a tyre pressure gauge on the expansion vessel Schraeder valve. The vessel may be re-pressurised, when necessary, using a suitable pump. When checking the air pressure, the water in the heating system must be cold and the system pressure reduced to zero.

6.4 Pressure Relief (Safety) Valve Operation

Check the operation of the pressure relief (safety) valve as follows:

1. Turning the head of the valve anticlockwise until it clicks. The click is the safety valve head lifting off its seat allowing water to escape from the system.

2. Check that the water is escaping from the system.

3. Top-up the system pressure, as necessary.

6.2 Filling the Sealed System

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

WARNING

Only ever fill or add water to the system when it is cold and the boiler is off. Do not overfill.

The procedure for filling the sealed system is as follows:

1. Check the air charge pressure in the expansion vessel BEFORE filling the system. The expansion vessel charge pressure should always be slightly greater than the maximum static head of the system, in bar, at the level of the vessel (1 bar =

10.2 metres of water). See Figure 6-1.

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

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

3. Ensure that the flexible filling loop is connected and that the double check shut off valve connecting it to the water supply is closed. A valve is open when the operating lever is in line with the valve, and closed when it is at right angles to it.

3. Open the fill point valve.

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

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

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

7. Continue to fill the system until the pressure gauge indicates between

0.5 and 1.0 bar. Close the fill point

valve. The system fill pressure (cold) should be 0.2 - 0.3 bar greater than the vessel charge pressure – giving typical system fill pressures of approx 0.5 bar for a bungalow and

1.0 bar for a two storey house. Refer to the Domestic Heating Design Guide for further information if required.

8. Repeat steps 5 and 6 as required until system is full of water at the correct pressure and vented.

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

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

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

6.3 Venting the Pump

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

Unscrew and remove the plug from the centre of the pump motor. Using a suitable screwdriver, rotate the pump spindle about one turn. Replace the plug in the motor. Do not over tighten.

NOTE

Some heating circulating pumps are not fitted with a vent plug so it is not possible to vent these pumps in the manner described above.

NOTE

The expansion vessel air pressure, system pressure and operation of the pressure relief valve must be checked on an annual service. Refer to Section 11.

Page 41

7 Flue System and Air Supply

7.1 Air Supply

The Grant Spira wood pellet boiler draws air for combustion from the room in which it is located.

Any room or space containing an appliance must have sufficient permanent air supply to ensure correct combustion of the fuel and effective operation of the flue system (i.e. to discharge of combustion products to the open air).

NOTE

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

For a boiler operating with a draught stabiliser:

• If design air permeability

>5.0m³/(h.m²) then:

• 300mm²/kW for the first 5kW of appliance rated output

• 850mm²/kW for balance of appliance rated output.

• If design air permeability ≤5.0m³/ (h.m²) then:

• 850mm²/kW of appliance

rated output*.

It is unlikely that a dwelling constructed prior to 2008 will have an air permeability of less than 5.0m³(h.m²) at 50 Pa unless extensive measures have been taken to improve air-tightness. See Appendix F of The Building Regulations Approved Document J.

To achieve this, the following minimum vent openings are required:

Minimum vent open area Boiler model

5-18kW 125.5 cm²

6-26kW 193.5 cm²

9-36kW 278.5 cm²

11-44kW 346.5 cm²

12-52kW 414.5 cm²

15-62kW 499.5 cm²

18-72kW 584.5 cm²

>5.0m³/(h.m²)

(20 in²)

(30 in²)

(44 in²)

(54 in²)

(65 in²)

(78 in²)

(91 in²)

≤5.0m³/(h.m²)

153 cm²

(24 in²)

221cm²

(35 in²)

306 cm²

(48 in²)

374 cm²

(58 in²)

442 cm²

(69 in²)

527 cm²

(82 in²)

612 cm²

(95 in²)

7.2 Flue Terminal Position and Clearances

The Grant Spira wood pellet boilers have high operating efficiencies and low flue gas temperatures. Only the Grant Biomass twin-wall insulated flue system must used with the Grant Spira boilers.

NOTE

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

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

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

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

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

• Grant recommends that an adjustable flue extension be fitted in the flue system as close to the boiler as possible, to enable the flue system to be disconnected from the boiler flue connection, as

and when required, for future boiler maintenance.

• The weight of the flue system must NOT be carried by the boiler, but must be supported using the various support options available in the Grant ‘Biomass’ flue system. Refer to Section 7.4.5.

• The minimum distance between the outer surface of any part of the flue system and any combustible material is 60mm. Refer to Section

7.3 for flue system designation. A minimum clearance of 25mm around the flue is required for the fitting/removal of locking bands.

• The flue terminal should be located in a downdraught free area, i.e. above the roof, where it can discharge freely and not present a fire hazard whatever the wind conditions. The flue outlet positions shown in Figure 7-1 (from Approved Document J) can meet this requirement.

• The heights and separation distances shown in Figure 7-1 may have to be increased in particular cases, e.g. where high wind exposure, surrounding tall buildings, or adjacent trees can cause adverse wind effects.

• The boiler flue cannot terminate into an existing brick or clay lined chimney. All masonry flues must be lined using the Grant ‘Biomass’ system stainless steel flexible flue liner.

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

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

NOTE

The only flue suitable for use with the Grant Spira condensing wood pellet boiler is the Grant Biomass twin-wall insulated conventional flue system.

This 125mm (5”) ‘Biomass’ flue system is suitable for the 5-18kW, 6-26kW and 9-36kW Spira models.

For the 44kW, 52kW, 62kW and 72kW double boiler installations each boiler must have a separate flue system.

Page 42

Adjacent

building

Regulated building

Figure 7-1: Flue terminal positions

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

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

B Elsewhere on a roof

(whether pitched or flat)

C Below (on a pitched roof) or within 2300mm horizontally

to an openable rooflight, dormer window or other opening (Note 3)

D Within 2300mm of an adjoining or adjacent building, whether

or not beyond the boundary (Note 3)

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.

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

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.

At least 1000mm above the top of the opening.

At least 600mm above any part of the adjacent building within 2300mm.

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

Page 43

7.3 Flue System Specification

The Grant ‘Biomass’ 125mm (5in) flue system is a fully insulated stainless steel twin-wall flue finished with a Black Polyester Powder paint finish. This insulated flue system reduces the possibility of the condensate freezing in the flue, and also has a high corrosion resistance suitable for solid fuel.

The CE designation of this ‘Biomass’ flue system (to BS EN 1856-1) is:

T450 N1 W V2 L50 G 60

Where: T450 – Temperature rating – 450°C maximum temperature for continuous operation N1 – Pressure rating – negative pressure W – Condensate resistance – able to contain condensate within the flue V2 – Corrosion resistance – resistant to attack from products of combustion from natural wood L50 – Liner material – 316L stainless steel 05 – Material thickness – 0.5mm G – Soot fire resistance – tested at 1000°C for 30mins 60 – Distance to combustibles – 60mm minimum clearance is required from combustibles.

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

7.4 Flue System Assembly

7.4.1 Fan Box and Inspection Pipe

The fan box supplied with the boiler (packed in the accessories box) incorporates:

• Exhaust fan

• Draught stabiliser

• Flue connection (to fit Grant ‘Biomass’ flue system)

The fan box is supplied with a neoprene gasket for connection to the boiler. This neoprene gasket is to accommodate the low temperature wet flue system of the Grant Spira boilers. Refer to Section

4.10 for fitting details.

The lead for the flue fan (supplied factory-fitted to the fan box) is connected to the same 5-way plug as the lead for the wash system

solenoid valve. Refer to Section 8.3 for connection details.

The flue system must include the Grant Inspection Pipe (product code: WPB/IP) supplied with the boiler. This should be fitted to the outlet of the fan box. Refer to Section 7.4.2 for guidance on how to join flue components. The Inspection Pipe incorporates a flue inspection hatch and combustion test point. The Inspection Pipe should be positioned such that the cover plate faces to the same side as the pellet hopper - but not to the front or rear.

When fitting the Inspection Pipe to the fan box, check the lip seal is fitted to the inner flue liner of the flue connector and the locking band is fitted to secure the joint.

When installed, the draught stabiliser must not be boxed in or obstructed from operation in any way.

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

NOTE

The combustion test point in the flue inspection pipe must NOT be used to monitor and adjust the % CO2 when commissioning the Spira boiler. The combustion test point, located at the left rear corner of the rear access cover (on the secondary heat exchanger) must only be used for this purpose. Refer to Section

10.10 of these instructions for further details.

7.4.2 Joining Components

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

Male collar

Insulation

Female collar

Figure 7-2: Male and female flue connections

Viton gasket seal detail

Figure 7-3: Twist lock joint between components

To join two components together:

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

First fit the lip seal supplied into the groove (in the inner flue liner) at the ‘male collar’ end of the flue component. Refer to Figure 7-2. The lip seal should be fitted ‘dry’, i.e. with no lubricating grease applied at this stage. The lubricating grease (also supplied with the component) should be applied to the seal after it is fitted but before fitting the two flue components together.

Loosen the locking band at the ‘female collar’ end. Insert the ‘male collar’ into the ‘female collar’ and twist through 1/6 of a turn to lock in place. Refer to Figure 7-3.

Ensure that the two beaded ends of the flue components are in contact with each other all round. Position the locking and so that it grips the beaded edge of both components and fasten using the spring clip. The locking bands provided MUST be fitted at ALL flue joints. Refer to Figure 7-4.

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

Page 44

Locking band

Figure 7-4: Fitting of locking band

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

WARNING

All joints in the flue system must be accessible for inspection. No joints should be located within a wall, floor or ceiling spaces or any other inaccessible place.

7.4.3 Adjustable Length

The Grant ‘Biomass’ flue system includes an Adjustable flue extension. Refer to Section 7.9. This allows any of the straight flue extension components to be extended in length by between 100mm to 280mm (this does not apply to the 200mm extension) - refer to Section 7.9. This adjustable extension must be used in conjunction with any straight extension (1000mm, 500mm, 333mm or 200mm) to achieve the actual straight length required.

To fit the adjustable extension, first remove insulation from between the inner and outer walls of the component, as necessary. Fit the open end over the ‘male collar’ end of the fixed extension and adjust to achieve the required overall length. Secure the two components together using the wide locking band supplied.

NOTE

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

7.4.5 Support Components

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

Ventilated Support Plate (product code: WPB/SP)

On internal systems, the weight can often be supported where the flue passes through an upstairs floor, using the Support Plate with clamp band. A four-sided square opening, formed by timber stringers between the joists, is required to support the plate. Ensure that the minimum distance of 60mm is achieved between the flue outer surface and the any combustibles (e.g. timber joists). A Ventilated Fire Stop Plate (Grant Ref. WPW/FP or WPB/FP) should be fixed to the ceiling below.

Ventilated Fire Stop Plate (product code: WPB/FP)

This is not a support but a Ventilated Fire Stop Plate is required to be fixed to the ceiling below a Ventilated Support Plate. When passing through a second upstairs floor (in a 3-storey house) either a second support plate can be fitted or alternatively two ventilated firestop plates (one above and one below) need be fitted if the flue is adequately supported at the first upstairs floor level.

The slots in the Stop Plate allow air to pass through but will not allow the passage of flame. Also, the slots enable the distance from combustibles to be checked. If no combustible material is visible though the slots, then the minimum clearance distance of 60mm has been met.

Intermediate Top Plate (product code: WPB/TP)

Flue systems running up against either an Internal or external wall surface can be supported using the Intermediate Top Plate. This is mounted on either a

pair of Wall Support Side Plates (Grant Ref. WPW/WS or WPB/WS) or a pair of Cantilever brackets (Grant Ref. WPB/ CANT), which are fastened to the wall, to provide support at either the base, or part way up, a vertical section of flue.

The ‘female collar’ (on the underside of the plate) is fitted into the flue below and the ‘male collar’ (on the upper side of the plate) is a twist-lock connection into the flue above. Both joints are secured using the clamp bands provided.

Wall Brackets (product code: WPB/ WB60)

Both the Wall bracket and the Adjustable Wall Bracket (Grant Ref. WPW/WB300 and WPB/WB300) are NOT load-bearing but are designed to give lateral support only. Wall brackets should be fitted with a maximum spacing of 3m on straight runs of flue and at any offset to ensure the system is rigidly supported.

Roof Support Band (product code: WP/RS)

As with the Wall Brackets, the Roof Support Band is not load bearing but is designed to give lateral support only.

Guy Wire Bracket (product code: WPB/GB)

Where the flue is free standing above the roof and its height exceeds 1.5m beyond the last support of the roof (e.g. Roof Support Band) a Guy Wire Bracket MUST be used and at every

1.5m thereafter. Grant does not supply the guy wires or tie rods to use with this bracket.

Structural Locking Band (product code: WPB/LBEXT)

A height of up to 3m above the last support at the roof can be achieved, without the need for guy wires, by using an extended Structural locking band at the joint immediately below, and at every joint above, the last flue support.

Page 45

7.4.6 Elbows

Two elbows are available - 30° (product code: WPB/30) and 45° (product code: WPB/45). To allow for alignment, the female collars of these elbows do NOT have the twist lock flutes, but the locking band MUST still be used to secure the two flue components together.

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

WARNING

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

7.4.7 Wall Sleeves

In accordance with the Building Regulations Approved Document J, a wall sleeve should be used where the flue system passes through a wall. A suitable wall sleeve is available as part of the Grant ‘Biomass’ flue system (product code: WP/SLE).

This 45° angled wall sleeve is available in 230mm diameter - giving a 25mm clearance all round from the 180mm diameter outer surface of the flue passing through it.

The sleeve is 45° mitred at one end. The other end of the sleeve should be cut on site to the correct length, to leave it flush with the wall on both sides. The sleeve should be adequately weatherproofed using a good quality mastic and fibre rope.

Oval one-piece trim collars are available to be fitted at either end of the wall sleeve (product code: WPB/TC). These should be fastened to the inside or outside wall using a suitable method of fixing. The trim collars should be adequately weatherproofed back to the wall using a good quality building

mastic or similar.

7.4.8 Firestop Plates Ventilated Fire Stop Plate (product code: WPB/FP)

A Ventilated Fire Stop Plate should be fixed to the ceiling below a Ventilated Support Plate. When passing through a second upstairs floor (in a 3-storey house) either a second support plate can be fitted or alternatively two ventilated fire-stop plates (one above and one below) need be fitted if the flue is adequately supported at the first upstairs floor level.

Magnetic Fire Stop Plate Cover Plate (product code: WPB/MF)

This can be fixed below a Ventilated Fire Stop Plate to cover the ventilation slots but still allow air flow through them. The Cover Plate is held in place by the four circular magnets provided in the kit. These are fixed using the four screws securing the Ventilated Fire Stop Plate to the ceiling. The cover can be lowered for inspection purposes by pulling it downwards and off the four magnets.

The Magnetic Fire Stop Plate can also be used as a ‘Bungalow’ Fire Stop Plate. This unventilated fire stop plate may only be used on a combustible ceiling in a bungalow where there is a minimum distance of 60mm between the flue and any combustibles, where the flue penetrates the ceiling area and the roof space above the ceiling is open and ventilated. Within the roof space a protective wire mesh guard must be built around the flue to ensure a minimum distance of 60mm from combustibles is maintained.

To fix the plate to the ceiling: drill four equi-spaced holes 25mm in from the outer edge and use suitably sized screws to secure to ceiling.

Page 46

7.4.9 Flexible Flue Liner Kit

A 125mm diameter twin skin stainless steel flexible flue liner is available to line a masonry chimney, if required. Both inner and outer layers are made from corrosion resistant 316L stainless steel. The outer is corrugated for high crush resistance and the inner is smooth to allow easy drain down of condensate, less opportunity for deposits to collect and ease of sweeping.

The CE designation for this flexible flue liner (to BS EN 1856-2) is:

T600 N1 W V2 L50012 G

This flexible flue liner must be installed as one continuous length with NO joints.

The liner is supplied in three standard lengths of 6m, 8m and 10m as part of a Flexible Flue Liner kit, as follows:

Grant product

code

WPKIT6/125 6 m

WPKIT8/125 8 m

WPKIT10/125 10 m

Prior to Installation

In all cases the chimney should be inspected for deterioration and, if necessary, and remedial work required should be carried out. The chimney should be swept, preferably by a member of the National Association of Chimney Sweeps (NACS) or a suitably qualified chimney sweep who would provide a certificate after sweeping and checking, which should be retained for future reference.

The flaunching at the top of the stack should be checked to ensure it is not cracked and if so it must be replaced. The brickwork pointing and flashings should be checked to ensure they are in good order and corrected as necessary. This is required to prevent the ingress of rainwater which, if mixed with the carbon deposits on the inside wall of the chimney, could damage the flue liner and the fabric of the building.

Installation

Prior to installation of the flexible liner, it is recommended that a test length (approximately 1.5m long), with a nose cone attached to each end, is pulled through the chimney to ensure that the chimney is suitably sized and free

Liner

length

from obstructions. Failure to do so may lead to the guarantee on the liner being invalidated if damage has occurred due to snagging on an obstruction. The flue liner should be pulled down the chimney using a nose cone and string/ rope.

Care must be taken to avoid overbending or kinking of the liner during installation. The minimum bend radius for the liner is 375mm.

Orientation

It is essential that the flexible flue liner is installed the right way up. The arrow on the outside of the liner indicated the direction of the flue gas flow and must be pointing upwards, i.e. towards the terminal.

Cutting the Liner

Extreme care must be taken when cutting the liner, Strong industrial gloves and long sleeved overalls should be worn as the cut edges are very sharp. Any tape on the ends of the liner, provided for safe handling prior to installation, must be removed before connecting the flue liner.

In addition to the liner, the Flexible Flue Liner Kit also contains the following components:

Anchor Plate (product code: WPB/AP)

This is located on the top of the chimney with the male collar on the top and the spigot below the plate. Fit the flexible liner onto the spigot. Seal with high temperature mastic sealant and secure in place with self-tapping screws.

The plate should then be bolted to the chimney and sealed using Fire cement.

Flex flue adaptor (product code: WPB/CA)

This is located at the bottom end of the flexible flue liner, where it connects to the rigid twin-wall flue section of the flue system. The adaptor is fitted vertically with the socket uppermost. The flexible liner is pushed fully into this socket, sealed with high temperature mastic and secured with self-tapping screws.

Roof Cowl (product code: WPB/RC)

The Rain Cap type terminal is fitted either directly to the Anchor Plate on the top of the chimney or, if necessary (i.e. to achieve the required distance between the terminal and the roof

surface), to a length of flue that is, in turn, connected to the Anchor Plate.

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

7.5 Flue Testing

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

7.6 Flue Notice Plate

The Building Regulations Approved Document J requires a notice plate that conveys essential information regarding the flue installed to be permanently displayed. A suitable self-adhesive notice plate is supplied with the Grant ‘Biomass’ flue system and this must be completed by the installer and displayed in an unobtrusive but obvious position within the building concerned, e.g. next to the flue system/boiler.

7.7 Carbon Monoxide Alarm

The Building Regulations Approved Document J requires a Carbon Monoxide alarm to be fitted in the room where the boiler is located.

This should be positioned between 1 and 3m horizontally from the boiler either:

• On the ceiling at least 300mm from any wall, or

• On a wall as high up as possible (above any windows or doors) at least 150mm from ceiling.

Page 47

7.8 Typical Flue Systems

Rain cap

Uni flashing

Rain cap

Extension

Uni flashing

Support plate

Ventilated firestop plate

Wall bracket

Cantilever

45° bend

Adjustable

extension

Extension

Wall sleeve

Support plate

Wall support side plate

Adjustable extension

Inspection pipe

1000mm extension

Support plate

45° bend

Ventilated firestop plate

Adjustable extension

Inspection pipe

Figure 7-5: Typical flue installations details

Page 48

7.9 Flue Component Dimensions

Nominal length

Effective length

200mm

333mm 500mm

1000mm

Straight pipe length

Product

code

Nominal length

(mm)

Effective length

(mm)

WPB/EXT200 200 160

WPB/EXT333 333 293

WPB/EXT500 500 460

WPB/EXT1000 1000 960

Effective lengths using a straight and adjustable extension

Product

codes

Minimum

(mm)

Effective length

WPB/EXT200 + adjustable 350 440

WPB/EXT333 + adjustable 393 573

WPB/EXT500 + adjustable 560 740

WPB/EXT1000 + adjustable 1060 1240

Adjustable pipe length

Product

code

Nominal length

(mm)

Effective length

WPB/ADJ250 75 - 250 mm 50 - 230mm

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

(mm)

↔

Adjustable 75 - 250mm

(mm)

Double 30° bend and straight pipe length

Effective

length

960

460

293

160

Dimension Length

A / B

1061 / 542

628 / 292

483 / 208

368 / 142

Double 45° bend and straight pipe length

Effective

length

960

460

293

160

Dimension Length

A / B

933 / 784

580 / 431

462 / 313

367 / 218

Page 49

7.10 Flue System Components

340

300

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

WPB/WB60 - Wall bracket (60mm)

WPB/IP - Inspection pipe

WPB/CA - Flue adaptor

Support plate (2 pieces)

WPB/CANT - Cantilever (570mm)

WPB/AP - Anchor plate

WPB/FP - Firestop plate (1 piece)

WPB/GB - Guy wire bracket

Page 50

WPB/WS - Wall support side plate

WPB/UF200 - Uni flashing (80 - 200mm)

1000

WPB/RC - Rain cap

330

184

WPB/TP - Intermediate top plate

WPB/LBEXT - Structural locking band

300

WP/SLE - Wall sleeve (45°)

Also requires WPB/TC or WPW/TC x 2)

WPB/SC - Storm collar

454

259

WPB/TC - Trim collar for Wall Sleeve (45°)

WPB/RS - Roof support (stainless steel) band

WP/PFL - Pitched lead flashing

Page 51

Rain cap

7.11 Flexible Flue Liner

Flexible Flue Liner Kit Contents

6/8/10 metre liner, Anchor plate/flex adaptor, Flue system to flex adaptor, Rain cap, Locking band x 3, Viton gasket x 3, Lubricant, Packing list and instructions

Anchorplate

to flue

Rain cap

Flexible flue liner

adaptor

Anchorplate to flue adaptor

Flexible flue liner

Adjustable extension

Inspection pipe

(access hatch to face left of boiler)

45° bend

Support plate

Extension

to flue

adaptor

45° bend

Adjustable

extension

Extension

Wall support

side plate

Extension to flue adaptor

Figure 7-6: Typical flue installation (flexible flue liner)

Page 52

8 Electrical

8.1 General Requirements

The Grant Spira Condensing Wood Pellet boiler requires a 230 V ~50 Hz electrical supply. The unit must be connected to a mains power supply via a fused spur that is protected by a 30mA RCD.

The boiler requires both a permanent mains supply and a switched live supply to control the boiler.

The fused spur of the power supply to the boiler and controls must be fitted with a 13A fuse.

A second fused spur (5A fuse) fed from the first fused spur is included to supply the heating system controls circulating pump. Refer to Figure 8-9 and 8-10.

For the UK, the electrical installation must be carried out by a competent installer in accordance with the requirements of the Electricity at work Regulations 1989 and BS 7671:2008 – IET Wiring Regulations 17th Edition (including all amendments).

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

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

8.2 Hopper Electrical Connections

All Grant Spira boiler pellet hoppers are fitted with two in-line 5A fuses. These are located inside the electrical wiring enclosure in the back of the pellet hoppers.

8.2.1 Single Boiler Hopper

(with a single auger) – in either a left hand or right hand version as required, to supply a single boiler.

This hopper is fitted with three pre-wired flying leads with factory-fitted plugs:

• 4-way plug – for connection of the permanent live, earth and neutral and also the switched live from the heating controls system.

• 5-way plug – to connect the hopper to the boiler.

• 6-way plug – to connect either a bulk pellet store auger or Grant SpiraVac vacuum system to the hopper and boiler.

Refer to Figure 8-7 for hopper wiring diagram.

8.2.2 Double Boiler Hopper

(with two augers) – to supply two boilers in a ‘double boiler’ installation.

This hopper is fitted with four pre-wired flying leads with factory-fitted plugs:

• 4-way plug – for connection of the permanent live, earth and neutral and also the switched live from the heating controls system.

• Two 5-way plugs – one to connect to each of the two boilers.

• 6-way plug – to connect either a bulk pellet store auger or Grant SpiraVac vacuum system to the hopper and boiler.

Refer to Figure 8-8 for double hopper wiring diagram.

8.2.3 For Installations with a Bulk Pellet Store only

Both single boiler and double boiler hoppers are supplied with the 6-way plug parked inside the wiring enclosure. See Figure 8-1.

If a bulk pellet store is to be used:

• Remove the wiring centre cover from the rear of the hopper.

• Unclip the 6-way plug from diaphragm switch bracket.

• Pass the 6-way plug lead through the grommet just below the wiring centre cover.

Figure 8-1: Hopper selector switch and 6-way plug

• Set the toggle switch on the

diaphragm switch bracket to ‘BULK STORE’. See Figure 8-1.

• Replace the wiring centre cover and

fasten in place using the screws previously removed.

• Connect the 6-way plug to the

corresponding 6-way connector on the pre-wired flying lead fitted to either the bulk pellet auger or Grant SpiraVac system.

• If using the Grant SpiraVac

system, refer to the installation instructions supplied with the system for further details on its installation and operation.

8.2.4 For Installations using the

Pellet Hopper only

The pellet hopper is supplied with the toggle switch set to ‘HOPPER ONLY’. When used without a bulk pellet store, the pellet hopper has the facility for the connection of a 230V ‘low pellet’ indicator lamp (not supplied). This will indicate to the householder that the pellets in the hopper have reached the 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 either Figure 8-7 or 8-8, as applicable, for the connection details.

If a bulk store is used, with either the Grant SpiraVac system or a Grant bulk auger, a ‘low pellet’ indicator lamp

cannot be fitted to the pellet hopper.

Page 53

8.3 Boiler/Hopper Plug Connections

Before making any electrical connections to the hopper (by connecting the 4-way plug and socket together) ensure that all the plug connections have been correctly made between the hopper, boiler and (if fitted) the bulk pellet supply system, as follows:

1. Fit the 5-way plug from the flue fan and solenoid valve into the socket at the top right rear of the boiler. See Figure 8-2. Ensure it is fully pushed home.

Figure 8-2: Flue fan/solenoid valve plug connection

2. Fit the 5-way plug from the hopper into the socket at the top left rear of the boiler. See Figure 8-3. Ensure it is fully pushed home.

Figure 8-3: Hopper plug connection Figure 8-4: Auger plug connection

3. On a double boiler installation, fit the second 5-way plug from the double hopper into the top left rear of the second boiler. Ensure it is fully pushed home.

Item number 1 needs to be repeated for double hopper/ second boiler.

4. Fit the two 7-way plugs (No.1 and No.2) from the boiler control panel into the two lower connections on the left side of the burner. These plugs are male and female and cannot be fitted into the wrong connections. Refer to Figure 8-4. Ensure that both plugs are fully pushed home until the small catch on each of them clicks into place.

5. Fit the 6-way plug (No.3) from the pellet feed auger motor into the upper connection on the left side of the burner. Refer to Figure 8-4. Ensure that the plug is fully pushed home until the small catch it clicks into place.

6. If a bulk pellet store is to be used,

connect the 6-way plug to the corresponding connection on the flying lead from either the Grant SpiraVac system or Grant bulk pellet store auger. Ensure that the plug and socket are fully pushed together until the small catch clicks into place.

Refer to instructions supplied with either the Grant SpiraVac or Grant bulk store auger for further details.

Page 54

8.4 Heating System Controls

The boiler can be used in conjunction with typical heating control system, e.g. ‘S-Plan’ or ‘Y-Plan’ type controls. Refer to Figures 8-9 and 8-10 and for typical control system wiring diagrams.

As the electrical connection (permanent mains supply and switched live from the heating control system) to the boiler is made via the flying lead with 4-way plug connection it will be necessary to provide a 4-core flying lead either

a) Directly from the heating controls wiring centre – if suitable located adjacent to the boiler/hopper, or

b) Via a junction box situated adjacent to the boiler hopper.

The length of 4-core flex required (between the wiring centre or junction box and the 4-way plug connection) must be sufficient to allow the hopper to be moved out enough to allow disconnection the 4-way plug.

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 Figures 8-7 or 8-8 as appropriate for connection details.

8.5 Connecting the Power Supply

WARNING

Before making any connections to the heating systems controls ensure that the electrical supply is isolated at the fused spur serving the controls and boiler, that the fuse has been removed and the isolator is locked off.

Do NOT connect the electrical supply to the hopper, by connecting the 4-way plug and socket together, until ALL plug connections have been correctly made between the hopper, boiler and (if fitted) the bulk pellet supply system.

The boiler requires a permanent mains supply and a switched live supply to control the boiler. For details of Controls refer to Section 8.4 and Figures 8-9 or 8-10.

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

The power supply cable and flex should be at least 1.5mm

The fused spur of the power supply to the boiler and controls must be fitted with a 13A fuse when a Grant SpiraVac vacuum system is fitted; otherwise a 5A fuse is required.

PVC.

NOTE

Connect the mains supply using the following procedure:

1. Press down on the small catch

(between the two parts of the factory-fitted 4-way plug/socket connector) to release it.

2. Separate the two parts and remove

the cover from the male 4-way plug.

3. Connect the flex to the 4-way male

plug as follows:

• Terminal L2 – Switched live (from heating system controls)

• Terminal N – Mains neutral

• Terminal (earth) – Mains earth

• Terminal L1 – Mains (permanent) live Refer to Figures 8-9 or 8-10

4. Replace the cover, ensuring outer

sheath of the flex is held in the cable grip of the plug, and secure using the screws previously removed.

5. Connect the other end of the 4-

core flex to the either the heating system controls wiring centre or junction box. Refer to either Figures 8-9 or 8-10, as appropriate, for details of the connections required.

6. Fit the two parts of the 4-way

connector back together. Ensure the plug and socket are fully pushed together until the small catch clicks into place.

WARNING

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.

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

Page 55

8.6 Wiring Diagrams

Plug No 2 (7 way)

Plug from Hopper

REAR UPPER LEFT HAND OF BOILER (WHEN VIEWED FROM THE FRONT)

On/Off Switch

2 C

Red

Green/Yellow

Earth Studs Earth Studs Earth Studs

Blue

Black

Green/Yellow

L3 N L2 L1

'Mains' Permanent Live Neutral Earth and Switch Live feed from Hopper

Limit

Thermostat

2 C

Black Black

Fan Box Assembly

Plug No 4 (5 way) Plug No 5 (5 way)

Green/Yellow

Brown

Blue

Green/Yellow

Brown

Blue

Green/Yellow

L3 N L2 L1

Flue Fan

Brown

Solenoid Valve

BOILER CASING

L3 N L2 L1

Socket No 5Socket No 4

BOILER CONTROL PANEL

Red

Relay

A1 A2

Blue Brown

2A 5B

On/On Switch

Momentary

one side

Red

Black

Blue Blue Brown Red

Blue

Boiler Cleaning

Motor

Green/Yellow BrownRed Blue

Red

Blue Green/Yellow Brown

Black Black

LINK

Blue Brown Green/Yellow

Blue

Brown

Green/Yellow

REAR UPPER RIGHT HAND OF BOILER (WHEN VIEWED FROM THE FRONT)

Blue

Switched

Black

Live

Permanent

Brown

Live

Door

Black

Interlock

Door

Black

Interlock

Flue Fan

Brown

Live

Flue Fan

Blue

Neutral

Green/Yellow

Thermistor

Pellet Feed Auger Motor

N L

Blue Green/Yellow Brown

Blue

Green/Yellow

Brown

Plug No 3 (6 way)

Blue

Brown

Black

T1 T2

Blue

Green/Yellow

Brown

Plug No 1 (7 way)

B4 L1 N

Black

Blue

Green/Yellow

Brown

BURNER BOX

L1 N T1 T2

B4 L1 N T1 T2

L1 N T1 T2

Black

Burner

Door

1 3

Isolation

Switch

COM NO

(For more information) See Figure 12-5: p66

Figure 8-5: Boiler internal wiring diagram

Page 56

CN1

CN14

CN16

91011121315 141617181920222324 21

SOCKET NO.1 SOCKET NO.2 SOCKET NO.3

Figure 8-6: Burner wiring diagram

Page 57

Yellow

NOTE

With the central heating

valve fitted, connect the pipe

thermostat between L4 and L7.

Without the central heating

valve fitted, connect the pipe

thermostat between L4 and L6.

Pipe Stat

(If fitted)

TO VACUUM

SYSTEM OR

SYSTEM ONLY

Thermostat

Frost

BULK AUGER

LN123

L5 L6

HOPPER

LIMIT

Red

SWITCH

Orange

5 AMP FUSE ( 5 X 20mm )

IN LINE FUSE HOLDER C/W

Brown

Blue

Black

Green/Yellow

1 2 3 4 5

L2 L3 L4

N N L1

PL1

Blue

Green/Yellow

Blue Blue

Brown

5 4 3 2 1

Brown

Grn/Yellow

Blue

Black

L2 N L1

SL1

To Low Pellet Warning Lamp.

ONLY USE IN 'HOPPER ONLY' MODE

Permanent Live

Earth

Neutral

L2 N L1

Switched Live

SL2 SL3

Red

Yellow

Orange

Brown

HOPPER

ONLY

8 5 2

STORE

BULK

5 AMP FUSE ( 5 X 20mm )

IN LINE FUSE HOLDER C/W

Brown Black Green/Yellow

AND SWITCHED

PERMANENT

MAINS SUPPLY

LIVE SUPPLY

SUPPLY

BOILER

FIT TO

REAR OF

BOILER

L2 L1

PERMANENT LIVE

SWITCHED LIVE

Figure 8-7: Hopper wiring diagram – single boiler hopper

Page 58

Yellow

NOTE

With the central heating

valve fitted, connect the pipe

thermostat between L4 and L7.

Without the central heating

valve fitted, connect the pipe

thermostat between L4 and L6.

Supply to Central Heating Valve

Pipe Stat

(If fitted)

TO VACUUM

SYSTEM OR

SYSTEM ONLY

Thermostat

Frost

BULK AUGER

LN123

L5 L6

HOPPER

LIMIT

Red

SWITCH

Orange

5 AMP FUSE ( 5 X 20mm )

IN LINE FUSE HOLDER C/W

Blue

Black

Brown

Green/Yellow

Blue

Black

Green/Yellow

1 2 3 4 5

5 4 3 2 1

To Low Pellet Warning Lamp.

ONLY USE IN 'HOPPER ONLY' MODE

Permanent Live

Earth

Neutral

L2 N L1

Switched Live

N N L1 L2 L3 L4

PL1

Blue

Green/Yellow

Blue Blue

Brown

Grn/Yellow

Blue

Black

L2 N L1

SL2 SL3

SL1

Red

Yellow

Orange

Brown

HOPPER

ONLY

8 5 2

STORE

BULK

IN LINE FUSE HOLDER C/W

Brown Black Green/Yellow

5 AMP FUSE ( 5 X 20mm )

AND SWITCHED

PERMANENT

MAINS SUPPLY

LIVE SUPPLY

SUPPLY

BOILER

FIT TO

REAR OF

BOILER

L2 L1

PERMANENT LIVE

SWITCHED LIVE

SUPPLY

BOILER

FIT TO

REAR OF

BOILER

L3 N L2 L1

Figure 8-8: Hopper wiring diagram – double boiler hopper

PERMANENT LIVE

SWITCHED LIVE

Page 59

Grey Grey

Permanent Live

Earth

Neutral

13A

Fuse

Switched Live

240V

50HZ

L N E

Cylinder

Room

Stat

2 1 3

Stat

1 C 2

Orange Orange

1 2 3 4 5 6 7 8 9 10

Link

Neutral

Permanent Live

Brown

Blue

Green/Yellow

Brown

Blue

Green/Yellow

Wiring Centre

Pipe Thermostat

Motor

2-Port Zone Valve

HTG

Motor

2-Port Zone Valve

Green/Yellow

Blue

Brown

(If fitted)

Frost

Thermostat

E N L

Pump

PL N SL

L1 N L2

Use 4-Core flex at least

1.5mm² between junction

}

box and hopper*

Four-way plug (comes fitted

to four-way socket on rear

L 1 2 3 4

OFF OFF ON ON HW HT HW HT

Grant 2-Channel

Wall Mounted

Programmer ESKIT

of Grant Spira Hopper)

NOTE

All cable to be 0.75mm2 minimum unless otherwise shown.

*See Figure 8-11 for wiring Pressure Switch Kit for use with plastic pipe in installation

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

Page 60

240V 50HZ

L N E

Room

Stat

2 1 3

Cylinder

Stat

1 C

Orange Grey

White

Blue

Green/Yellow

Motor

13k2W270k

0.25W

Permanent Live

Earth

Neutral

PL N SL

13A

Fuse

L N E

Fuse

Switched Live

Use 4-Core flex at least

1.5mm² between junction

}

box and hopper*

1 2 3 4 5 6 7 8 9 10

Link

Neutral

Permanent Live

L 1 2 3 4

OFF OFF ON ON HW HT HW HT

Grant 2-Channel

Wall Mounted

Programmer ESKIT

3-Port Mid Position

Zone Valve

Wiring

Centre

Green/Yellow

Blue

Brown

E N L

Pump

Pipe Thermostat

(If fitted)

Frost

Thermostat

NOTE

Earth and some Neutral connections have been excluded for clarity. All switches are shown in the closed position.

Pressure

Switch

L1 N L2

Four-way plug (comes fitted

to four-way socket on rear

of Grant Spira Hopper)

NOTE

All cable to be 0.75mm2 minimum unless otherwise shown.

*See Figure 8-11 for wiring Pressure Switch Kit for use with plastic pipe in installation

Figure 8-10: Heating system controls – Y-plan type system connection diagram

PLSLN

Wall mounted

Junction box*

Use 4-Core flex at least

1.5mm² between junction

}

box and hopper*

EARTH

SWITCHED LIVE

NEUTRAL

Four-way plug (comes fitted

to four-way socket on rear

of Grant Spira Hopper)

PERMANENT LIVE

L1 N L2

Figure 8-11: Connection of Grant low water pressure switch (product code: MPCBS62)

Page 61

9 Burner

9.1 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 is automatically activated 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 pre-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 the ‘TEMP DELTA’ temperature (default value 5°C) the output of the boiler is reduced by one modulation step.

Each subsequent 1°C increase in boiler temperature reduces the output of the boiler by one further modulation step until the temperature reaches the set point plus the ‘TEMP DELTA’ temperature.

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 shown in Section 9.3.

9.2 Burner Operating Modes

‘BOILER WAIT THERMOSTAT’:

(operation code 03) Boiler is in standby awaiting the following;

• A switched live input signal from the control system.

• The boiler temperature to drop below the set point less the ‘DELTA RESTART’ temperature. (‘DELTA RESTART’ is the temperature below the set point the burner restarts after maximum temperature has been reached).

• If required, the boiler temperature to drop below the set point less the ‘DELTA RESTART’ temperature. ‘DELTA RESTART’ (default value 5°C) is the temperature below the set point at which 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 set point less ‘DELTA RESTART’ temperature.

• Deactivated after time exceeds 65 seconds.

‘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 reaches 2 lux.

‘WAIT LIGHTING’–FLAME STABILISATION: (operation code 45)

Period of time to allow flame to stabilise after pellets have ignited.

• Activated after ignition mode.

• Deactivated after time exceeds 30 seconds.

‘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 stabilisation mode.

• Deactivated after time exceeds 120 seconds.

‘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 boiler temperature is higher than the set point less ‘TEMP DELTA’.

‘PELLET BURNER FIRING’: Power modulating (operation code 13) Flame is reduced and boiler output is modulating.

• Activated when the boiler temperature is higher than the set point less ‘TEMP DELTA’.

• Deactivated after the boiler temperature exceeds the set point plus ‘TEMP DELTA’.

‘PELLET BURNER FIRING’: Power minimum (operation code 13) Flame is reduced and boiler is at minimum output.

• Activated once the boiler temperature exceeds the set point plus ‘TEMP DELTA’.

• Deactivated after the temperature exceeds ‘TEMP OFF H2o’ (default value 80°C).

‘TURNING OFF BRAZIER’: (operation code 14). Burn down period to remove any pellets remaining in the brazier.

• Activated when switched live input signal from control system is switched off or the boiler temperature exceeds ‘TEMP OFF H2o’ setting or the ON/STANDBY switch on the control panel is set to the ‘STANDBY’ position.

• Deactivated once photocell lux reading has dropped to 1 lux.

‘WAIT POST PURGE’: (operation code

26) Period of time after burn down is complete to ensure no unburnt pellets ignite.

• Activated after ‘TURNING OFF BRAZIER’ is complete.

• Deactivated after time exceeds 180 seconds.

Page 62

9.3 Burner Operating Sequence Flow Chart of Operation of Wood Pellet Boiler

Wait Boiler Thermostat

Temp >set point less the ‘Delta Restart’ Temp or Switched Live Input Off

Switch live Activated

Switched Live Input Off

Temp < below the set

point ‘Temp Delta’ Range Switched Live Input Off

Temp > above the set

point ‘Temp Delta’ Range Switched Live

Input Off

Wait Pre Load Brazier

(Pressure Switch Check)

Wait Pre Load Brazier

Wait Lighting

(Ignition)

Wait Lighting

(Flame Stabilisation)

Wait Lighting

(Lighting Feed Reduced)

Pellet Burner Firing

(Max Flame)

Pellet Burner Firing

(Modulating)

Pellet Burner Firing

(Min Flame)

Temp < set point less the ‘Delta Restart’ Temp and Switched Live Input On

Pressure Switch Check OK

T > 65 Sec Pre Load Time

Lux = 2 Lux

T > 30 Sec Flame Stabilisation

T > 120 Sec Lighting Feed Reduced

Temp < below the set point ‘Temp Delta’ Range

Temp > above the set point ‘Temp Delta’ Range

Flash Cleaning = 1

Auger run time > ‘Time Clean Braz’ and/ or ‘Time Clean Boiler’

Temp > ‘Temp Off H2o’

Turning Off Brazier

Wait Brazier is Opening >>>

Flash Cleaning = 0

Auger Run Time > ‘Time Clean Boiler’

Auger Run Time > ‘Time Clean Braz’

Turning Off Brazier

Auger Run Time > ‘Time Clean Boiler’

15 03

Wait Cleaning Boiler

Lux < 2 Lux

Wait Brazier is Closing >>>

Wait Post Purge

180 seconds

For ‘STEP AUTO’ function (the two digit code allocated to each function). Refer to Section 9.7.3.

Page 63

9.4 Burner Display Screen

Active symbols

= Heating demand (from control system) = Burner fan operational = Pressure switch closed = Ignition element operational = Feed auger operational = Photocell lux reading >’Flame On’ setting = n/a = Error

9.5 Burner Control Buttons

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

Button No.1

Button No.2

Button No.3

Button No.4

Button No.6

Button No.5

Normal Mode; Increase temperature set point by 1˚C - up to 75°C maximum Menu mode; Scroll up

Normal mode; Decrease temperature set point by 1˚C - down to 55°C maximum Menu mode; Scroll down

Menu mode; Scroll forward

Normal mode; Reset fault Menu mode; Scroll back

Menu mode; Increase parameter value

NOTE

These buttons are presented as they appear on the burner control panel, i.e. buttons 5 and 6 are not sequentially ordered.

Menu mode; Decrease parameter value

}

Page 64

9.6 Burner Menu Navigation Chart and Factory Default Settings

LUX %

STEP AUTOMA

VIEW CLE BRAZ

VIEW CLE BOIL

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

LANGUAGE

RESET SERVICE

menu 2-4

menu 4-4

FAN

menu 3-4

INSTAL

SETUP

H2o

POWER PELLET

CLEAN

ITALIAN

ENGLISH

TO RE-LOAD

FACTORY

SETTING

MANUFACT

INSTAL

MANUFACT

INSTAL

VIEW

MANUFACT

USER

VIEW

PSW 0

INSTAL







TO STEP

BACK

2 3

SET

RESET

SET 75°C

H2o XX°C

PELLET BU



(T17)

(T18)

(T16)

T05

T06

T21

POWER MAXIMUM

POWER MINIMUM

SET POINT RANGE 55°- 75°C

Not applicable

= BURNER CONTROLS BUTTON

CODE

5°

80°

5°

180

400

100

5-18 =2.5 6-26 =2.5 9-36 =6.5

5-18 =31 6-26 =36 9-36 =43

5-18 =22.0

6-26 =14.0

9-36 =25.0

5-18 =16 6-26 =21 9-36 =26

5-18 =4.8 6-26 =2.5 9-36 =2.5

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9.7 Burner Menu

Using the main menu flow chart shown in Section 9.6 navigate the menus using the buttons as described in Section 9.5.

Each of the four main folders is described in further detail as follows; ‘INSTAL’, Installer folder, see Section

9.7.1

‘MANUFACT’ not applicable. ‘VIEW’ folder, see Section 9.7.3. ‘USER’ folder, see Section 9.7.4.

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.

9.7.1 ‘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:

9.7.1.1 ‘menu 1-4- H2o’ sub folder contains three parameters stored within this folder:

• TEMP DELTA: Defines the boiler temperature either side of the Set- point in which the boiler will modulate Units - °Celsius. Default setting: 5-18, 6-26 and 9-36 = 5 (5°C)

• TEMP OFF H2o: Temperature the burner’ shuts down. Units -°Celsius. Default setting: 5-18, 6-26 and 9-36 = 80 (80°C)

• DELTA RESTART: Temperature drop below the set-point before burner re-starts. Units - °Celsius. Default setting: 5-18, 6-26 and 9-36 = 5 (5°C)

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CAUTION

Settings in the burner menu’s below are based on the boiler using the Grant fixed angle pellet feed auger at 45° and an auger motor fixed speed of 8.1 rpm. Only EN Plus Grade A1 (BS EN ISO 17225-2) pellets MUST be used with the Grant Spira boilers. These pellets must be bark and sand free AND approved by Grant UK BEFORE being used in the Spira boilers. Failure to use approved pellets will invalidate the product guarantee.

9.7.1.2 ‘menu 2-4- POWER PELLET’

The parameters stored within this folder are:

• 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: 5-18 and 6-26 = 25 (2.5 seconds) Default setting: 9-36 = 65 (6.5 seconds)

• 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).

• 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 5-18: 0220 (22.0 seconds) Default setting 6-26: 0140 (14.0 seconds) Default setting 9-36: 0250 (25 seconds)

NOTE

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 and load/ pause settings.

9.7.1.3 ‘menu 3-4- CLEAN’

The parameters stored within this folder are:

• TIME CLEAN BRAZ: Total pellet feed auger run time before burner brazier cleaning operation activates. Default setting: 5-18, 6-26 and 9-36 =180 (180 minutes)

• TIME CLEAN BOILER: Total pellet feed auger run time before boiler cleaning operation activates. Default setting: 5-18, 6-26 and 9-36 =180 (180 minutes)

• TIME CLEAN PERIOD: Time period boiler cleaning function is operational once ‘TIME CLEAN BOILER’ has elapsed. Default setting: 5-18, 6-26 and 9-36 =60 (60 seconds)

• FLASH CLEANING: Setting determines when the burner brazier and boiler cleaning operations start after the ‘TIME CLEAN BRAZ’ and ’TIME CLEAN BOILER’ periods have elapsed. 1 = Burner firing interrupted and shut down, brazier and boiler cleaned immediately auger run time exceeds ‘TIME CLEAN

BRAZ’ and ‘TIME CLEAN BOILER’ periods.

0 = Burner firing not interrupted. Brazier and boiler cleaned at next burner shut-down after auger run time exceeds ‘TIME CLEAN

BRAZ’ and ‘TIME CLEAN BOILER’ periods.

Default setting: 5-18, 6-26 and 9-36 = 1.

Consideration must be given to the demand of the heating system before adjusting this setting. For example, if the boiler is to be installed in a hotel, you may choose to change this setting to 0 to ensure there is an uninterrupted supply.

• HOURS SERVICE: Time lapse period before the burner screen displays ‘SERVICE’. This is to indicate a service is now due. Default setting 5-18, 6-26 and 9-36 = 400 (400 hrs). RESET SERVICE: to cancel the ‘SERVICE’ display on the burner screen after the boiler has been serviced. Press button 3 (‘SET’) followed by button 4 (‘RESET’) five times to exit the menu.

IT IS ESSENTIAL TO RESET THE SERVICE DISPLAY AFTER EACH SERVICE.

9.7.1.4 ‘Menu 4-4- SETUP FAN’

• POWER MAXIMUM: Burner fan

speed setting when burner in ‘max’ output mode. Default setting: 5-18 = 31 Default setting: 6-26 = 36 Default setting: 9-36 = 43

• POWER MINIMUM: Burner fan speed setting when burner in ‘min’ output mode. Default setting: 5-18 = 16 Default setting: 6-26 = 21 Default setting: 9-36 = 26

• POWER LIGHTING: Burner fan speed setting when burner in lighting mode. Default setting: 5-18, 6-26 and 9-36 = 20

• 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.

• LOAD DEFAULT: Load factory default settings. Press button 3 to activate factory default settings.

9.7.2 ‘MANUFACT’ Menu Folder

‘MANUFACT’ displays the manufacturer folder; this folder cannot be accessed or modified by the installer or service engineer.

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9.7.3 VIEW Menu Folder

9.7.4 USER 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;

‘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 ‘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 boiler is in when viewing. The list of the functions are as follows:

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

03 - Wait Boiler Thermostat 13 - Pellet Burner Firing 14 - Turning Off Brazier 15 - Brazier is moving back 15 - Brazier is moving forward 26 - Post Purge 29 - Air Pressure Error 33 - Failed Pellet Lighting 34 - Servo Motor Blocked 40 - Pre-load 41 - Wait Lighting (Ignition) 42 - Wait Lighting (Lighting Feed Reduced) 45 - Wait Lighting (Flame Stabilisation) 47 - Probe Fault

c. VIEW CLE BRAZ Total pellet feed auger run time since brazier last cleaned. When ≥ 180 Min 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 ≥ ‘180 Min boiler cleaning operation will commence. Resets after each boiler clean.

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10 Commissioning

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

For double boiler installations this procedure must be carried out in full on both boilers.

10.1 Equipment Required

To carry out a complete and comprehensive commissioning of the Grant Spira wood pellet boiler the following equipment is required:

• Draught gauge.

• Flue gas analyser (with “wood pellet” fuel setting).

• Container of at least 1 litre capacity.

10.2 Preliminary Inspection

Before switching on the power supply to the hopper and boiler, check the following:

10.2.1 Heating System

Check the following:

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

4.14.

• That a magnetic in-line filter has been fitted in the system. Refer to Section 4.14.

• The auto air vent (supplied with the boiler) is open.

• The boiler drain cock (supplied with the boiler) is closed.

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

• On sealed systems the expansion vessel charge pressure is correct and system is filled to correct pressure.

• For any leaks at joints, fittings, etc.

10.2.2 Electrical Connections

Check the following:

• The 5-way plug (from the hopper) is fully inserted in the socket at the top left rear of boiler. Refer to Figure 8-3.

• The 5-way plug (from the flue fan and wash system solenoid valve) is fully inserted in the socket at the top right rear of the boiler. Refer to Figure 8-2.

• The two 7-way plugs (from the boiler control panel) are fully inserted into the corresponding two lower connections on the left side of the burner. Refer to Figure 8-4.

• The 6-way plug (from the pellet

auger) is fully inserted into the upper connection on the left side of the burner. Refer to Figure 8-4. On double boiler installations, repeat the process for the second boiler.

10.2.3 Wash System

Check the following:

• The wash system flexible hose is correctly fitted to the outlet of the solenoid valve at the rear of the boiler.

• The solenoid valve head is correctly fitted and secured in position with the steel clip provided with the boiler.

• The solenoid valve is connected to an uninterrupted mains water supply. Refer to Section 4.9.

• All valves in this water supply are open.

On double boiler installations, repeat the process for the second boiler.

10.2.4 Condensate Disposal System

Check the following:

• The condensate trap (supplied with

the boiler) and condensate disposal pipework has been fitted correctly. Refer to Section 5.

• If a condensate pump is fitted, that

a condensate holding tank of at least 40 litres capacity has also been installed. Refer to Section 5.

10.2.5 Flue System

Check the following:

• The draught stabiliser damper, on the fan box, is unobstructed and free to move. Ensure that the damper locking lever is in the ‘unlocked’ position’. Refer to Figure 10-1.

• The flue system conforms to the

relevant requirements of The Building Regulations Approved Document J for solid fuel appliances.

Figure 10-1: Draught stabiliser

10.2.6 Combustion Ventilation

Check that the combustion air supply conforms to the relevant requirements of The Building Regulations Approved Document J, for solid fuel appliances with a draught stabiliser. Refer to Section 7.1.

10.3 Boiler

10.3.1 Control Panel

Isolate the electrical power to the hopper and boiler.

Unscrew and remove the six self tapping screws securing the boiler control panel cover and lift the cover off the control panel.

Check the following:

• That both the overheat thermostat probe and thermistor bulb are fully inserted in the boiler waterway pocket, and the retaining clip is fitted. Refer to Figure 10-2.

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

Refit the control panel cover and secure with the six screws previously removed.

Figure 10-2: Boiler control panel (cover removed)

10.3.2 Combustion Chamber

Fit removable handle into slot in door catch.

Lift handle to disengage catch.

Open front access cleaning door.

Check ash pan is empty and correctly positioned on base of combustion chamber.

Close the front access cleaning door and ensure that door catch is fully engaged (to activate door cut-out switch).

Remove handle and keep in safe place for future use.

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Test the automatic cleaning functions as follows:

• Set the ON/STANDBY switch to STANDBY.

• Switch on the electrical supply to the hopper and boiler. The burner fan should briefly run.

10.4 Pellet Hopper

Check the pellet feed auger is fully inserted into the pellet hopper and secured with the single screw through the auger fixing flange. Refer to Figure 10-4. Do NOT fill hopper with pellets

until AFTER the auger is fitted and secured.

Figure 10-3: Front and rear access

covers

10.3.3 Heat Exchangers

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

To gain access to the top of both heat exchangers:

• Remove the boiler top casing panel.

• Unscrew and remove the two nuts (and washers) securing the front access cover and remove it from the primary heat exchanger. Figure 10-3.

• Unscrew and remove the two nuts (and washers) securing the rear access cover and remove it from the secondary (condensing) heat exchanger. The wash system manifold is attached to a length of flexible hose and does not need to be detached to lift.

• Check that the spiral baffles in the primary heat exchanger are all in place. Lift and drop each one to check all are free to move in their respective tubes.

• Check that the spiral baffles in the secondary heat exchanger are all in place and are all aligned with the top edges running ‘front to back’.

Secondary Heat Exchanger

• Check the two jet sprays are not blocked.

• Refit the rear access cover only and secure with the nuts (and washers) previously removed. Do not over tighten.

• Turn on the cold water supply to the wash system.

WARNING

Ensure that fingers are clear of all moving parts inside the top of the primary heat exchanger BEFORE operating ‘CLEANING TEST’ switch.

• Press and hold down the ‘CLEANING’ switch, on the boiler control panel, in the ‘TEST’ position.

• Release switch to automatically reset cleaning function back to ‘AUTO’.

• Note that setting this switch to ‘TEST’ does NOT operate the burner cleaning function, but only that of the two heat exchangers.

Primary Heat Exchanger

• Check the shaker unit (located in the top of the primary heat exchanger) is operating freely and that the spirals are moving up and down with two intermittent vertical motions.

• Refit the front access cover and secure with the nuts (and washers) previously removed. Do not over tighten.

Figure 10-4: Auger fixing

WARNING

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

Ensure that only pellets that comply with EN Plus Grade A1 standard, to BS EN 17225-2:2014, are used with the Grant Spira boiler. Refer to Section 3.

Fill the hopper with pellets either:

• By hand from bags, or

• Automatically from a bulk pellet store, via a bulk auger or Grant SpiraVac vacuum pellet feed system.

When using a Grant SpiraVac system, refer to the Installation instructions supplied with the Grant SpiraVac vacuum pellet feed system.

10.5 Safety Device Checks

WARNING

This procedure involves disconnecting a live mains connection. Do NOT insert any item into the opening of the moulded cap on the end of the thermostat lead.

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Figure 10-5: Location of thermostat

10.5.1 Pellet Feed Tube Thermostat When the burner display reads ‘WAIT BOILER THERMOSTAT’ check the

operation of the pellet feed tube (‘burnback’) thermostat as follows:

• Remove the red burner cover by loosening the four M5 screws (two on each side of the cover) and lifting it off the burner.

• The thermostat is located on the pellet feed tube. Refer to Figure 10-5.

• Disconnect the lead from the thermostat terminals. Refer to Figure 10-6.

The burner display screen should automatically go blank, as all power to the burner has been interrupted.

To make the burner operational again:

• Re-connect the lead.

• Refit the burner cover and tighten the four fixing screws.

Figure 10-7: Combustion door catch

• The burner display screen should automatically go blank, as all power to the burner has been interrupted.

To restart the display; close the door and fully engage the door catch to re-make the cut-out switch. Refer to Figure 10-7.

Closing the door will reconnect the power supply to the burner and the display will return, confirming that the door interlock is operating correctly.

Remove handle and keep in a safe place for future use.

WARNING

The interlock on the combustion chamber door interrupts the power supply to the burner if the door is opened. IT DOES NOT IMMEDIATELY EXTINGUISH THE BURNER FLAME. If the burner door is opened whilst the burner is firing, there can still be a large uncontrolled flame from the brazier.

control panel. Refer to Section 1.1 for required flow and return temperatures.

10.7 Priming the Pellet Feed Auger

The pellet feed auger MUST be fully primed BEFORE attempting to start the boiler.

Prime the auger as follows:

• Disconnect the 6-way plug (No.3), from the pellet feed auger, from the upper socket on the left side of the burner. Refer to Figure 10-8.

Figure 10-8: Pellet feed auger plug (3)

• Disconnect the 7-way plug (No.1) from the socket on the left side of the burner. Refer to Figure 10-8.

• Disconnect the pellet delivery hose from the pellet feed tube (on the burner) and place in a container of at least 1 litre capacity. Refer to Figure 10-9.

Figure 10-6: Removal of thermostat

lead

10.5.2 Combustion Chamber Door Switch When the burner display reads ‘WAIT BOILER THERMOSTAT’ check the

operation of the combustion chamber door interlock as follows:

• The interlock is activated by opening the combustion chamber door.

• Fit removable door handle into slot in door catch. Lift handle to disengage catch and open the door.

10.6 Burner Settings

The boiler comes with the burner pre-set from the factory. However, the burner settings should be checked as part of the commissioning process and recorded on the Commissioning Report form. Refer to Section 10-12.

With the electrical power to the hopper and boiler Switched on, and the burner ON/STANDBY switch set to STANDBY, check that ALL burner settings in the ‘INSTAL’ (Installer) menu are as given in Section 9.6.

Refer to Section 9.7 for details of how to access and check these settings.

Set the boiler temperature set point using buttons 1 or 2 on the burner

Figure 10-9: Pellet delivery hose

• Insert the 6-way plug into the 7-way plug. Refer to Figure 10-10. It is not possible to connect these two plugs incorrectly as they will only fit together one way. The feed pellet feed auger will now run continuously until the plug and socket is disconnected.

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Figure 10-10: Connection of the two plugs

• Leave the auger running until there is a continuous flow of pellets from the pellet delivery hose. This will take between 15 to 20 minutes.

• Disconnect the two plugs from each other and the auger will stop. The pellet feed auger is now fully primed.

• Refit the pellet delivery hose onto the pellet feed tube of the burner.

• 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 draught through the boiler resulting in the pellet tube (burn back) thermostat operating and shutting down the burner.

• Finally, re-fit both the 6-way and then 7-way plugs to their corresponding sockets on the left side of the burner. Ensure that both plugs are fully pushed home until the small catch clicks into place. Refer to Figure 10-8.

WARNING

Ensure the pellet delivery hose forms an air tight seal each end and that the hose is not damaged. Leakage of air could cause increased temperature in the pellet delivery hose and result in the pellet tube thermostat shutting down the burner.

10.8 Lighting the Boiler

Ensure that the electrical supply to the hopper and boiler is switched on connected and that the heating system controls are operating and are calling for heat.

NOTE

If the boiler ON/STANDBY switch is set to STANDBY during the initial pellet pre-load period, the pellet feed will stop. The burner will then complete the shut-down sequence before it can start-up again, even if the ON/STANDBY switch is reset to ON.

If the ON/STANDBY switch is set to STANDBY during the start-up sequence, but AFTER the pre-load is finished, then the burner will immediately enter and complete the shut-down sequence before it can start-up again, even if the ON/ STANDBY switch is reset to ON.

Set the burner ON/STANDBY switch to ON. The flue fan will start and pellets will be delivered to the burner.

Refer to Section 9.1 for details of the burner start-up, running and shut down sequences.

After completing the start-up sequence, the burner should be firing at maximum output and the display on the burner control shows ‘BURNER FIRING 100%’.

10.9 Combustion Chamber Draught

10.9.1 Draught Measurement

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

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

• Ensure the burner display is showing ‘BURNER FIRING 100%’.

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

• After setting the zero on the draught gauge, insert the end of the draught gauge sample tube into the test point on the door. Ensure that it is pushed through the door insulation and into the combustion chamber.

• A draught reading of between 0.1 and 0.15mbar is required (0.04 and

0.06 in.wg).

Figure 10-11: Draught test point

10.9.2 Draught Stabiliser Adjustment

The combustion chamber draught should be between of 0.1 to 0.15mbar (0.04 and 0.06 in.wg) with the boiler firing at maximum output (i.e. the burner display is showing ‘BURNER FIRING 100%’).

To adjust the combustion chamber draught reading, slacken the grub screw re-position the weight on the stabiliser door arm as follows:

• To increase draught – move the weight away from the damper (or add extra weights if necessary – see below).

• To decrease draught –move the weight closer to the damper. Refer to Figure 10-12.

If it is necessary to increase the draught, but the weight fitted is already at the end of the damper arm, extra slotted disc weights (supplied with the boiler) can be used.

These weights are fitted on the ‘flue end’ of the damper arm, as follows:

• Slacken the grub screw and slide the fitted weight along the arm towards the damper.

• Fit one of the slotted weights onto the arm.

• Secure by inserting a flat bladed screwdriver into the slot and twisting it. Refer to Figure 10-12.

• Slide both the weights to the end of the shaft and secure by tightening the grub screw in the fitted weight. Refer to Figure 10-13.

Repeat this process as necessary to achieve the required draught.

NOTE

Ensure that the grub screw is tightened to secure the weight(s) to the shaft after adjusting the draught.

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Figure 10-12: Draught stabiliser arm

Check the draught and, if required, adjust the position of the weight to achieve a draught within the required range of 0.1 to 0.15mbar (0.04 and 0.06 in.wg).

It may be necessary to make further adjustments to both the position of the slider arm and the draught stabiliser weight until the correct draught of between 0.1 to 0.15mbar is achieved with the minimum opening of the draught stabiliser door.

Secure the slider arm to the fan box by re-fitting the screw previously removed from the slider arm.

10.10 Flue Gas Analysis

Check the %CO2 in the flue gases at maximum output as follows:

• Ensure the burner display is showing ‘BURNER FIRING 100%’.

• Remove the screw from the combustion test point, located at the left rear corner of the rear access cover (on the secondary heat exchanger). Refer to Figure 10-16.

Figure 10-13: Fitting slotted disc weight

10.9.3 Fan Box Slider Adjustment

In order to minimise the possibility of tar-like deposits forming in the fan box and flue, it is important to reduce the opening of the draught stabiliser door to a minimum.

If, after setting the draught (as described in section 10.9.2), the gap between lowest point of the door and the draught stabiliser opening is more than 10mm, it will be necessary to use the fan box slider plate.

Remove the screw from the slider plate arm. Refer to Figure 10-14. Slowly pull out the slider plate arm (to open the slider plate) until the draft stabiliser door is almost fully closed, i.e. there is only a gap of around 5mm between the lowest point of the door and the draught stabiliser opening.

Figure 10-14: Draught stabiliser weights

Figure 10-15: Fan box slider plate

Figure 10-16: Combustion test point

NOTE

The combustion test point in the flue inspection pipe must NOT be used to monitor and adjust the %CO2 when commissioning the Spira boiler. Only use the combustion test point at the left rear of the rear access cover (on the secondary heat exchanger) for this purpose.

• Insert the analyser probe a minimum of 100mm into the test point.

• Monitor the %CO minutes to see the maximum and minimum values reached.

• The %CO between a maximum of 12% and a minimum of 10%. If necessary the %CO to be adjusted to be within these limits, as follows:

• Access the ‘INSTAL’ (Installer) menu in the burner control settings and go to the ‘SETUP FAN’ sub menu.

• Go to the ‘POWER MAXIMUM’ value and adjust the burner fan speed using buttons 5 and 6 on the burner control panel. Refer to Section 9.4.

• To decrease the %CO the fan speed using button 6.

for a few

measured should range

may have

– increase

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• To increase the %CO the fan speed using button 5.

• To confirm the change in the ‘POWER MAXIMUM’ fan setting, press button 4 twice, to exit the ‘SETUP FAN’ and ‘INSTAL’ menus and return to the normal control panel display (showing H2o and SET temperature).

• Monitor the %CO minutes to see if the maximum and minimum values are 12% and 10% as required.

• If necessary make a further adjustment of the fan speed and check the resulting %CO described above, until it remains within the required maximum and minimum limits.

• Record the maximum and minimum CO Commissioning Report form. Refer to Section 10.12.

It is essential to continue to monitor the combustion chamber draught, whist adjusting the CO gases, and to adjust the draught stabiliser to keep it within the required limits. Refer to Section

10.9.

On double boiler installations, the above process – as covered in Sections 10.3 to 10.10 – must be fully carried out on BOTH boilers.

NOTE

– decrease

for a few

values on the

in the flue

10.11 Customer Handover

The customer/user must be informed of the correct operation and use of their Grant Spira wood pellet boiler installation. This must include the following information:

• The use of the boiler controls – how to switch the boiler off and on, as required. Refer customer to the User Instructions supplied with the boiler/s. The use of the heating system controls – how to set the programmer, room and cylinder thermostats, etc.

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

• The need to routinely check the pellet level in the pellet hopper and how to re-fill it (hopper only installations)

• The need to routinely check the pellet level in the bulk pellet store (bulk pellet store installations only). The customer must also be made aware that is can take several days or longer, depending on the time of year, before the store can be re-filled.

• How to turn the boiler off and back on (bulk pellet store installations only) prior/after a bulk delivery.

• How to access the ash pan and the need to periodically empty the ash pan. Refer to Section 1.5 and the User instructions.

• The need to have the boiler serviced either annually or when ‘SERVICE’ is shown on the burner control panel display (whichever comes first). Refer to Section 1.5 and User Instructions.

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

10.12 Commissioning Report

Form

The Commissioning Report form (supplied with the boiler) must be completed at the end of the commissioning process. Refer to Section 4.15.

For a double boiler installation, a commissioning form must be completed for each of the two boilers.

The following information must be entered on the form:

• Boiler details (model, serial

number, etc.)

• Combustion readings

• Installation details

• Burner settings

• Customer handover details

The completed form must be signed by both installer and customer/user.

A copy of the completed form must be left with the customer/user, one must be returned to Grant UK and the remaining third copy retained by the Installer. Refer to Section 4-15.

10.13 Commissioning Check List

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

Preliminary Inspection Tick box

Heating system 

Electrical connections 

Condensate disposal 

Flue system 

Combustion ventilation 

Boiler

Control panel 

Combustion chamber 

Heat exchanger – primary 

Heat exchanger – secondary 

Pellet Hopper

Auger 

Pellets 

Safety Device Checks

Pellet feed tube thermostat 

Combustion chamber door switch 

Priming Pellet Feed Auger 

Lighting the Boiler 

Combustion Chamber Draught 

Flue Gas Analysis 

Customer Handover 

Commissioning Report Form 

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11 Servicing

11.1 General

It is essential that the Grant Spira boiler is serviced at regular intervals of no longer than 12 months OR when the ‘SERVICE’ is shown on the burner control panel display.

The burner will automatically indicate ‘SERVICE’ on the burner control panel display once the pre-set period of pellet feed auger run time (‘HOURS SERVICE’) is achieved. Refer to Section

9.7 for details on how to access and check this setting in the ‘INSTAL CLEAN’ sub-menu of the burner settings.

This interval is based on the auger running time, i.e. the actual quantity of pellets used based on the pellet feed auger rate and pellet delivery settings. Refer to Section 9.7 for details on how to access and check this setting in the ‘POWER PELLET’ sub-menu of the burner settings.

Servicing and replacement of parts must only be carried out by a Grant trained installer who has successfully completed the Grant Spira wood pellet boiler training course.

display before proceeding further.

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

• Disconnect the 5-way plug (on the lead from the hopper) from the socket at the left rear of the boiler. Refer to Figure 11-1.

Figure 11-1: Disconnecting hopper 5-way plug

• If a double boiler installation, remove the 5-way plug from both boilers.

• Disconnect the 5-way plug (on the lead from the flue fan and solenoid) from the socket at the right rear of the boiler. Refer to Figure 11-2.

11.3 Heating System

Check the boiler for any indication of leaks from:

• Flow and return connections

• Automatic air vent (at rear of boiler)

• Drain cock (at lower rear of boiler)

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

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

• System pressure

• Pressure relief valve operation

• Expansion vessel air charge pressure (when the system pressure is zero)

Re-fill and vent the system to the required pressure. Refer to Section 6.

On either sealed or open-vented systems:

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

• Ensure that adequate corrosion protection is present in system.

WARNING

Before starting any work on the boiler, or on the pellet storage and supply installation, please read the health and safety information in Section 14.

NOTE

Details of every service should be entered in the Service log in the User Instructions supplied with the boiler.

11.2 Checks Before Servicing

BEFORE starting any service work on the boiler or pellet storage/supply installation:

• Set the ON/STANDBY switch, on the boiler control panel, to STANDBY. If the boiler was operating, wait for it to shut-down and ‘WAIT BOILER THERMOSTAT’ is shown on the burner control panel

Figure 11-2: Disconnecting fan/ solenoid 5-way plug

• Disconnect the 4-way plug from the socket (on the flying lead) at the rear of the hopper.

This will allow the hopper to be moved to give easy access to the rear of the boiler for servicing.

Page 75

11.4 Flue System

11.4.1 Flue Terminal

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

11.4.2 Inspection Pipe (product code: WPB/IP - supplied with boiler)

Undo and remove the two screws and remove the outer cover plate.

To remove the inspection hatch, turn the knurled knob (in the centre of the hatch) approximately one turn anticlockwise and pull the hatch out of the flue. Refer to Figure 11-3.

Inspect inside flue. Clean inside and remove ALL ash deposits by sweeping as required.

Replace the hatch and outer cover plate using the reserve procedure.

CAUTION

When cleaning the fan blades ensure they are all thoroughly cleaned. Uneven cleaning will result in the fan being ‘out of balance’ and could cause damage to the fan motor.

Figure 11-5: Flue fan

WARNING

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.

11.6 Boiler

11.6.1 Control Panel

WARNING

Ensure the electrical supply to the hopper and boiler is isolated before proceeding.

Unscrew and remove the six self tapping screws securing the boiler control panel cover and lift the cover off the control panel.

Proceed as follows:

• Check both the overheat thermostat probe and thermistor bulb are fully inserted in the boiler waterway pocket, and the retaining clip is fitted. Refer to Figure 11-6.

Figure 11-3: Inspection pipe

11.4.3 Draught Stabiliser

Check draught stabiliser damper is free to move. Remove draught stabiliser from fan box and clean if required. Refer to Figure 11-4.

Figure 11-4: Draught stabiliser

Re-fit draught stabiliser to fan box and check damper is free to move.

Draught stabiliser setting must be checked when boiler is operational. Refer to Section 10.9.

11.4.4 Flue Fan

Unscrew the four screws securing the flue fan to the fan box and remove the fan. Thoroughly clean ALL ash deposits from the fan blades and mounting plate. Refer to Figure 11-5.

This may require the removal of the fan impeller from the motor shaft. The nut securing the impeller to the shaft has a LEFT HAND thread and must be undone by turning CLOCKWISE. When re-fitting impeller, turn the nut ANTICLOCKWISE TO TIGHTEN.

11.5 Combustion Ventilation

Check that the combustion air supply conforms to the relevant requirements of The Building Regulations Approved Document J, for solid fuel appliances with a draught stabiliser. Refer to Section 7.1.

Check that all ventilation openings are free from any obstructions, both inside and outside. If necessary remove any blockages (e.g. fluff, dog hair, leaves, etc.).

Figure 11-6: Boiler control panel (cover removed)

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

• Grease the edge of the shaker motor cam with high temperature grease. Refer to Figure 11-7.

• Refit the control panel cover and secure with the six screws previously removed.

Figure 11-7: Cross-section of shaker motor cam location (covers omitted for clarity)

Page 76

11.6.2 Heat exchangers

Shut off the cold water supply to the wash system.

To gain access to the top of both heat exchangers. (Refer to Figure 11-8):

Figure 11-8: Top of heat exchangers

• Remove the boiler top casing panel.

• Unscrew and remove the two nuts (and washers) securing the front access panel and remove it from the top of the primary heat exchanger.

• Unscrew and remove the two nuts (and washers) securing the rear access cover and remove it from top of the secondary (condensing) heat exchanger.

Primary heat exchanger – clean as follows:

• Remove all of the mild steel spiral baffles by lifting them vertically up and out from the primary heat exchanger tubes.

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

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

• Clean and check condition of all spiral baffles.

• Re-fit spiral baffles into heat exchanger tubes, fitting them through shaker plates.

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

Secondary heat exchanger – clean as follows:

• Disconnect the flexible hose from the wash system manifold.

• Check and clean (if required) the two wash system jets.

• Remove all of the stainless steel Spiral baffles from the secondary heat exchanger tubes.

• Clean all ash deposits from top chamber of secondary heat exchanger (above tubes) and from rear flue gas duct (at rear of secondary heat exchanger) using brush and vacuum.

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

• Ensure that ALL ash deposits are removed from base of rear flue gas duct.

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

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

Figure 11-9: Spiral baffles

• Check the two wash system spray jets on the underside of the rear access panel are not blocked.

• Inspect the condition of the REAR access panel before re-fitting. Replace any damaged or worn rope seals if necessary

• Re-fit REAR access panel and secure with the nuts (and washers) previously removed. Do not overtighten.

• Ensure that the rear access panel is fitted with the flue gas sample point in the rear left-hand corner.

• Reconnect the flexible hose.

• Turn on the cold water supply to the wash system.

• Check the operation of the automatic cleaning of the heat exchanger. Refer to Section 10.3.3.

11.6.3 Combustion Chamber

WARNING

Ensure the electrical supply to the hopper and boiler is isolated before proceeding.

Disconnect the pellet delivery hose from the burner pellet feed tube. Fully open the combustion chamber door on the front of the boiler and clean as follows:

• Clean the underside of upper rear section of the primary heat exchanger (at the rear of combustion chamber).

• Remove the ash pan and dispose of the ash in a safe manner.

WARNING

Ensure ash has cooled before removing ash pan. Extreme care is required when emptying the ash pan as smouldering ash could be present and cause serious damage to persons or property.

• Clean down the combustion chamber side, back and base surfaces, removing all ash deposits.

• Clean any ash deposits from the top of the burner hood and the inner face of the combustion chamber door.

• Clean out the burner brazier to remove as much loose ash as possible using a vacuum.

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

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

Page 77

11.7 Burner Brazier

WARNING

Ensure that electrical supply to the hopper and boiler is isolated before proceeding.

11.7.1 Removal of Burner

To clean the burner thoroughly it will be necessary to remove it from the boiler, as follows:

• Disconnect the three plugs from the left side of the burner. Refer to Figure 11-10.

Figure 11-10: Burner plugs

• Remove the red burner cover by loosening the four M5 screws (two each side of the cover) and lift it off the burner.

• Whilst supporting the burner, unscrew and remove the two M8 burner securing nuts, one on each side of the burner.

• Carefully withdraw the burner from the combustion chamber door taking care not to damage the burner door gasket.

• Place the burner on a suitable bench (e.g. portable ‘workmate’ type bench or similar) to work on.

11.7.2 Cleaning Burner Brazier

Dismantle and clean the burner as follows:

• Remove the burner hood by loosening the two M5 bolts (highlighted below) each side of the brazier. Slide the hood forwards and then up to disengage the hood from the burner. Refer to Figure 11-11.

Figure 11-11: Removal of burner hood

• Clean and inspect the hood for any damage or distortion. Replace if necessary. Remove all ash deposits and check that all air holes (on the inside surface of the hood) are clear. Open the brazier manually by operating the release switch on the servo motor and carefully pulling on the end wall of the brazier.

WARNING

After a period of time in use, the semi circular 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.

• To operate the switch and release the motor, press and hold the switch down. Refer to Figure 11-12.

Failure to operate the servo motor release switch WILL result in damage to the servo motor gears.

Figure 11-12: Manual opening of

brazier

DO NOT ATTEMPT TO FORCE THE BRAZIER OPEN WITHOUT OPERATING THE SERVO MOTOR RELEASE SWITCH.

• With the brazier open, dismantle the brazier to thoroughly clean all parts as follows, referring to Figure 13-2:

• Unscrew and remove the upper two M6 nuts and washers on either side of the brazier chassis, securing the two brazier flame plates.

• Remove the four M6 screws from the inside of the brazier.

• Unscrew and remove the two M6 screws securing the photocell back plate to the burner.

• Remove both the two brazier flame plates and photocell back plate from brazier.

• Unscrew and remove the two M6 nuts and washers on either side of the brazier chassis securing the 3-sided grate enclosure

• Remove the four M6 screws from inside the brazier and remove the grate enclosure.

• Unscrew and remove the two M6 screws and washers (one each side of the brazier chassis) securing the ignition element mounting plate, and remove it from the brazier chassis.

• From below the burner, unscrew and remove the single cap screw attaching the push rod of the moveable brazier base to the shaft of the servo motor.

• Disengage the push rod from the motor shaft and remove brazier base assembly from the brazier chassis.

Inspect all components for distortion or damage and replace if necessary.

Clean all ash and clinker deposits from all surfaces (in particular the upper surface of the brazier chassis and the underside of the brazier base assembly) using wire bush and, where necessary, a flat scraper.

Ensure that all air holes are clear.

Page 78

Reassemble the brazier using the following procedure:

• Fit the moveable brazier base assembly to the burner and reconnect the pushrod to the motor shaft using the cap screw.

• Whilst operating the servo motor release switch, push the brazier base assembly fully back into the brazier chassis.

• Insert the brazier clearance gauge plate (supplied with the boiler) between the brazier chassis and brazier base assembly. Refer to Figure 11-13.

Figure 11-13: Fitting brazier clearance gauge

• The clearance gauge should slide in using manual force only. DO

NOT FORCE THE GAUGE INTO THE BRAZIER!

• Reassemble the remainder of the brazier, using the reverse of the dismantling procedure.

• Leave all screws loose until all components (excluding the burner hood) are assembled correctly.

• BEFORE fitting the burner hood, tighten the two screws securing the photocell back plate to the front of the burner.

• Fit the burner hood and then finally tighten all remaining burner fixings.

• Remove brazier clearance gauge from burner brazier.

• Operate servo motor release switch and manually open and close brazier to check it is free to move.

Figure 11-16: Ignition element

11.8 Burner Components

11.8.1 Burner Fan

Check the burner fan inlet is clear of debris.

If there is a build-up of debris remove fan from burner and clean the fan blades and fan housing. Refer to Figure 11-14 and 11-15.

Figure 11-14: Burner fan, photocell and ignition element (5-18kW model shown with air restrictor plate)

Figure 11-15: Burner fan, photocell and ignition element (6-26 and 9-36kW models)

11.8.2 Ignition Element

Remove and check the condition of the ceramic heating element. Replace if damaged.

To remove the element from the tube, grasp the black grommet and pull out of the tube. Do NOT pull on the element power cable.

Unscrew and remove the single screw securing the ignition element tube and pull it out of the burner.

Check the condition and thoroughly clean the inside of the tube. Replace the tube in the burner and secure with the screw.

Check that the ceramic element is correctly fitted into the ceramic socket.

Replace the ignition element in the tube, ensuring that the element is correctly positioned inside the tube, i.e. with a distance of 127mm between the grommet flange and the ceramic socket. Refer to Figure 11-16.

11.8.3 Photocell

Remove photocell from mount. Check and clean the photocell. Replace if damaged.

Remove the two screws securing the photocell mount and pull out the photocell tube. Check the condition and thoroughly clean the inside of the tube. Refit tube to burner.

Ensure the photocell clamp is fitted 25mm from end as shown in Figure 11-17. Refit into photocell mount.

Figure 11-17: Photocell clamp position

11.8.4 Pellet Feed Tube

Unscrew the three fixing screws and remove the feed pipe and gasket from the top of the burner.

Check the condition of the gasket and replace if necessary.

Check the condition of the feed tube and thoroughly clean the inside.

Check that the pellet feed tube thermostat is correctly mounted on the side of the tube.

Replace on burner, ensuring gasket is correctly fitted, and secure with the three screws.

Page 79

11.9 Refitting the Burner

Before re-fitting the burner, check the condition of the burner door gasket. Replace if necessary.

• With the gasket correctly located, re-fit the burner to the combustion chamber door.

• Carefully insert the burner brazier through the opening and locate the holes in the burner flange onto the M8 studs (on either side of the burner).

• Secure the burner to the door with the two M8 nuts previously removed.

• Re-connect the three plugs to their corresponding sockets on the left side of the burner. Ensure that each plug is fully pushed home until the small catch clicks into place. Refer to Figure 11-10.

• Check the condition of the pellet delivery hose and ensure it forms an air tight seal each end.

• Check for any damage to the hose and replace if necessary. A damaged pellet delivery hose can allow a back draught through the boiler, resulting in the pellet tube (burn-back) thermostat operating and shutting down the burner.

• After completing the Safety Device Checks (refer to Section 11.13), re-fit the burner cover and tighten the four screws to secure in place.

11.10 Condensate Disposal System

11.10.1 Condensate Trap

Disconnect the condensate disposal system from the outlet at the back of the boiler. Check that the boiler condensate outlet is clear. Remove any blockage or ash build-up.

Remove the condensate trap (supplied with the boiler) from the condensate disposal system. Dismantle and check the condition of the trap.

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

Reconnect the disposal system to boiler outlet.

NOTE

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

11.10.2 Condensate Disposal Pipe

Check entire length of discharge pipe, for any leaks or blockages. Clean or replace as necessary.

Check any other traps in the condensate disposal pipework. Dismantle and thoroughly clean to remove any deposits. Re-fit to condensate disposal system pipework.

Check that any outlets to a gully or hopper are not obstructed. Remove any blockages.

11.10.3 Condensate Pump (if fitted)

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

• The condition of the holding tank. Thoroughly clean to remove any deposits.

• Operation of the overflow cut-out float switch.

• The pump is operating correctly.

11.11 Cleaning Function Test

Test the automatic heat exchanger cleaning functions as follows:

• Check the ON/STANDBY switch, on the boiler control panel, is set to STANDBY.

• Re-connect the 5-way plug (on the lead from the hopper) to the socket at the left rear of the boiler. Refer to Figure 11-1.

• If a double boiler installation, re-connect the 5-way plugs to both boilers.

• Re-connect the 4-way plug to the socket (on the flying lead) at the rear of the hopper.

• Replace the fuse in the 13A fused spur and switch on the electrical supply to the hopper and boiler.

The burner fan should briefly run.

• Press and hold down the ‘CLEANING TEST’ switch on the boiler control panel for about 60 seconds.

WARNING

Ensure that fingers are clear of all moving parts inside the top of the primary heat exchanger BEFORE operating ‘CLEANING TEST’ switch.

• To end test of cleaning functions

- release switch to automatically reset cleaning function back to

‘AUTO’.

NOTE

Note that setting this switch to ‘TEST’ does NOT operate the burner brazier cleaning function, but only that for the two heat exchangers.

Page 80

Primary heat exchanger

Check the shaker unit (located in the top of the primary heat exchanger) is operating freely and that the spirals are moving up and down with two intermittent vertical motions.

If there is no movement of the shaker system, isolate the electrical supply and check that:

• the motor and cam is rotating.

• the cam follower is in contact with the cam.

• the condition of the cam follower spring (located in the rear of the control panel). Replace if necessary.

Inspect the condition of the FRONT access panel before re-fitting. Replace any damaged or worn rope seals if necessary.

Re-fit FRONT access panel and secure with the nuts (and washers) previously removed. Do not overtighten.

11.12 Burner Settings

Check the burner control settings match those set on commissioning (i.e. as recorded on the Commissioning Report form), a copy of which was left with the householder/user.

Refer to Section 9.7 for details of how to access and check these settings.

Reset the SERVICE timer as follows:

• Go to the ‘CLEAN’ sub menu in the installer (‘INSTAL’) menu

• Go to the ‘RESET SERVICE’ setting.

• Press button 3 to reset timer to zero.

Refer to Section 9.7.1.3 for further details on settings.

11.13 Safety Device Checks

The following safety checks must be made before putting the boiler back into operation:

11.13.1 Pellet Feed Tube Thermostat

Check operation of pellet feed tube thermostat. Follow the procedure given in Section 10.5.1.

11.13.2 Combustion Chamber Door Switch

Check operation of combustion chamber door switch. Follow the procedure given in Section 10.5.2.

11.14 Combustion Checks

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

11.14.1 Combustion Chamber Draught

Check the combustion chamber draught, and adjust the draught stabiliser setting as required. Follow the procedure given in Section 10.9.

11.14.2 Flue Gas Analysis

Check the %CO and adjust the burner fan setting as required. Follow the procedure given in Section 10.10.

To ensure safe and efficient operation of the boiler it is important that boiler/burner is re-commissioning as detailed in Section 10.

in the flue gases

WARNING

Page 81

12 Fault Finding

12.1 General

If a fault occurs with the boiler, the display screen on the burner control panel helps to identify the nature and cause of that fault.

There are THREE basic screen displays that can be seen in the event of a fault, as follows:

• Normal screen display (with ‘WAIT BOILER THERMOSTAT’ continuously scrolling across the lower part of the screen). Refer to Figure 12-1. If this is the case go to Section

12.2 for fault finding procedure.

• No display – screen is BLANK. Refer to Figure 12-2. If this is the case go to Section

12.3 for fault finding procedure.

• An ERROR message is displayed. If this is the case refer to ‘Error Messages’ below.

It is essential, at this stage, to check and identify which of these three displays is shown on the burner control panel screen, before proceeding to attempt to diagnose the fault.

Figure 12-1: Normal screen display

Figure 12-2: Blank screen display

Figure 12-3: Error message screen display

H2o 60˚C SET 75˚C

WAIT BOILE

Error Messages

There are FOUR possible error messages that can be displayed on the burner control panel screen in the event of a fault. In all cases the cursor will be next to the error symbol (at the lower left corner of the display). Refer to Figure 12-3.

The four possible error messages that can be displayed (continuously scrolling across the lower part of the screen) are listed below. Each one identifies a particular fault. Refer to the relevant section of this manual for detailed guidance to diagnose and rectify the fault, as follows:

• FAILED PELLET LIGHTING -

Go to Section 12.6

• SERVO MOTOR BLOCKED -

Go to Section 12.7

• PROBE FAULT -

Go to Section 12.8

• AIR PRESSURE ERROR -

Go to Section 12.9

Page 82

12.2 Normal Screen Display - Boiler will not fire – but NO error message is displayed

H2o 60˚C SET 75˚C

WAIT BOILE

WAIT BOILER THERMOSTAT

Primary Fault

Secondary follow on checks

Is the cursor next to the thermostat

symbol on the

burner display?

Note 1 Note 3 Note 4 Note 5

Yes

Is H2o Temp higher than the set point minus

the Delta restart

temperature?

Note 2

Yes

NO FAULT! Boiler is waiting for system temp

to drop

Note 1 - Is the cursor next to the thermostat symbol on the burner display?

When there is a switched live supply to the burner (i.e. when the heating system controls are ‘calling’ and the ON/STANDBY switch is set to ON), the burner screen display shows a cursor highlighted next to the boiler thermostat symbol. Refer to Figure 12-4.

Is the burner

‘ON/STANDBY’

switch set to

‘ON’ position?

Set burner

‘ON/STANDBY’

switch to ‘ON’

Is there a

Yes Yes

sufficient quantity

of pellets in the

pellet hopper?

No No No No No No No

Fill hopper with

correct grade of

pellets

Are the heating

system controls

(Programmer,

Room Stat)

‘CALLING’ for

heat?

Set system

controls to call

for heat

Yes Yes Yes Yes

Is there power

to terminal L2

on 4-way plug

at rear of hopper?

Check the

switched live

supply to hopper/

boiler and rectify

as necessary

terminals T1 and

T2 on burner

Check plug is

correctly fitted

Note 3 - Is there a sufficient quantity of pellets in the pellet hopper?

The effect of insufficient pellets will depend on the type of pellet storage used, as follows:

Using a pellet hopper only – (with toggle switch set to ‘HOPPER ONLY’) if there are insufficient pellets, the hopper contents switch will break the switched live to the boiler, causing ‘WAIT BOILER THERMOSTAT’ to be displayed. Refill the hopper to start the boiler. Refer to Section 1.4.4 for further details.

Using a bulk pellet store – (with toggle switch set to ‘BULK STORE’) the hopper contents switch will control

Figure 12-4: Burner screen display

Note 2 - Is the boiler above set point less the ‘DELTA RESTART’ temperature?

If the boiler has exceeded the ‘TEMP OF H2o’ setting (80°C) the boiler will shut down. The boiler temperature will have to fall to below the set point less the ‘DELTA RESTART’ (5°C below the boiler set point temperature) before it

the operation of either the bulk store auger or Grant SpiraVac system. When used with a bulk store auger it will NOT interrupt the switched live to the boiler and thus ‘WAIT BOILER THERMOSTAT’ will NOT be displayed. The boiler will continue to operate until ALL pellets in the hopper are used and then stop, with ‘FAILED PELLET LIGHTING’ displayed on the burner control screen. In this case, check that:

can start again. Refer to Section 9.1.

Is there

continiuty

between

plug No2?

Is there power

across the

boiler ‘ON/OFF’

switch?

Replace faulty

switch

Is there power

at relay (in boiler

on Terminals 21

and 24 when coil

Replace faulty

• there are pellets in the bulk store

• the bulk store auger, or Grant SpiraVac system, is operating correctly (refer to instructions supplied with the SpiraVac system).

Rectify as necessary. When used with a Grant SpiraVac refer to instructions supplied with unit.

Note 4 - Is there a switched live from the heating system controls connected to the hopper/boiler?

Check that switched live from the controls is correctly connected to terminal L2 on the 4-way plug at the rear of the hopper. Also check that this 4-way plug is fully pushed into the socket on the flying lead, at the rear of the hopper. Refer to Sections 8.4 and

8.5 for further details.

Check that ALL controls (programmer and room thermostats) are ‘calling’ and that there is a 230V output to the boiler.

Note 5 - Is there continuity between terminals T1 and T2 on burner plug No.2?

Disconnect the plug from left side of burner and check for continuity between terminals T1 and T2. Refer to Figure 8-5 for wiring details.

control panel)

is energised?

relay

Page 83

12.3 No Screen Display - Boiler will not fire – blank screen

Primary Fault

Secondary follow on checks

BLANK DISPLAY SCREEN

Is electrical

supply switched

on? Is there power to terminal L1 on 4-way plug

at rear of hopper?

Note 1 Note 3Note 2 Note 4 Note 5

Check electrical

supply to hopper/

boiler

and rectify as

necessary

Note 1 - Is there a permanent mains live supply connected to the hopper/boiler?

Check that the permanent live from the fused spur is correctly connected to terminal L1 on the 4-way plug at the rear of the hopper. Also check that 4-way plug is fully pushed into the socket on the flying lead, at the rear of the hopper. Refer to Sections 8.4 and

8.5 for further details.

Also check that 5-way plug from hopper is fully pushed into the socket at the top left rear of the boiler.

Check that the fused spur is switched ON and, if necessary, check the fuse is OK.

Are all plugs

Yes

correctly fitted?

i.e. the three

burner plugs and

the plug from hopper to the

boiler?

No Yes Yes No No

Correctly fit

all plugs –

push fully into

sockets

Has the boiler

Yes No

overheat stat

tripped?

Unscrew black cover on control panel and check

Go to the ‘BOILER

OVERHEAT

STAT’ fault

finding chart

Has the pellet feed tube stat

tripped? Unclip

and remove lead

from stat and

check

Go to the

‘PELLET FEED

TUBE STAT’ fault finding

chart

No Yes Yes Yes Yes

combustion

chamber door

closed and the

door catch fully

Close door and

fully engage

door catch

Note 2 - Is there a permanent mains live supply connected to the burner?

Check that the two 7-way plugs are fully pushed into the two lower sockets on the left side of the burner.

Also check for permanent live on terminal L1 of burner plug No.1. Refer to Figure 8-5.

Note 3 – Has the boiler overheat thermostat tripped?

Unscrew and remove the black cover from the overheat reset button on the boiler control panel to check if boiler overheat thermostat has tripped. If YES, go to Section 12.4 for further guidance.

Note 4 – Has the pellet feed tube thermostat tripped?

Remove top section of burner cover and disconnect the lead from the pellet feed tube thermostat. Check the reset button to see if thermostat has tripped, if YES, go to Section 12.5 for further guidance.

Is the

engaged?

Is the power

to terminal L1

of burner plug

No.1?

Is door catch

microswitch operational?

Note 5

Replace

faulty door

microswitch?

Check continuity

of burner fuse

on PCB.

Is it OK?

No No

Replace burner

fuse

Is the ribbon

cable fitted

correctly to PCB

and back of

display?

Correctly fit

ribbon cable at

both ends

Replace burner

PCB does

this rectify the

problem?

Correctly fit

ribbon cable at

both ends

Note 5 - Is the combustion chamber door closed and catch fully engaged?

The combustion chamber door is fitted with a safety interlock. Once the door catch is disengaged all power to the burner is interrupted. Refer to Section

10.5.2. Check that catch is FULLY engaged when door is closed.

Note 6 - Is the door microswitch operational?

Check electrical continuity of door micro-switch. Replace if faulty. Refer to Figure 8-5 and 12-5.

Figure 12-5: Location of door microswitch (side panel removed)

Page 84

Note 7 - Is the fuse on the PCB OK?

Remove fuse from holder on PCB and check. Replace if necessary. Fuse type F5AL250V. Refer to Figure 12-6.

Figure 12-6: Location of fuse on PCB

Page 85

12.4 Boiler Overheat Thermostat

BLANK DISPLAY SCREEN

BOILER OVERHEAT STAT TRIPPED

Primary fault

Secondary follow on checks

Is the central

heating system

and boiler full of

water and vented of

any air locks?

Note 1 Note 2 Note 3 Note 4 Note 5

Fill and vent

system

Is the heating

Yes

thermistor correctly

fitted in the pocket

(inside the boiler

control panel)? Unclip and remove lead from stat and

check

Correctly fit

heating thermistor

in pocket and

reset overheat

Is overheat stat

Yes Yes

capillary in good condition and not damaged, kinked

or broken?

No No No No

stat

Press reset.

Is there now

continuity between

the overheat stat

terminals?

Replace faulty

overheat stat

Yes

Is the system

circulating pump

operational?

Replace faulty

circulating pump

Yes

water flow from

restriction to

Is there any

the boiler?

Remove any

Yes

restriction e.g.

open any valves,

or remove

blockage

preventing flow

Page 86

Note 1 - Is heating system and boiler full of water and vented?

The central heating system must be free of any air locks. Ensure auto air vent on secondary heat exchanger (at left rear of the boiler) is open and vented. Vent the primary heat exchanger on the heating flow pipe. If installed on a sealed system: check expansion vessel charge pressure and correct as necessary. Check system pressure and top-up as necessary. Refer to Section 6 for sealed system details.

Note 2 - Is the heating thermistor correctly fitted?

Isolate electrical supply and remove boiler control panel cover. Check that the heating thermistor, and the overheat thermostat sensor, are correctly fitted into the pocket (inside the boiler control panel). Refer to Section 10.3.1. Ensure that both are held in place with the retaining clip supplied.

Also, check the condition of the thermistor and the overheat thermostat capillary for any damage, replace if necessary.

Note 3 - Is there continuity between the overheat thermostat terminals?

With electrical supply isolated, reset the overheat thermostat and check electrical continuity across the terminals. If no continuity found, replace the overheat thermostat.

Note that the thermostat continuity can be checked by removing the 7-way plug (plug No. 1) from the socket on the left of the burner and testing between terminals T1 and T2. Refer to Section 8 and Figure 8-5.

Note 4 - is the circulating pump operational?

With the burner ON/STANDBY switch set to ‘STANDBY’, reconnect the power supply to the boiler and check that the heating system controls are ‘calling’. Set the switch to ON and the pump should be running.

If not check that:

• the pump is vented

• there is power to the pump

• that the pump is not seized/stuck

If pump has failed then replace it.

Note 5 - Is there any restriction to flow from the boiler?

Check that all valves on the heating circuit are open and that there are no blockages.

Rectify as necessary.

Page 87

12.5 Pellet Feed Tube Thermostat

BLANK DISPLAY SCREEN

PELLET FEED TUBE STAT TRIPPED

Primary fault

Secondary follow on checks

When pellet feed

tube has cooled

- does pressing RESET button on stat correct

the fault?

Note 1 Note 3Note 3 Note 4 Note 5 Note 6 Note 7 Note 8

Is the lead correctly

connected?

Is there continiuty

between the

terminals?

Note 2

Replace pellet feed tube stat

Is the pellet

Yes

delivery hose

damaged?

Yes No No No No No No

Replace pellet

delivery hose

Is the room

ventilation adequate?

Note 9 Note 10 Note 10 Note 6 Note 11 Note 11

Is the pellet

No Yes

delivery hose

air tight at both

ends?

Correctly fit

pellet delivery

hose or replace

if necessary

Is the mains water

Yes Yes Yes Yes Yes

supply to boiler

connected and

switched on?

Is the ash pan

overflowing?

Is there a build

up of ash on the combustion chamber baffle?

Clean out the ash

pan and boiler.

Clean all ash from

the combustion

chamber baffle

Is the boiler wash system operating

correctly when

tested (using the

test switch)?

No No No Yes

Is the

combustion

chamber

draught

correct?

Check the

switched live

supply to hopper/

boiler and rectify

as necessary

Is the shaker

cleaning system

operating correctly

when tested (using

the test switch)?

Is the condensate

trap and/or

discharge pipe

blocked or

frozen?

Clean condensate

trap and pipe to

clear blockage

Is the boiler

cleaning interval

correctly set?

Is the flue used

the correct type?

Is it correctly

installed and not

blocked?

Rectify or replace

flue if necessary.

Remove any flue

blockage

Is the duration

of the boiler

cleaning period

correctly set?

Is the flue fan (in flue fan box) operational and

Rectify fan fault

or replace if

Clean fan if

clean?

necessary.

required

No No No No No No

Unblock or

increase

ventilation as

required

Connect the mains water

supply and

switch on

Is solenoid

valve operating

correctly?

Yes

Check that

manifold jets are

clear?

Check operation

of cleaning motor

and shaker

mechanism

In burner menu

reset ‘TIME CLEAN BRAZIER’ and ‘TIME CLEAN

BOILER’ settings

In burner menu

reset ‘TIME CLEAN

PERIOD’ setting

Page 88

Note 1 - Is the fault cleared by pressing the reset button?

Is the pellet feed tube less than 90°C? If not then allow it to cool before proceeding.

When cool, remove the steel retaining clip and disconnect the lead from the pellet feed tube (burn back) thermostat. Press the reset button on the thermostat.

Note 2 - Is feed pipe thermostat (burn back sensor) damaged or faulty?

Check the electrical continuity and condition of the thermostat. Replace if necessary.

Note 3 - Is the pellet delivery hose damaged/correctly fitted?

Check the condition of the hose. Is it damaged? If so replace it.

Is it fitted correctly at both ends – with an air tight fit onto both pellet feed pipe and pellet auger outlet? Rectify as necessary.

A damaged (or incorrectly fitted) pellet delivery hose can allow a back draught through the boiler, resulting in the pellet tube (burn back) thermostat operating and shutting down the burner.

Note 4 - Is the ash pan overflowing?

An overflowing ash pan, and ash build-up on the baffle, can block the passage of the combustion gases from the burner, causing them to backup through the burner into the pellet feed tube. This will activate the pellet feed tube (burn back) thermostat. The ash pan must be periodically emptied, and also any ash build-up on the baffle removed, by the user at MONTHLY intervals for the FIRST THREE MONTHS. After this the ash pan should be emptied, and ash on the baffle removed, regularly, on at least a monthly basis, or as indicated by the amount of ash found during the first three months cleaning. Refer to Section

1.5.

The combustion chamber baffle is no longer fitted to the current versions of the Spira boilers. If fitted, it can be removed from earlier versions when the boiler is serviced. Removal of the baffle will require the combustion chamber draught and flue gas CO2 to be checked and reset as necessary.

Note 5 - Is combustion chamber draught correct?

Check combustion chamber draught. Refer to Section 10.9 for procedure. If it is incorrect, BEFORE making any adjustment to the draught stabiliser, carry out the following checks as per the flow chart:

• Is condensate trap or pipework blocked or frozen? Defrost/remove blockage as necessary.

• Is ash pan overflowing? Empty and clean ash pan as necessary.

• Is the flue system incorrectly installed or blocked? Rectify as necessary.

• Is the flue fan operational?

• Is the room ventilation adequate?

If all the above are OK, then adjust the draught stabiliser as necessary to achieve the required combustion chamber draught. Refer to Section 10.9 for procedure.

Note 6 - Is condensate trap/pipe blocked?

Thoroughly check the entire condensate disposal system, including all the pipework and the trap(s), to ensure that it is not blocked or frozen (even partially).

If the condensate backs-up into the condensing heat exchanger, it can block the passage of the combustion gases from the burner, causing them to back-up through the boiler and burner into the pellet feed tube. This will activate the pellet feed tube (burn back) thermostat.

Note 7 - Is the flue correct type and correctly installed?

Only the Grant ‘Biomass’ flue system can be used with the Grant Spira wood pellet boilers. Check that the flue has been correctly assembled and that the terminal position complies with the requirements of The Building Regulations – Approved Document J. Refer to Sections 7.2 for guidance.

Note 8 - Is flue fan operational and clean?

If the flue fan is not running, or is coated with ash, the draught in the combustion will be reduced causing the combustion gases from the burner to back-up through the burner into the pellet feed tube. This will activate the pellet feed tube (burn back) thermostat.

Note 9 - Is the room ventilation adequate?

Check that sufficient permanent ventilation is present in the room containing the boiler(s). Refer to Section

7.1 for guidance.

Lack of ventilation will lead to incomplete combustion, and an increased temperature in the pellet feed tube that will activate the burn back thermostat.

Note 10 - Is the wash system operating correctly?

Check the water supply to the wash system is connected and turned on. Operate the CLEANING switch and check the solenoid valve is opening and the water jets are all clear. Refer to Section 10.3.3.

In hard water areas an anti-scale device should be fitted on the cold water supply to the wash system to prevent scale build-up in the manifold and jets.

Note 11 - Is the boiler cleaning period correct?

Go to the ‘CLEAN’ sub menu of the burner control settings and check that both ‘TIME CLEAN PERIOD’ and ‘TIME CLEAN BOILER’ are correctly set. If not, re-set to the correct value. Refer to 9.7.1.3.

Page 89

12.6 Failed Pellet Lighting

H2o 60˚C SET 75˚C FAILED PEL

FAILED PELLET LIGHTING

Primary Fault

Secondary follow on checks

Is there a

sucient quantity

of pellets in

the hopper?

Note 1 Note 2 Note 3 Note 5 Note 6 Note 7

Fill hopper with correct grade of

pellets

Is the required lux level being

detected by

photocell?

Note 8 Note 10

Is the pellet

Yes

auger fully

primed?

Fully prime pellet

auger

Yes Yes Yes Yes Yes

Are pellets being

delivered to the

burner?

Is the auger

operating?

Check auger

motor power &

coupling

seYseY

unburnt pellets

in the brazier?

Is hopper outlet

Yes

blocked or full of

Clean out hopper

& re-prime auger

stabilisation time

Are there

dust?

Yes

Is the ame

(45) correct?

Is there clinker

Yes No Yes Yes

in the brazier?

Is the correct

grade of pellets

being used?

Empty hopper & rell with correct

grade pellets

Is the required lux level being

detected by

photocell in

‘LIGHTING CYCLE

REDUCED’ (42)?

Note 11

Is the ignition

operational?

Check power to

Yes

element. Check is

element OK?

Replace element

element

if faulty

Is the

‘TIME LOAD

LIGHTING’ time

4 seconds?

Is the burner

cleaning interval

correctly set?

In burner menu

reset ‘TIME

CLEAN BRAZIER’

& ‘TIME CLEAN

BOILER’ settings

Is the

‘TIME PAUSE

LIGHTING’ time

15 seconds?

Contact GRANT

Is the pellet pre-load time correctly set?

oNoNoNYesoNoN

for advise to

reset pellet pre-load time

Is the

‘TIME LIGHTING CYCLE REDUCED’ time 120 seconds?

No oNoNoNoNoN

Does the

ignition

element on

period

exceed 360

seconds?

No No No No

Contact GRANT for assistance

Is the

Yes Yes Yes

ignition element

operational?

Replace

element if

faulty

Is photocell operational?

Check that

photocell

& tube are

clear

Replace

photocell if

faulty

Is pre-load quantity of

pellets

correct?

9 etoN5 etoN

Contact GRANT for assistance

to set

pre-load

Contact GRANT for assistance

In burner menu

reset ‘TIME

CLEAN BRAZIER’

& ‘TIME CLEAN

BOILER’ settings

Contact GRANT for assistance

Page 90

Note 1 - Is there a sufficient quantity of pellets in the pellet hopper?

The effect of insufficient pellets will depend on the type of pellet storage used, as follows:

Using a pellet hopper only – if there are insufficient pellets, the hopper contents switch will break the switched live to the boiler, causing ‘WAIT BOILER THERMOSTAT’ to be displayed. Refill the hopper to start the boiler. Refer to Section 1.4.4 for further details.

Using a bulk pellet store – the hopper contents switch will control the operation of either the bulk store auger of Grant SpiraVac system. It will NOT interrupt the switched live to the boiler and thus ‘WAIT BOILER THERMOSTAT’ will NOT be displayed.

The boiler would continue to operate until ALL pellets in the hopper are used and then stop, with ‘FAILED PELLET LIGHTING’ displayed on the burner control screen.

In this case, check that:

• there are pellets in the bulk store

• the bulk store auger, or Grant SpiraVac system, is operating correctly (refer to instructions supplied with the SpiraVac system)

Rectify as necessary.

Note 2 - Is the pellet auger fully primed?

Refer to Section 10.7 for procedure to prime the auger.

Note 3 - Is there ‘clinker’ in the burner brazier?

Clinker is the hard deposits of solidified ash, containing sand particles, which the automatic burner cleaning system is unable to remove. Clinker is caused by using unsuitable pellets. See note 4.

If there is no clinker, but brazier is full of unburnt pellets, remove all pellets and clean brazier.

Note 4 - Are the correct pellets being used?

Check the pellets being used. Only EN Plus Grade A1 pellets conforming to BS EN ISO 17225-2 must be used with the Grant UK Spira boilers. Refer to Section

3.1 for detailed pellet specification.

Check the brazier cleaning setting – ‘TIME CLEAN BRAZIER’. Refer to Section 9.7.1.3 for settings.

Note 5 - Is the ignition element operational?

To check, isolate electrical supply and disconnect the two leads from the element cable. Grasp the black grommet and pull the complete element and cable from the tube. Check the condition of the ceramic element and that it is correctly fitted into the ceramic socket. Also check it is correctly positioned inside the tube. Refer to Section 11.8.3 for details.

Check across the two terminals for electrical continuity. Resistance of element ≈89Ω. If no continuity is found, then replace the element.

Note 6 - Is the burner cleaning interval correct?

Go to the ‘CLEAN’ sub menu of the burner control settings and check that

‘TIME CLEAN BRAZIER’ and ‘TIME CLEAN BOILER’ are correctly set.

Refer to 9.7.1.3.

Note 7 - Is the pellet pre-load time correct?

Measure the duration of the pellet pre-load period (i.e. whilst the ‘STEP AUTO’ function is 40 in the ‘VIEW’ menu), at the beginning of the burner lighting sequence. Refer to Section 9.3 for burner operating sequence and also Section 9.7.3 for ‘VIEW’ menu folder. Pre-load should be 65 seconds. If not, contact Grant UK for technical advice on how to adjust the pre-load period.

Note 8 - Is the required LUX level being detected by the photocell?

In the ‘WAIT LIGHTING (IGNITION)’ period of the burner lighting sequence (i.e. whilst the ‘STEP AUTO’ function is 41 in the ‘VIEW’ menu), if the LUX value fails to reach 2 after a time of 360 seconds, then the error message ‘FAILED PELLET LIGHTING’ is displayed. Refer to Section 9.7.3 for procedure to access LUX value in

‘VIEW’ menu.

Note 9 - Is the preload quantity of pellets correct?

When the pre-load operation is complete, the pellets should cover the heating element but not cover the opening at the end of the photocell tube.

Note 10 - Is the flame stabilisation period correct?

The ‘FLAME STABILISATION’ period (i.e. ‘step auto’ function 45 in the ‘VIEW’ menu) is an over-run of the ignition element on period AFTER the 2 lux has been detected. This is factory set at 30 seconds.

Note 11 - Is the required LUX level being detected by the photocell?

In the ‘LIGHTING CYCLE REDUCED’ period of the burner lighting sequence (i.e. whilst the ‘STEP AUTO’ function is 42 in the ‘VIEW’ menu), if the flame drops to or below 1 lux then the error message ‘FAILED PELLET LIGHTING’ is displayed. Refer to Section 9.7.3 for procedure to access LUX value in ‘VIEW’ menu.

Page 91

12.7 Servo Motor Blocked

H2o 60˚C SET 75˚C

SERVO MO

SERVO MOTOR BLOCKED

Primary fault

Secondary follow on checks

Open the

combustion

chamber door.

Is the brazier

blocked up?

Note 1 Note 2 Note 3 Note 4 Note 5 Note 6

Yes

Remove the

blockage and close

the combustion

chamber door

Note 1 - Opening the combustion chamber door.

Before attempting to open the combustion chamber door, set the ON/

STANDBY switch to STANDBY.

Note 2 - Can the brazier be opened manually?

First clear any blockage (clinker/ash) from the brazier. To open the brazier manually, operate the release switch on the servo motor. Refer to Section

11.7.2.

Can the brazier

be opened manually?

No No No No No

Is the brazier

distorted or

damaged?

Yes No

Replace damaged

parts and reset

brazier clearance

Is the brazier

Yes Yes

clearance correctly

set?

Reset brazier

clearance using Grant UK brazier clearance gauge

Note 4 - Is the servo motor operating correctly?

Set the ON/STANDBY switch to STANDBY. Go to the ‘CLEAN’ sub

menu of the burner control settings and set ‘TIME CLEAN BRAZIER’ to 0.

Set the ON/STANDBY switch to ON and start the boiler. When the burner display shows ’100% POWER’ set the ON/STANDBY switch back to STANDBY. When the burner has completed the shut down process the

Is the servo

motor operating

correctly?

Is the servo

motor correctly

set?

Reset servo

motor controls

Yes Yes

Is the boiler

cleaning interval

correctly set?

In burner menu

reset ‘TIME CLEAN BRAZIER’ and ‘TIME CLEAN

BOILER’ settings

Is the duration

of the brazier

cleaning period

correct (4 to 5

minutes in total)?

motor setting or

replace servo

brazier cleaning operation will start

DO NOT FORCE THE BRAZIER OPEN WITHOUT OPERATING THE SERVO MOTOR RELEASE SWITCH OR THE SERVO MOTOR GEARS WILL BE DAMAGED AS A RESULT!

Note 3 - Is the brazier clearance correctly set?

To check the gap between the fixed and moving part of the brazier, use the

automatically. The burner control screen will first show ‘BRAZIER CLEANING FORWARD’ for between 2 to 2½ minutes. Then the burner fan will start and the screen will show ‘BRAZIER CLEANING BACK’ for between a further 2 to 2½ minutes. Thus the total time for the brazier cleaning operation is between 4 to 5 minutes.

brazier clearance gauge (supplied with the boiler). Refer to Section 11.7.2. If it is necessary to dismantle the brazier, the burner must be removed from the combustion chamber door. Refer to Section 11.7.

Adjust servo

motor if

necessary

Ensure ‘TIME CLEAN BRAZIER’ is then reset to its original setting or the brazier cleaning operation will be repeated every time the burner shuts down.

Note 5 - Is the servo motor correctly set?

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

Note 6 - Is the boiler cleaning interval correct?

Go to the ‘CLEAN’ sub menu of the burner control settings and check that

‘TIME CLEAN BRAZIER’ and ‘TIME CLEAN BOILER’ are correctly set.

Refer to 9.7.1.3

Page 92

12.8 Probe Fault

H2o 60˚C SET 75˚C

PROBE FAI

PROBE FAULT

Primary fault

Secondary follow on checks

Are all three

burner plugs

correctly fitted?

Note 1 Note 2 Note 3

Correctly fit

plugs – push

fully into sockets

Is the heating

Yes

thermistor damaged?

Yes No

Replace

thermistor

No Yes

from burner plug/

Is thermistor connected to control PCB?

Check thermistor

connections

socket to control

Notes 1 - Are burner plugs correctly fitted?

Check that all three plugs are fully pushed into sockets on the left side of the burner – in particular plug No.2. Refer to Section 8 and Figure 8-5.

Replace

thermistor

PCB

Note 2 - Is heating thermistor damaged?

Isolate electrical supply to boiler and remove boiler control panel cover. Check the condition of the thermistor for any damage and replace if necessary.

Check that the heating thermistor is correctly fitted into the pocket (inside the boiler control panel). Refer to Section 10.3.1. Ensure that both thermistor and thermostat sensor are held in place with the retaining clip supplied.

Note 3 - Is thermistor connected to burner PCB?

With electrical supply to boiler still isolated, remove both the burner cover and PCB cover. Check the thermistor connections to the PCB – from terminals S3 and B4 on plug/socket No.2. Refer to Section 8 and Figure 8-6.

If fault still exists, replace thermistor.

Page 93

12.9 Air Pressure Error

H2o 60˚C SET 75˚C

AIR PRESS

AIR PRESSURE ERROR

Primary fault

Secondary follow on checks

Reset error by pressing the ‘RESET’ button

on burner control

panel

Restart the

boiler does the

fault occur during

the lighting

sequence?

Note 1 Note 2 Note 3 Note 4 Note 5

No No Yes No No

Is the burner fan

Yes Yes

operational?

Check plug connections between the

burner fan and

control PCB

Is the fan

blocked?

Remove any

blockage or replace

fan if necessary

No Yes

Is air

pressure switch

operational?

Is fan air pressure

tube OK?

Yes

Check operation

of pressure

switch

Is the burner

fan pressure

Replace burner

Is burner

fan pressure

now correct?

correct?

fan.

Replace

control PCB

Page 94

Note 1 - Does fault occur during lighting sequence?

During the ‘PRE-LOAD’ operation, the burner controls check that burner fan is generating enough air pressure to close the air pressure switch. If the pressure switch is not closed during pre-load, then the warning ‘AIR PRESSURE ERROR’ is displayed on the burner screen.

Figure 12-7: Air pressure switch and fan

Note 2 - Is the burner fan operational?

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.

Check that the fan inlet is not blocked and that the fan blades are free to rotate. If necessary, thoroughly clean and remove any dust or debris. If fan still does not rotate freely, replace fan.

Figure 12-8: Checking air pressure from fan

Note 3 - Is the air pressure switch operational?

Check that air supply tube is correctly connected to the pressure switch and not blocked or twisted. Refer to Figure 12-7. Rectify as necessary. Check condition of tube and replace if damaged. Check operation of air pressure switch.

Note 4 - Is fan air pressure tube OK?

Check that the plastic tube from the fan is not twisted, kinked or blocked. Check that it is correctly connected to the both the fan and pressure switch (lower of the two connections on the pressure switch).

Note 5 - Is burner fan pressure correct?

Using a digital manometer (set for positive pressure) check the pressure generated by the burner fan is the minimum of 0.8mbar required to activate the air pressure switch. Refer to Figure 12-8. If fan pressure is incorrect, replace fan.

If correct pressure is still not achieved, replace burner PCB.

Page 95

13 Spare Parts

13.1 Boiler

Figure 13-1: Boiler components – exploded view

Page 96

13.2 Boiler Parts List

Item Description Product code Qt y - 5-18kW Qty - 6-26kW Qty - 9-36kW

1 Rear lower panel WPS34 1 1 1

2 5 way mains connection - male fixed WPS35 1 1 1

3 Rear upper panel WPS36 1 1 1

4 5 way mains connection - female detechable WPS37 1 1 1

5 5 way flue fan / cleaning solenoid connection - male

6 5 way flue fan / cleaning solenoid connection - female fixed WPS39 1 1 1

7 Flue fan sealing gasket WPS40 1 1 1

8 Fan box WPS41 1 1 1

9 Cleaning door sealing gasket - secondary

10 Cleaning door - secondary

11 Flue fan WPS46 1 1 1

12 Air vent MPCBS29 1 1 1

13 Air fold manifold WPS48 1 1 1

14 22mm secondary to primar y pipe

15 Return assembly

17 Draught stabiliser WPS55 1 1 1

18 Fan box/secondary gasket WPS56 1 1 1

19 Secondar y heat exchanger spiral baffle WPS57 30 30 40

20 Cleaning door sealing gasket - primar y

21 Secondary heat exchanger

22 Shaker arm assembly

23 Spring anchor - fixed WPS64 1 1 1

24 Shaker chamber

25 Primar y/secondary gasket WPS67 1 1 1

27 Cleaning pipe manifold

28 Cleaning door - shaker chamber

29 Fibre rope - shaker chamber do or

1” BSP flow pipe (5-18 and 6-26kW) WPS53 1 1

detachable

1¼” BSP flow pipe (9-36kW) WPS54 1

Top panel

WPS38 1 1 1

WPS42 1 1

WPS43 1

WPS44 1 1

WPS145 1

WPS49 1 1

WPS50 1

WPS51 1 1

WPS52 1

WPS58 1 1

WPS59 1

WPS60 1 1

WPS61 1

WPS62 1 1

WPS63 1

WPS65 1 1

WPS66 1

WPS68 1 1

WPS69 1

WPS70 1 1

WPS71 1

WPS72 1 1

WPS73 1

WPS74 1 1

WPS75 1

Page 97

Boiler Parts List continued

Item Description Product code Qt y - 5-18kW Qty - 6-26kW Qty - 9-36kW

30 Solenoid valve WPS76 1 1 1

31 Primary heat exchanger spiral baf fle WPS77 18 18 24

32 Spiral hanger

33 Shaker assembly mounting flange WPS80 1 1 1

34 Spring anchor - movable WPS81 1 1 1

35 Cleaning mechanism spring WPS82 1 1 1

36 Right side panel

37 Cleaning mechanism cam WPS85 1 1 1

38 Cleaning motor mounting flange WPS86 1 1 1

39 Cleaning mechanism motor WPS87 1 1 1

40 Door interlock WPS88 1 1 1

41 Shaker chamber mounting gasket

42 Left side panel

44 Primar y heat exchanger

45 Combustion chamber baffle

46 Ash pan handles WPS99 2 2 2

47 Ash pan

48 Combustion chamber cleaning door rope WPS102 1 1 1

49 Combustion chamber cleaning door WPS103 1 1 1

50 Combustion chamber cleaning do or panel WPS104 1 1 1

51 Front panel WPS105 1 1 1

52 Combustion chamber cleaning door handle WPS106 1 1 1

53 On / off switch EFBS22 1 1 1

54 Limit stat WPS107 1 1 1

55 Momentar y switch (double pole on / off) WPS108 1 1 1

56 Control panel chassis WPS109 1 1 1

57 Relay MPCBS72X 1 1 1

58 Control panel cover WPS110 1 1 1

N/A Circuit board (5-18kW) WPS112C 1

N/A Circuit board (6-26kW) WPS112 1

N/A Circuit board (9-36kW) WPS112B 1

Brass fitting 1” BSP x 22mm (311) WPS93 1 1

Brass fitting 1¼” BSP x 28mm (311) WPS94 1

WPS78 1 1

WPS79 1

WPS83 1 1

WPS84 1

WPS89 1 1

WPS90 1

WPS91 1 1

WPS92 1

WPS95 1 1

WPS96 1

WPS97 1 1

WPS98 1

WPS100 1 1

WPS101 1

Page 98

13.3 Burner

21 3119

36 kW

NOTE

36 kW only

The 5-18kW model has an air

adjuster disc (not shown) fitted

beneath the burner fan (item 3).

Figure 13-2: Burner – exploded view

Page 99

13.4 Burner Parts List

Item Description Product code Qt y - 5-18kW Qty - 6-26kW Qty - 9-36kW

1 Air pressure switch WPS111 1 1 1

2A Primary printed circuit board (5-18) WPS112C 1 - -

2B Primar y printed circuit board (6-26) WPS112 - 1 -

2C Primar y printed circuit board (9-36) WPS112B - - 1

3 Burner fan and motor WPS03 1 1 1

N/A Air restriction plate (5-18kW only) WPS178 1 - -

4 Servo motor (for brazier) WPS04X 1 1 1

5 LED display unit WPS05 1 1 1

6 LED display support WPS06 1 1 1

7 Electrical connector (7-way female) - burner plug No. 2 WPS07 1 1 1

8 Electrical connector (7-way male) - burner plug No. 2 WPS08 1 1 1

9 Photocell WPS09 1 1 1

10 Ignition element (no housing) WPS10A 1 1 1

11 Pellet feed tube thermostat WPS11 1 1 1

12 Pellet feed tube thermostat cover WPS12 1 1 1

N/A Pellet feed (flexi) tube WPS13 1 1 1

14 Pellet feed tube gasket WPS14 1 1 1

15 Burner fan gasket WPS24 1 1 1

16 Ignition element housing (housing only) WPS10B 1 1 1

17 Photocell tube WPS17 1 1 1

18 Electrical connector (6-way male) - burner plug No. 3 WPS18 1 1 1

19 Brazier - chassis WPS19 1 1 1

20A Brazier - bottom (5-18 and 6-26 kW) WPS33A 1 1 -

20B Brazier - bottom (9-36kW) WPS33B - - 1

21A Brazier - angle plate (5-18 and 6-26 kW) WPS32A 1 1 -

21B Brazier - angle plate (9-36kW) WPS32B - - 1

22A Burner hood (5-18 and 6-26kW) WPS29X 1 1 -

22B Burner hood (9-36kW) WPS29Y - - 1

23 Ignition element mounting plate WPS22 1 1 1

24 Boiler water thermistor WPS25 1 1 1

25 Burner back plate and base WPS27 1 1 1

26 Burner cover WPS28 1 1 1

27 Special - contact Grant UK N/A 1 1 1

28 Special - contact Grant UK N/A 1 1 1

29 Cleaning mechanism spring WPS82 1 1 1

30 Special - contact Grant UK N/A 1 1 1

31 Special - contact Grant UK N/A 1 1 1

32 Back plate for photocell WPS23 1 1 1

33 Special - contact Grant UK N/A 1 1 1

N/A Brazier measuring to ol WPS199 1 1 1

Pellet feed tube (one piece) WPS174 1 1 1

Pellet feed tube (two piece) WPS174A 1 1 1

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13.5 110kg Pellet Hopper

Figure 13-3: 110kg Pellet hopper components - exploded view

13.6 200kg Pellet Hopper Parts List

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Figure 13-4: 200kg Pellet hopper components - exploded view