Grant Spira 6-26 kW Installation instructions

1
IRL NO.012 Rev; 0 April 2011
USER INSTRUCTION
for
GRANT SPIRA 6-26 kW CONDENSING WOOD PELLET BOILER
GRANT SPIRA 9-36 kW CONDENSING WOOD PELLET BOILER
Leave the user manual with the householder.
This appliance is deemed a control service and specific regional statutory requirements
may be applicable.

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

3
1. Introduction
This guide is intended to assist and instruct the User
in the operation of the Grant SPIRA Condensing
Wood Pellet Boiler. A separate manual is available to
Engineers for the installation, servicing and
commissioning of the boiler.
The following special text formats are used in this
manual of the purposes listed below;
Warning of possible human injury as a consequence
of not following the instructions in the “warning”
Caution concerning likely damage to equipment or
tools as a consequence of not following the
instructions in the “Caution”
Note text. Used for emphasis or information not
directly concerned with the surrounding text but of
importance to the reader.
2. About your boiler.
Your Grant SPIRA wood pellet boiler should only be
installed, commissioned and serviced by a FETAC
registered Engineer. They are also required to have
undergone specific product training by Grant
Engineering (Ireland) Ltd.
When commissioned correctly, your Grant SPIRA
condensing wood pellet boiler operates automatically
as it is equipped with an automatic cleaning system.
The ash pan will need to be emptied after each 3
tonnes of pellet consumption and serviced annually by
a Service Engineer who has completed the Grant
training course. Details of each service should be
recorded in the Service Log in the back of this
manual.
The burner is equipped with a brazier where the
combustion of the wood pellets takes place within the
boiler. The self cleaning device on the brazier and
boiler activates after the auger run time has exceeded
a predetermined set time. The auger run time for
brazier and boiler cleaning is set in the burner menu.
Both cleaning functions may be activated at different
stages, this is normal.
As long as there are sufficient pellets in the hopper,
the system is „calling‟ and the auger is charged then
the boiler is fully automatic once switched on,
providing central heating and also heating your
domestic hot water if you have a cylinder fitted.
If your appliance is controlled by a remote
programmer and/or a room thermostat, it will provide
hot water and central heating during the periods as
set on the programmer, when either the room
thermostat and or the hot water thermostat are calling.
The system comes complete with an intermediate
hopper. This hopper stores 110 kg (169 lt.) of wood
pellets. The hopper is for indoor use only and should
be positioned in a dry environment. As the hopper
comes with castors, allow sufficient area in front of the
hopper for removal during servicing. The hopper
should be filled to the point where it is still possible to
close the top door.
Do not adjust or modify the appliance in anyway as to
do so could cause malfunction of the appliance, injury
to persons or death or result in a potential fire hazard.
Only allow a qualified Service Engineer who has
completed the Grant training course should carry out
any work on the appliance.
All national and local regulations and European
Standards shall be complied with during the operation
of the appliance.
Always ensure the front access door of the
combustion chamber is fully closed and latched
during operation.
Certain external surface of the boiler will be hot to
touch when in operation, due care is needed.
WARNING
!
CAUTION
!
NOTE
!
WARNING
!
WARNING
!

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3. About your Fuel
Once your boiler has been commissioned the burner settings are adjusted for use with that fuel. Only use one of following wood
pellet brands with the Grant Wood pellet boiler.
6mm „BNM Premium‟,
6mm „Balcas Brites‟
6mm „GWP‟ pellets.
If the Commissioning Engineer has commissioned your boiler for use with an alternative fuel supplier (other than that listed
above) check with Grant Engineering (Ireland) Limited as you may need to have the boiler recommissioned if you plan to change
your fuel supplier. Each bulk pellet manufacturer has clear guidelines on the requirements of a bulk storage hopper used to store
their pellets together with requirements on positioning, access, and minimum deliveries. Check with the pellet supplier
/manufacturer you wish to use before installing your bulk hopper system.
This Grant SPIRA boiler is designed to run on wood pellets that meet the following criteria;
Key Parameter
Limits
Category as per
prCEN/TS 14961:2004
Diameter
6mm
D06,
Average length
L<5 x diameter
Maximum length
40mm
Moisture Content
<10%
S0.05
Mechanical durability
>97.5%
DU 97.5
Amount of fines
<1.0%
F1.0
Additives
None
Nitrogen
< 0.3%
N0.3
Nett calorific value
Ca. 4.8 to 5.2 kWh/kg
Bulk density
Ca 650 kg/m3
Chlorine
< 0.03%
CL 0.03
Additives; Additives are used to improve the stability of the pellets. If manufactured correctly, and of a sufficiently low moisture content, quality
pellets will require no additives.
Ash; Ash represents the non-combustible content of the pellet. Higher ash content reduces the calorific value of the pellet and requires
the appliance to be cleaned more frequently.
Average length: To provide a predictable flow of fuel into the burner, the recommended length of a pellet is deemed greater than 5mm and less than
5 times the diameter.
Bulk density; Bulk density is the ratio between the weight of the pellet and the amount of space they take up. A good quality pellet will have a
density of 650 kg/m3.
Chlorine; High levels of chlorine in the flue gases emissions can give rise to corrosion.
Diameter The most common diameter is 6mm with some 8mm also available. This boiler is designed for 6mm only.
Fines Pellets are made from compressed wood. As pellets rub together they can break down slightly, producing dust or fines. Too many
fines indicate a poor quality pellet and can impede pellet flow in addition to causing dust problems when delivering and storing the
pellets.
Mechanical Durability This is a measure of how stable the pellet is and how likely it is to produce fines from normal handling. A high durability percentage
is an indicator of a good quality pellet.
Moisture content Moisture affects the calorific value of the pellet. Low moisture content guarantees constant and predictable combustion efficiency.
Higher moisture contents can result in pellet breakdown.
Net Calorific Value This is the useful energy contained in a kilogram of fuel. This value is affected by the amount of non-combustible materials (ash)
and the moisture content of the pellet. Typical values range from 4.8 kWh/kg to 5.2 kWh/kg.
Nitrogen High levels of nitrogen in the flue gases emissions can give rise to corrosion.
Sulphur High levels of sulphur in the flue gases emissions can give rise to corrosion.

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4. Cleaning and Servicing your boiler.
To ensure the safe and trouble free operation of the
boiler ensure the ash pan is emptied after each 3
tonne of pellets burnt as failure to do so could cause
the boiler to malfunction.
Ensure the boiler is serviced annually. Only allow
a qualified Competent Service Engineer who has
completed the Grant Engineering Training course
on Wood pellet boilers to service your boiler.
Ensure the service details are recorded in the
Service log at the back of this book.
5. User Controls
The boiler control panel has the following controls that
are designed for the user to operate.
Burner switch, interrupts the signal from a
remote programmer and/or a room
thermostat. This switch should be left in the
ON position during normal operation of the
boiler.
CLEANING; Auto / Test. This switch is
normally in Auto mode which allows the
controls automatically clean the boiler. In test
mode the controls are bypassed allowing the
Operator or Service Engineer to activate the
cleaning of the boiler. The switch is spring
loaded to return to the Auto mode after Test
mode is released.
Overheat reset; A built in safety feature is
provided to prevent the temperature of the
boiler overheating. This can be manually
reset. If the re-setting is continually required
contact your Service Engineer.
The burner control panel has the following controls
that are designed for the user to operate.
Increases the boiler temperature set point
Decreases the boiler temperature set point
Resets any error.
NOTE
!
1
2
4
RESET

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6. Burner display
6.1 Set point
The set point is the temperature setting about which
the modulation of the boiler output is activated.
5°C below the set point the boiler is in 100%
power mode.
5°C above the set point the boiler has
reached minimum output.
The set point is not the cut out temperature of the
burner. The burner cut out temperature of the burner
is factory set in the burner menu‟s, but may have
been adjusted by the commissioning Engineer.
6.2 Boiler system temperature.
This is the temperature of the water in the boiler.
Note;When the burner cuts out the temperature will
continue to rise as the heat from the flame is
transferred to the system water.
6.3 Burner function
The function the boiler is in when viewed, is scrolled
across the bottom of the display screen. This can be
any one of a number of functions depending on the
mode the boiler is in when viewed.
Error messages are also displayed on this section of
the screen.
6.4 Operating functions:
‘WAIT PRELOAD BRAZIER’ Initial loading of pellets
into the brazier to enable combustion to start.
‘WAIT LIGHTING’ –IGNITION Period of time given for
pellets to light.
‘PELLET BURNER FIRING’; Power 25-100% Flame
is fully developed and boiler is operating on full power.
‘TURNING OFF BRAZIER’; Burn down period to
remove any pellets remaining in the brazier.
‘WAIT POST PURGE’ Period of time after burn down
is complete to ensure no unburnt pellets ignite.
‘BOILER WAIT THERMOSTAT’; Boiler is in standby
awaiting a switched live input signal and/or the burner
switch is in OFF mode.
6.5 Error messages;
FAILED PELLET LIGHTING
SAFETY BOILER THERMOSTAT
SERVO MOTOR BLOCKED
PROBE FAULT
SAFETY CHARGE PIPE THERMOSTAT
AIR PRESSURE ERROR
For further details on Errors messages see section on
„Boiler fails to light‟
6.6 Active Symbols
Active symbols: To the left of the burner display a
range of symbols are shown. Once the symbol has a
curser displayed beside it in the screen area then that
item is active. The list of function symbols are as
follows:
1
2 3
6
54
!
SET RESET
SET 75°C
H2o 60°C
PELLET BU
Temperature set point
(User adjustable)
increase temperature set point
decrease temperature set point
1
2 3
6
54
!
SET RESET
SET 75°C
H2o 60°C
PELLET BU
Boiler system
water temperature
1
2 3
6
54
!
SET RESET
SET 75°C
H2o 60°C
PELLET BU
BURNER FUNCTION
1
2 3
6
54
!
SET RESET
SET 75°C
H2o 60°C
PELLET BU
!
= Boiler thermostat calling
= Burner fan operational
= Pressure switch closed
= Ignition element operational
= Feed auger operational
= Photocell lux reading >5 i.e. flame present
= n/a
= Error
Active symbols
!
= Boiler thermostat calling
= Burner fan operational
= Pressure switch closed
= Ignition element operational
= Feed auger operational
= Photocell lux reading >'Flame On' setting
= n/a
= Error

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7. Priming the auger
1. Disconnect the 7 pin plug and 6 pin socket
from the left-hand side of the burner.
2. Disconnect the pellet delivery hose from the
burner and place in a container of at least 1
litre capacity as shown below.
3. Place the 7 pin plug into the 6 pin socket as
shown below. The feed auger will now run
continuously until the plug and socket are
disconnected.
4. The auger will prime itself with wood pellets
after a period of 15 to 20 minutes depending
on the auger length. Once there is a
continuous flow of pellets from the pellet
delivery hose disconnect the plug and
socket. The auger is now fully primed.
5. Refit the pellet delivery hose into the pellet
delivery tube of the burner.
6. Refit the 7 pin socket and 6 pin plug into the
original position on the side of the burner.
8. Lighting the boiler.
1. Ensure that system controls are calling for
heat.
2. Switch the „Burner Standby/On‟ switch on
the boiler control panel to the „On‟ position.
The highlighted curser should now be
displayed beside the thermostat symbol
before the boiler can fire. If not check
„Burner Standby/On‟ switch is in „on‟ position
and all controls are calling.
If the burner On/Off switch is switched off
at this stage the pellet feed will stop and
the burner will run through the post
purge sequence before pellet feed starts
again.
Do not repeatedly switch on and off the
burner at this stage as a build up of
pellets in the brazier will occur resulting
in poor combustion during lighting.
3. The flue fan will start and pellets will be
delivered to the burner. The boiler will now
light automatically after a short lighting
period.
4. Set the HW and CH functions to Timed. The
boiler will now operate during the „on‟
periods set on the programmers.
= Boiler thermostat calling
NOTE
!
CAUTION
!

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9. Emptying the Ash
The interlock on the burner door disconnects
the power to the burner to prevent firing when
the door is opened. It does not extinguish the
flame immediately. If the burner door is
opened during the operation of the burner
there can be a large uncontrollable flame
emitted from the brazier.
After the burner has been switched off (either
manually by the switch on the control panel,
the boiler stat’, or the switched live input) the
burner needs to burn-down the remaining
pellets in the brazier. Do not AT ANY TIME
open the front combustion chamber access
door until the burner display reads “WAIT
BOILER THERMOSTAT”
1. Switch the „Burner Standby / On‟ switch to
standby.
2. Wait until the display screen function reads
„WAIT PELLET THERMOSTAT‟
3. Disconnect the pellet delivery hose from the
burner.
4. Open the front access cleaning door. Slide
the ash pan forward. Remove any ash
resting on the baffle above the ash pan as
shown below.
5. Using the handles provided remove the ash
pan from the boiler. Remove any remaining
ash that may be left in the base of the boiler.
Extreme care is required when empting the ash
pan as smouldering ash could be present and can
cause serious damage to persons or property.
Ensure the ash is disposed of in a safe manner.
Servicing and replacement of parts must only be
carried out by a suitably qualified engineer who
has completed the Grant training course on wood
pellet boilers.
Details of every service should be entered in the
service log, in the boiler hand book.
Failure to maintain a clean flue may result in
the emission of flue gases into the dwelling
or damage from potential fire in the flue.
Thus it is important that your boiler is
serviced annually be a suitably qualified
engineer who has completed the Grant
training course on wood pellet boilers
WARNING
!
WARNING
!
WARNING
!
CAUTION
!
NOTE
!
CAUTION
!

9
10. If your boiler fails to light.
If you boiler fails to light, make the following checks;
1. Check the „Burner Standby/On‟ switch is in the On
position.
2. Check the remote programmer(s) is working and is
in an „On‟ period.
3. On systems without a bulk hopper fitted; Check
there is sufficient quantity of pellets in the
intermediate hopper to engage the low level
diaphragm in the rear of the hopper.
The curser should now be lit on the burner display
beside the thermostat symbol, if not then recheck
the programmer(s) and/or add more pellets to the
hopper.
Error messages
10.1 Failed pellet lighting;
1. On systems with a bulk hopper fitted; If the
bulk and intermediate hopper is allowed to
run out of pellets then the error message
„FAILED PELLET LIGHTING‟ will be
displayed on the burner screen. Once the
hoppers have been filled the auger will need
re-priming. See section 7 „Priming the Auger,
and the error cancelled by pressing the reset
button on the burner control panel.
2. Check auger is rotating
3. Check sufficient pellets being delivered to
the burner..
4. Check auger primed fully.
5. Check for dust or blockage in auger.
Pellets that contain excessive dust will
prevent the auger from pulling the pellets
out of the hopper. The hopper will need to
be cleaned of any dust.
6. Check for clinker in the brazier. If present
check quality of pellets.
10.2 SAFETY BOILER THERMOSTAT;
1. The boiler is fitted with a safety overheat
thermostat which will automatically switch off
the boiler in the case of control malfunction
causing overheating. If this occurs the error
message „SAFETY BOILER THERMOSTAT‟
is displayed on the burner screen. Remove
the plastic cap and press the „OVERHEAT
RESET‟ button, then replace the plastic cap.
2. Cancel the error message on the burner
screen by pressing RESET on the burner
controls.
If the condition continually repeats contact
your Service Engineer.
10.3 SERVO MOTOR BLOCKED
1. Switch the „Burner Standby / On‟ switch to
standby.
2. Wait until the display screen function reads
„WAIT PELLET THERMOSTAT‟
3. Disconnect the pellet delivery hose from the
burner.
4. Open the front access cleaning door.
5. Check the brazier for solid clinker, remove if
present.
6. To cancel the error message press reset on
the burner control panel.
10.4 PROBE FAULT
Contact your Service Engineer
10.5 SAFETY CHARGE PIPE THERMOSTAT
1. Check pellet delivery tube is fitted correctly
and not damaged in any way.
2. Check drain pipe from boiler is not blocked
or frozen.
3. To cancel the error message press reset on
the burner control panel.
4. If none of the above are applicable contact
you service engineer.
10.6 AIR PRESSURE ERROR
Contact your Service Engineer.
Do not under any circumstances enter a wood
pellet hopper that has been in operation as if the
boiler has malfunctioned there may be a build-up
fumes within the enclosure.
= Boiler thermostat calling
NOTE
!
WARNING
!

10
11.Ventilation
Do not attempt to „box in‟ the boiler or build a
compartment around it before contacting your
Installer
Do not place any combustible material around or
on the boiler or flue pipe.
Do not adjust or block any ventilation openings in
the building that the boiler is located in.
12.Frost protection
Your installer may have fitted a frost thermostat. If
not, and you are likely to be away for a short time
leave the boiler on. For longer periods the boiler
should be turned off and the system drained down.
Contact your service Engineer for draining and
filling the system.
Grant recommend that a combined inhibitor
be used in the primary water system.
13. Electricity supply
If the electricity supply fails, the boiler will not
operate. It should relight after the supply is
restored. However it may burn-down any
smouldering pellets still present in the brazier
before it starts the lighting sequence.
If a remote programmer is connected, it may retain
the time settings for some time and may not have
to be reset to the correct time of day when the
supply is restored. Refer to the instructions
supplied with your programmer for further details.
It is recommended that you check the time
settings after a power failure has occurred.
The electrical connections to the boiler must be
earthed.
14.Sealed Central Heating System
If your boiler is operating on sealed heating
system, the installer will have adjusted the
pressure in the system and should have told you
(or set it on the pressure gauge) the system
pressure when cold. This is normally between 0.5
and 1.0 bar, which will increase slightly when hot.
If the pressure (when cold) is below the set
pressure mentioned above, you can re-pressurize
the system. If this is frequently required, ask your
Installer or service engineer to check the heating
system for leaks and to check the expansion
vessel air charge.
The boiler or system will be fitted with an
automatic air vent to remove any air from the
system. Any trapped air in the radiators should be
removed by venting the radiators using the vent
screw at the top of each radiator. Only vent a
radiator if the top is cool and the bottom is hot.
Excessive venting will reduce the system
pressure, so only vent when necessary and check
the system pressure as mentioned above. Re-
pressurise the system as necessary.
A sealed system should have a safety valve to
release excess pressure. If water or steam is
emitted from the end of the safety valve discharge
pipe, switch off the boiler and contact your installer
or Service Engineer.
NOTE
!
CAUTION
!

11
15. Visual guide to assess Wood pellet Quality

12
16. Service log
Service Engineer: ____________________
Date ; _____________________
Service carried out by Qualified Engineer service as
per instruction and training by Grant Engineering
(Ireland) Limited.
Service Engineer:___________________
Date ; ____________________
Service carried out by Qualified service Engineer
as per instruction and training by Grant
Engineering (Ireland) Limited.
Service Engineer: ____________________
Date ; _____________________
Service carried out by Qualified Engineer service as
per instruction and training by Grant Engineering
(Ireland) Limited.
Service Engineer:___________________
Date ; ____________________
Service carried out by Qualified service Engineer
as per instruction and training by Grant
Engineering (Ireland) Limited.
Service Engineer: ____________________
Date ; _____________________
Service carried out by Qualified Engineer service as
per instruction and training by Grant Engineering
(Ireland) Limited.
Service Engineer:___________________
Date ; ____________________
Service carried out by Qualified service Engineer
as per instruction and training by Grant
Engineering (Ireland) Limited.
Service Engineer: ____________________
Date ; _____________________
Service carried out by Qualified Engineer service as
per instruction and training by Grant Engineering
(Ireland) Limited.
Service Engineer:___________________
Date ; ____________________
Service carried out by Qualified service Engineer
as per instruction and training by Grant
Engineering (Ireland) Limited.
Service Engineer: ____________________
Date ; _____________________
Service carried out by Qualified Engineer service as
per instruction and training by Grant Engineering
(Ireland) Limited.
Service Engineer:___________________
Date ; ____________________
Service carried out by Qualified service Engineer
as per instruction and training by Grant
Engineering (Ireland) Limited.
Service Engineer: ____________________
Date ; _____________________
Service carried out by Qualified Engineer service as
per instruction and training by Grant Engineering
(Ireland) Limited.
Service Engineer:___________________
Date ; ____________________
Service carried out by Qualified service Engineer
as per instruction and training by Grant
Engineering (Ireland) Limited.

13
14. Warranty
1. The company shall mean Grant Engineering (Ireland) Limited.
2. The boiler is guaranteed for a period of 12 months from the date of purchase, providing that;
a. The boiler is commissioned & installed by an engineer who has completed the Grant Wood pellet training
course on wood pellet boilers and is an SEAI registered installer.
b. Any work undertaken is authorised by the Company and carried out by an approved service agent.
c. The boiler is run on approve 6mm wood pellets as described in section 2.3 & section 3 of this manual.
3. The primary and secondary heat-exchangers of the wood pellet boiler manufactured by Grant Engineering (Ireland)
Limited are guaranteed for a period of 5 years from the date of installation. All other components except consumables
are guaranteed for a period of 1 year.
4. The guarantee starts from the date of purchase.
5.The guarantee does not cover breakdowns caused by incorrect installation, neglect, misuse, accident or failure to
operate this boiler in accordance with the manufacturer‟s instructions.
6. This guarantee is non transferable unless sanctioned by the company.
7. The company will endeavour to provide prompt service in the unlikely event of a problem occurring, but cannot be
held responsible for any consequence of delay however caused.
8. This guarantee does not cover labour handling or shipping.
9. This guarantee applies to boilers installed on the island of Ireland both North and South. Provision for warranty
cover elsewhere is subject to agreement with Grant Engineering (Ireland) Limited.
10. All claims under this guarantee must be made and agreed with by Grant Engineering (Ireland) Ltd. prior to any
work being carried out. Proof of purchase and date of installation must be provided on request. Invoices for call
out/repair work carried out by any third party will not be acceptable unless previously authorised by the company.
11. Grant Engineering do not accept any responsibility for damage, how so ever caused, to plastic piping or fittings
used on the heating system.