Grant Spira 6-26kW User guide

- 1 -
IRL NO.011 Rev;3 July 2011
INSTALLATION, COMMISSIONING
AND
SERVICING INSTRUCTIONS
GRANT SPIRA 6-26 kW CONDENSING WOOD PELLET BOILER
GRANT SPIRA 9-36 kW CONDENSING WOOD PELLET BOILER
After installing the boiler leave these instructions with the Appliance.
Leave the user manual with the householder.
This appliance is deemed a controlled service and specific regional statutory requirements may be
applicable.

2
Index of Wood pellet Boiler installation manual
1. Introduction
1.1
How the wood pellet boiler operates
1.2
Boiler description
1.3
Boiler components
2. Technical data
2.1
Boiler & Hopper technical data
2.2
Boiler output data
2.3
Flue gas analysis
2.4
Boiler & hopper set up Dimensions
3. Pellet specification & storage
3.1
Pellet specification
3.2
Pellet storage
4. Installation information
4.1
Introduction
4.2
Boiler location
4.3
Regulations to comply with
4.4
Preparation for installation
4.5
Installing the boiler
4.6
Make the water connections
4.7
Fan box
4.8
Burner
4.9
Intermediate hopper
4.10
Pellet Feed Auger
5. Condensate disposal
5.1
General requirements
5.2
Connections
5.3
Pipe work
5.4
External pipework
5.5
Condensate soak away
5.6
Condensate trap
5.7
Inspection and cleaning of trap
6. Flue system & Air supply
6.1
Air supply
6.2
Flue position and clearances
6.3
Flue Components & assembly
7. Electrical
7.1
Connecting the power supply
7.2
Frost protection
8. Burner
8.1
Burner operation
8.2
Burner modes
8.3
Operational sequences
8.4
Burner display screen
8.5
Burner control buttons
8.6
Burner menu navigation chart
8.7
Burner menu description
9. Commissioning
9.1
Equipment required
9.2
Before switching on
9.3
Priming the pellet feed auger
9.4
Lighting the boiler
10. Boiler servicing
10.1
Checking before servicing
10.2
Cleaning the burner
10.3
Cleaning the boiler & Flue
11. Fault finding
11.1
Boiler won’t fire (no error message)
11.2
Blank display screen
11.3
Error messages
11.3
12 Spare parts.
13 Health & safety information.
14 Warranty.
15 Notes

3
Grant SPIRA Condensing Wood Pellet Boiler & Intermediate Hopper

4
This manual is intended to guide Engineers who have
completed the Grant Wood Pellet Boiler Installer training
course on the installation, commissioning and servicing of the
Grant SPIRA Condensing Wood Pellet Boiler. A separate
manual is available to guide users in the operation of the
boiler.
The following special text formats are used in this manual of
the purposes listed below;
Warning of possible human injury as a consequence of not
following the instructions in the “warning”
Caution concerning likely damage to equipment or tools as a
consequence of not following the instructions in the “Caution”
Note text. Used for emphasis or information not directly
concerned with the surrounding text but of importance to the
reader.
1.1 How the condensing wood pellet boiler operates
During the combustion process, hydrogen and oxygen
combine to produce heat and water vapour. The water vapour
produced is in the form of superheated steam in the heat
exchanger. This superheated steam contains sensible heat
(available heat) and latent (heat locked up in the flue gas). A
conventional boiler cannot recover any of the latent heat and
this energy is lost to the atmosphere through the flue.
The Grant SPIRA Condensing wood pellet boiler contains an
extra (secondary) heat exchanger which is designed to
recover the latent heat normally lost by a conventional boiler.
It does this by cooling the flue gases to below 90°C thus
extracting more sensible heat and some of the latent heat.
This is achieved by cooling the flue gases to their dew point.
To ensure maximum efficiency, the boiler return temperature
should be 55°C or less (minimum of 40°C) at maximum
operating temperature. This will enable the latent heat to be
condensed out of the flue gases.
The boiler will achieve full load efficiency as follows;
SPIRA 6-26 Full output = 97.4% Reduced output = 96.4%
SPIRA 9-36 Full output = 93.1% Reduced output = 98.1%
The Grant SPIRA condensing wood pellet boiler operate
extremely high efficiencies even when it is not in condensing
mode and therefore is suitable for fitting to an existing heating
system without alteration to the radiator sizes. The boiler is
capable of a maximum flow temperature 80°C.
The burner is a drop feed burner. The output of the burner is
determined by varying the feed and pause time of the pellet
feed auger suppling pellets to the burner.
1.2 Boiler Description
When commissioned correctly, the Grant SPIRA condensing
wood pellet range of boilers operate automatically as they are
equipped with an automatic cleaning system. The ash pan
will need to be emptied after each 3 tonnes of pellet
consumption and serviced annually by a Grant trained service
Engineer. Details of each service should be recorded in the
Service Log in the back of the User Operating Manual.
To ensure the safe and trouble free operation of the
boiler ensure the ash pan is emptied after each 3 tonne
of pellets burnt as failure to do so could cause the boiler
to malfunction.
The boiler is suitable for use on a sealed or open vented
central heating system. All models are supplied with the
control panel factory fitted. The burner, combined fan box &
flue starter, pellet feed auger and hopper come separately
and needs to be fitted by the installer. See section 4 for boiler
installation.
WARNING
!
CAUTION
!
NOTE
!
CAUTION
!
1 Introduction

5
The boiler needs to be connected to a conventional flue
system. There is no provision for connection to a balanced
flue system as there is draft regulator fitted to the appliance.
The boiler is not designed specifically for operation on a
system with a buffer tank/ thermal store, however when used
on a system with a buffer tank/ thermal store there is no effect
on the boiler performance.
The only flue system suitable for the Grant SPIRA
condensing wood pellet boiler is the Grant „Black‟
insulated conventional flue system.
This 125mm (5”) „Black‟ flue system is suitable for both
models 6-26 & 9-36.
1.3 Boiler components
1.3.1 Burner. The burner is supplied separately and will need
to be mounted to the boiler on site. All burners are supplied at
a factory default setting. During commissioning each burner
parameter will need to be checked and adjusted if necessary
as pellet feed auger angle, pellet size and flue sizes/length
can have significant effect on the boiler performance. Refer to
commissioning in section 9. The Burner is equipped with a
self cleaning device to prevent a build up ash and clinker in
the burner brazier. The burner output is determined by the
feed / pause times of the pellet feed auger supplying the
burner. See section 8 for full burner operation.
1.3.2 Boiler. The SPIRA condensing boiler is supplied with a
combined primary and secondary heat-exchanger. The boiler
is also equipped with a self cleaning system, of which the
primary cleaning system comes fitted in the boiler and the
secondary cleaning system needs to be fitted. See section 4.
Boiler Installation.
1.3.3 Boiler controls. The temperature of the water leaving
the boiler to heat the radiators and hot water cylinder is user
adjustable by adjusting the set point on the burner menu see
section 8. The boiler is fitted with an overheat thermostat
(which allows it to be used on a sealed central heating
system) which will automatically switch off the boiler if the
temperature exceeds a pre-set temperature of 110°C. The
control panel is fitted with a Burner ON/STAND-BY switch.
This switch interrupts the switched live supply to the burner, it
does not isolate the electrical supply to the burner. The
control panel is also fitted with a cleaning switch, in the
default position it allows the boiler cleaning system to perform
automatically, when pressed it allows the cleaning system to
be manually tested. Only operate the cleaning switch when
the boiler is in „WAIT BOILER THERMOSTAT‟. See figure 1.1
Fig. 1.1
After the burner has been switched off (either manually
by the switch on the control panel, the boiler stat‟, or the
switched live input) the burner needs to burn-down the
remaining pellets in the brazier. Do not AT ANY TIME
open the front combustion chamber access door until
the burner display reads “WAIT BOILER THERMOSTAT”
1.3.4 Pellet Feed Auger. The pellet feed auger is a hollow
spiral type. Its function is to deliver the pellets from the
hopper to the burner. The output of the boiler is determined
by varying the on/off periods of the pellet feed auger motor.
All Grant hoppers are fitted with a fixed angle feed pellet feed
auger at 45° to maintain consistent feed. Once the pellet feed
auger angle is altered the input to the boiler is also altered.
1.3.5 Hopper. The system comes complete with an
intermediate hopper. This hopper stores 120 kg (169 lt) of
wood pellets with a refill capacity of 80 kg The hopper is for
indoor use only and should be positioned in a dry
environment. Position the hopper to the left side of the boiler
only and on the same floor level as the boiler. The hopper is
supplied with castors, allow sufficient area in front of the
hopper for removal during servicing. The hopper comes
with „knock-out‟ to allow entry of pellets from a bulk
hopper system, this knockout is positioned to ensure the
pellets drop into the hopper and will de-activate the low
level indicator. Making an alternate opening in the
intermediate hopper could effect the operation of the low level
indicator.
Always ensure that the door and top panel of the intermediate
hopper are fitted to ensure no foreign debris enters the
hopper. If a bulk system is fitted ensure the bulk auger does
not stop the opening of the intermediate hopper access door.
NOTE
!
WARNING
!

6
2 Technical Data
2.1 Boiler & Hoper technical data
Model
Units
SPIRA
6-26
9-36
Water content
Litres
51.5
60
Weight boiler heat-exchanger
kg
201
231
Weight of auger
kg
8.35
8.35
Weight burner
Kg
25.5
25.5
Weight intermediate hopper (empty)
Kg
33
33
Weight intermediate hopper (full)
kg
143
143
Weight fan box
Kg
5
5
Maximum heat Output
kW
26
36
Btu/hr
88,700
122,800
Flow connection
--
1” B.S.P. (F)
1 1/4” B.S.P. (F)
Return connection
--
1” B.S.P. (F)
1 1/4” B.S.P. (F)
Waterside resistance ΔT = 10°C
mbar
26.0
Waterside resistance ΔT = 20°C
mbar
9.5
Mains water (cleaning system)
Litre/min
Minimum of 16
Condensate connection
--
1 ¼ ” B.S.P. Female
Conventional flue
--
125mm (5”) Black system
Combustion chamber draught requirement
mbar
0.10 to 0.15 (running)
Maximum static head
m
25
Minimum circulating head
m
1
Boiler temperature set point range
°C
55° to 80°
Boiler temperature cut out point
°C
65° to 80°
Minimum return temperature
°C
40°
Water system overheat cut-out temp.
°C
110°
Burn-back overheat cut-out
°C
60°
Electricity supply
--
230V ~50Hz
Max operating pressure -sealed system
bar
2.5 bar
Max operating pressure -open system
bar
2.5 bar
Maximum auger length (bulk hopper)
meter
3.0
Minimum flue length
m
2.0
Maximum flue length
m
8.0
Heating element rating
Watts
450
Intermediate auger motor power
Watts
55
Intermediate auger motor starting current
Amps
0.64
Intermediate auger motor running current
Amps
0.64
Intermediate auger speed
rpm
8.5
Flue fan motor power
Watts
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
amp
2.5
Total burner run current
amp
0.60

7
2.2 Boiler output data
Settings in the table below are based on the boiler using the Grant fixed angle pellet feed auger at 45° and an auger
motor fixed speed of 8.5 rpm using 6mm „BNM Premium ‟, 6mm „Balcas Brites‟ or 6mm „GWP‟ pellets.
For settings on other brand pellets contact Grant Engineering.
2.2.1 Burner settings
Model
Pellet
feed
Auger
angle
MAX flame
MIN flame
Burner setting
Heat Output
Heat Input
Burner
setting
Heat Output
’TIME
LOAD
MAX
’TIME
PAUSE’
kW
Btu/h
kW
Btu/h
Full
Eff.
Input
kg/hr
*
’TIME
PAUSE
MIN’
kW
Btu/h
SPIRA
6-26
45°
0025
(2.5sec)
0025
(2.5sec)
26.3
89,735
27.1
92,510
97.4
5.70
0175
(17.5sec)
6.5
22,100
SPIRA
9-36
45°
0065
(6.5sec)
0025
(2.5 sec)
36
122,832
38.7
132,078
93.1
7.78
0250
(25sec)
9
30,700
1. * = Based on a calorific value of 4.81 kW/kg
2. Data given above is approximate only.
3. The above settings will have to be adjusted on site for correct operation of burner.
4. The installer must amend the boiler data label if the output is changed.
2.3 Flue Gas Analysis
Only use a calibrated flue gas analyser that has
a „Wood Pellet‟ fuel setting. Setting the fuel to
an alternative fuel will give incorrect readings.
To allow the boiler to be commissioned and serviced,
the boiler is supplied with a test point in the top cleaning
door. When this test point is used, note that the test
point is for CO2 and smoke reading only.
The boiler efficiency and flue gas analysis must be taken
from the flue test point that is closest to the flue
connection chamber on the top rear cleaning door. To
gain access to this test point, remove the top panel from
the boiler.
NOTE
!
Do not sample flue gases through the
draught stabilizer or within the flue as the
gases will have been diluted with air from the
draught regulator. Only use the test points in
the top rear access door
CAUTION
!
To obtain good combustion the minimum
„TIME LOAD MAX‟ setting should not be set
lower than 25 (2.5 seconds)
CAUTION
!

8
Fig 2.1
FLUE
EXHAUST FAN
PLAN VIEW - BOILER & HOPPER
40
50
DRAUGHT
REGULATOR
140
400
266
268
227
255
510
1021
1293
1538
103
254
95
66
SIDE VIEW - BOILER & HOPPER FRONT VIEW - BOILER & HOPPER
REAR VIEW - BOILER & HOPPER
727
770 1012
97
172
275
413
BULK HOPPER
INLET OPTION
1186
1635
CLEARANCE REQUIRED
FOR ACCESS TO
DRAUGHT STABILIZER &
REMOVE WASH MANIFOLD
225
150
MINIMUM NON-COMBUSTIBLE BASE AREA
- 125MM THICK
-SAME FLOOR LEVEL AS HOPPER BASE
150

9
Fig 2.2
FLUE
EXHAUST FAN
PLAN VIEW - BOILER & HOPPER
40
50
DRAUGHT
REGULATOR
140
400
266
268
227
255
510
1021
1293
1538
103
254
195
66
SIDE VIEW - BOILER & HOPPER FRONT VIEW - BOILER & HOPPER
REAR VIEW - BOILER & HOPPER
727
770 1012
97
172
275
413
BULK HOPPER
INLET OPTION
1186
1635
CLEARANCE REQUIRED
FOR ACCESS TO
DRAUGHT STABILIZER &
REMOVE WASH MANIFOLD
225
150
MINIMUM NON-COMBUSTIBLE BASE AREA
- 125MM THICK
-SAME FLOOR LEVEL AS HOPPER BASE
150

10
3.1 Pellet specification.
This Grant SPIRA boiler is designed to run on wood pellets that meet the following criteria;
Key Parameter
Limits
Category as per
prCEN/TS 14961:2004
Diameter
6mm
D06,
Average length
L<5 x diameter
Maximum length
40mm
Moisture Content
<10%
S0.05
Mechanical durability
>97.5%
DU 97.5
Amount of fines
<1.0%
F1.0
Additives
None
Nitrogen
< 0.3%
N0.3
Nett calorific value
Ca. 4.8 to 5.2 kWh/kg
Bulk density
Ca 650 kg/m3
Chlorine
< 0.03%
CL 0.03
Additives; Additives are used to improve the stability of the pellets. If manufactured correctly, and of a sufficiently
low moisture content, quality pellets will require no additives.
Ash; Ash represents the non-combustible content of the pellet. Higher ash content reduces the calorific
value of the pellet and requires the appliance to be cleaned more frequently.
Average length: To provide a predictable flow of fuel into the burner, the recommended length of a pellet is deemed
greater than 5mm and less than 5 times the diameter.
Bulk density; Bulk density is the ratio between the weight of the pellet and the amount of space they take up. A
good quality pellet will have a density of 650 kg/m3.
Chlorine; High levels of chlorine in the flue gases emissions can give rise to corrosion.
Diameter The most common diameter is 6mm with some 8mm also available. This boiler is designed for 6 only.
Fines Pellets are made from compressed wood. As pellets rub together they can break down slightly,
producing dust or fines. Too many fines indicate a poor quality pellet and can impede pellet flow in
addition to causing dust problems when delivering and storing the pellets.
Mechanical Durability This is a measure of how stable the pellet is and how likely it is to produce fines from normal handling.
A high durability percentage is an indicator of a good quality pellet.
Moisture content Moisture affects the calorific value of the pellet. Low moisture content guarantees constant and
predictable combustion efficiency. Higher moisture contents can result in pellet breakdown.
Net Calorific Value This is the useful energy contained in a kilogram of fuel. This value is affected by the amount of non-
combustible materials (ash) and the moisture content of the pellet. Typical values range from 4.8
kWh/kg to 5.2 kWh/kg.
Nitrogen High levels of nitrogen in the flue gases emissions can give rise to corrosion.
Sulphur High levels of sulphur in the flue gases emissions can give rise to corrosion.
3. Pellet Specification, Storage & Delivery

11
3.2 Pellet Storage
3.2.1 Intermediate Hopper & Pellet Feed Auger. The
appliance is supplied with an intermediate hopper and a 1.2
metre pellet feed auger to deliver the pellets from the hopper
to the boiler. The intermediate hopper should only be fitted on
the left-hand side of the boiler. Once commissioned the angle
of the intermediate pellet feed auger should not be adjusted
in any way as this will vary the input to the boiler. The
intermediate hopper and pellet feed auger together with the
boiler should be installed in an indoor area and should be
protected from dampness. Both the boiler and the
intermediate hoper should be situated on the same level. The
intermediate hopper also has a system to control the pellet
feed auger from a bulk hopper. See figure 7.4. The top rear
panel of the intermediate hopper has a knock-out to allow the
pellet delivery hose from the bulk hopper auger to enter the
hopper.
Fig. 3.1
3.2.2 Bulk Hopper. It is advisable to fit a bulk hopper storage
unit to take advantage of the lower cost of bulk pellets.
The boiler can be fed directly from a bulk storage unit. If
a bulk storage unit is used directly, careful attention is
needed during commissioning as the angle and speed of
the pellet feed auger motor will determine the amount of
pellets delivered to the boiler. Contact Grant Engineering
for further details.
The use of an intermediate hopper between the bulk hopper
and the boiler is advisable as any problems with a bulk pellet
quality can be isolated and the intermediate hopper can be
used as the main input to the boiler.
Only use a bulk storage unit that is
(a) Specifically designed to store wood pellets
(b) Is waterproof.
(c) Vented
(d) Supplied with appropriate connections for delivery
which are within the drivers reach.
(e) Is electrically earthed.
The length of the pellet feed auger used to feed pellets from
the bulk hopper should be limited to a maximum of 3 meters
in length, as any longer can damage the pellets.
The use of a self constructed wood pellet storage facility
should be preapproved by the fuel supplier before any pellets
are delivered and should meet relevant building and fire
regulations.
The ONORM M7137 standard should be used as a guideline
for DIY bulk storage units.
A storage unit should not be positioned where it would result
in a fire risk.
Bulk hopper feeding intermediate hopper.
Fig. 3.2
Each bulk pellet manufacturer has clear guidelines on
the requirements of a bulk storage hopper used to store
their pellets together with requirements on positioning,
access, and minimum deliveries. Check with the pellet
supplier/manufacturer you wish to use before installing a
bulk hopper system.
CAUTION
!
NOTE
!

12
Boiler operates.
4.1Introduction
The appliance comes complete on one pallet, this consists of
the boiler, burner, intermediate hopper (fitted with pellet feed
auger) and combined fan box & flue starter (complete with
exhaust fan and draught stabilizer packed inside the boiler).
Check the packing list (supplied in the boiler) to ensure all
items were delivered.
The Grant SPIRA condensing wood pellet flue system comes
separately and its configuration will depend on the installation
requirements.
4.2Boiler 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.
4.3Regulations to comply with
Installation of a Grant wood pellet boiler and hopper must be
in accordance the following recommendations;-
All National Building Regulations and any local
Byelaws which you must check with the local
authority for the area.
Model and local Water Undertaking Byelaws.
The installation should also be in accordance with the
latest edition of the following standard codes of Practice;
BS 715 Metal flue pipes, fittings, terminals and
accessories.
BS EN 12828:2003. Heating systems in buildings.
Design for water-based heating systems
BS EN 12831:2003. Heating systems in buildings.
Method for calculation of the design heat load.
BS EN 14336: 2004. Heating systems in buildings.
Installation and commissioning of water based
heating systems.
BS 7593 Code of Practice for treatment of water in
heating systems.
BS 7671 Requirements for electrical installations,
IEE wiring regulations.
The ONORM M7137 standard should be used as a guideline
for DIY bulk storage units.
4.4Preparation for installation
With the units on the pallet, remove all outer packaging from
the units.
Open the boiler front cleaning door and remove the ash-pan
and all items from the combustion chamber.
Remove the packing list and check all items are present.
Fit the ash-pan in place in the combustion chamber and close
the front cleaning door.
4 Installation Information

13
4.5 Installing the boiler
The boiler and hopper must be positioned on a level, solid,
non-combustible material of at least 125mm thick. It must
also extend past the boiler and hopper by 225mm at the front
and 150mm on the remaining sides. The boiler position must
comply with clearances shown in section 2.4.
4.6 Make the water connections
Flow and return connections: The flow and return connection
are as follows;
SPIRA 6-26 = Flow 1” BSP Female
Return 1” BSP Female
SPIRA 9-36 = Flow 1” ¼ BSP Female
Return 1” ¼ BSP Female
All flow and return connections are at the rear of the boiler,
refer to section 2.4 for dimensions.
Pipework connections
Fit the ½” drain cock to the bottom rear ½” BSP connection.
Fit the air vent assembly into the ½” connection on the rear of
the boiler (this is to vent the secondary unit only), the flow
pipe from the boiler must be vented.
Condensate Connection;
Refer to section 5 for details on condensate connections and
disposals.
Wash system;
The boiler is supplied with a cleaning system to wash the
condensing unit of any ash build up in the tubes. A 15mm
(1/2”) compression connection is needed to supply mains
water to this pipe. A minimum flow of 16 litres of water per
minute is required to maintain an adequate supply. The wash
system has to be fitted from the right-hand side of the boiler.
Ensure adequate clearance (400mm) for removal of the
system during servicing. Refer to section 2.4 for clearance
dimensions.
If using plastic piping for the heating system consult with
the manufacturer of the pipe before use on how best to
protect the piping from overheating.
If you then choose to use plastic piping after advice from
the pipe manufacture, fit a minimum of one meter of
copper on the flow and return from the boiler, do not
connect plastic piping directly to the boiler. Grant
Engineering do not accept any responsibility for any
damage, how so ever caused, to plastic piping or fittings.
4.7Combined fan box & flue starter
Fit the combined fan box & flue starter to the flue outlet of the
boiler using the M8 nuts and washers supplied. Ensure there
is an adequate seal between the unit and the boiler. Fit the
solenoid head (fitted to the lead from the fan box) to the
solenoid valve on the wash system just fitted. Fit the plug
from the flue fan /solenoid to the socket into the rear of the
boiler as shown in figure 4.1.
Fig 4.1
4.8 Burner
Fit the burner to the front of the boiler door using the two M8
nuts that come fitted to the boiler. Ensure the burner gasket
makes an adequate seal with the boiler. Fit the seven pin
plug and socket into the side of the burner.
4.9 Intermediate hopper
Position the intermediate hopper on a firm level surface on
the left-hand side of the boiler with the top access door facing
forwards as per the dimensions shown in section 2.4. Failure
to adhere to these measurements can cause blockage of the
pellets in the pellet delivery hose or can prevent access for
servicing at a later date. The hopper is supplied with castor
wheels which allows the hopper be moved during servicing.
Once in the correct position engage the brakes on the front
casters to main this position.
4.10 Pellet feed Auger
The intermediate auger comes fitted to the Intermediate
hopper. Fit the pellet delivery hose onto the pellet feed auger
and the opposite end onto the burner feed tube. (The pellet
delivery hose may need to be cut if too long). A lubricant such
as Vaseline may be required to ensure the pellet delivery
hose is easily fitted. Ensure the pellet delivery hose is not
kinked in any way. Plug the 6 way plug from the pellet feed
auger into the 6 way socket on side of the burner as shown in
Fig 4.2.
WARNING
!

14
Fig 4.2
Ensure the pellet delivery hose forms an air tight seal
each end and that the pellet delivery hose is not damage.
Leakage of air could cause increased temperature in the
pellet delivery hose and result in the „SAFETY CHARGE
PIPE THERMISTOR‟ shutting down the burner.
WARNING
!

15
5.1 General Requirements
When in condensing mode the Grant SPIRA condensing
wood pellet boilers produce condensate from the water
vapour in the flue gases and the fuel. This condensate is
slightly acidic with a ph value of around 3 (similar to
vinegar); provision must be made for the safe and effective
disposal of this condensate.
Condensate should be disposed of using an internal 4”
gulley connected to a foul water system or alternatively or
into a purpose built high capacity soakway.
All condensate disposal pipes must be fitted with a trap –
whether they are connected internally or externally to a
domestic waste system/soil stack or run externally to a
gully, hopper or soakway.
5.2 Connections
Connections into a rainwater hopper, external drain or
gulley should be terminated inside the hopper/drain/gulley
below the grid level but above the water level.
Condensate disposal pipes should not be connected directly
into rainwater downpipes or to waste/soil systems
connected to septic tanks.
Condensate should not be discharged into „grey water‟
systems that re-use water used in the home (not including
water from toilets).
It should be noted that connection of a condensate pipe to
the drain may be subject to local building control.
5.3 Pipework
All condensate pipework must be adequately protected
against freezing, however if the condensate pipe is
frozen, water will build up and discharge through the
overflow on the trap.
Condensate disposal pipework must be plastic.
Copper or steel pipe is not suitable and must not be used.
Condensate disposal pipes should have a minimum
„nominal‟ diameter of 38mm (1 1/2”) plastic pipe.
Condensate disposal pipes must be fitted with a fall (away
from the boiler) of at least 2.5° (~45mm fall per metre run).
Where it is not possible for the pipe to fall towards the
point of discharge –either internally into a waste system
or externally to a gulley (e.g. for boilers installed in a
basement), it will be necessary to use a condensate
pump. When fitting a condensate pump, a condensate
holding tank of at least 40 litres is required. This is to
ensure that when the boiler cleaning cycle has operated
the holding tank can collect the total volume of the
water used in the wash down and the condensate pump
can then discharge the waste effectively. A boiler
interlock should be fitted to shut off the boiler in the
event of a malfunction of the condensate pump.
When using a condensate pump and condensate
holding tank, the burner settings for „T18‟ / „TIME
CLEAN PERIOD‟ (time boiler cleaning in operation)
must not be set greater than 600 (60 seconds) and the
„T17‟/ „TIME CLEAN BOILER‟ (time between boiler
cleaning operations) must not be set less than 240
minutes, as modifying these times could result in larger
and more frequent wash down of the boiler which could
exceed the capabilities of the tank and condensate
pump.
Condensate disposal pipes should be kept as short as
possible and the number of bends kept to a minimum.
Pipes should be adequately fixed to prevent sagging, i.e. at
no more than 0.5 metre intervals.
5.4 External Pipework
Ideally, external pipework, or pipework in unheated areas,
should be avoided. If unavoidable, external pipework should
be kept as short as possible (less than 3 metres) and 38mm
waste pipe used to minimise the risk of ice blocking the pipe
in freezing conditions.
The number of bends, fitting and joints on external pipes
should be kept to a minimum to reduce the risk of trapping
condensate.
CAUTION
!
NOTE
!
NOTE
!
WARNING
!
5 Condensate Disposal

16
For a boiler installed in an unheated area such as an
outhouse or garage, all condensate pipework should be
considered as an „external‟.
5.5 Condensate Soakway
To keep external pipework to a minimum, locate the soak
away as close as possible to the boiler but ensure it is at
least 1 metre from building foundations and away from other
services, for example gas, electricity or other services.
The condensate pipe may be run above or below ground
level and can enter either the top or side of the soakway
tube. Refer to figure 6.1
Ensure that the drainage holes in the soakway tube face
away from the building.
Backfill the soakway tube and the hole around it with 10mm
limestone chippings. Only use a soakway where the soil is
porous and drains easily.
Fig 5.1
5.6 Condensate Trap
Grant SPIRA condensing boilers are supplied with a 1 ¼”
G.B female condensate connection on the rear of the boiler.
Fit the 1 ¼” 316 fitting supplied into this connection on the
boiler and fit the pipework and trap as shown in fig. 5.2. A
condensate discharge pipe with a minimum diameter of
38mm is required to be fitted to this connection. The
condensate trap must be situated where it can be easily
accessed for removal and cleaning. For added frost
protection leave the overflow connection open.
Fig 5.2
5.7 Inspection and Cleaning of Trap
The trap must be checked at regular intervals (e.g. on every
annual service) and cleaned as necessary to ensure that it
is clear and able to operate.
Failure to regularly check and clean the condensate
trap may result in damage to the boiler and will not be
covered by the product warranty.
NOTE
!
2.5° fall
600 800 (min)
25
400
CAUTION
!

17
The only flue system suitable for the Grant SPIRA Wood
pellet boiler is the Grant „Black‟ insulated conventional
flue system.
This 125mm 5” „Black‟ flue system is suitable for both
models 6-26 & 9-36. The use of a masonry chimney is
not permitted due to the condensate produced from the
boiler.
6.1 Air supply
The Grant wood pellet boiler draws air from the room in
which the boiler is located. A sufficient permanent air supply
to the boiler should be provided;
a. For proper combustion of fuel and effective
discharge of combustion products to the open air.
b. To supply enough free air to the draught stabilizer.
A permanent air vent with a total free area of 550 mm2per
kW shall be provided for combustion along with 300 mm2
per kW to supply free air to the draught stabilizer. To
achieve this, the following is the vent opening requirements.
Boiler model
Vent opening
Grant SPIRA 6-26
Wood pellet
221 cm2 (35 in2)
Grant SPIRA 9-36
Wood pellet
306 cm2 (48 in2)
If a bulk hopper is fitted internally refer to the manufacturer
instructions for ventilation requirements.
6.2 Flue position and clearances
The Grant wood pellet boilers have high operating
efficiencies and low flue gas temperature. Care should be
taken to ensure that only the „Black‟ system is used, as this
is the only flue system suitable for the range of Grant wood
pellet boilers.
The boiler flue cannot terminate into an existing brick or
clay lined chimney.
The flue must terminate as per the details shown in Fig.
6-1.
The flue must also discharge in a down draught free
area, i.e. at least 1 metre above the point of exit through
the roof or 600mm above the apex of the roof. See fig
6.1 for further details.
No other appliance can be connected to the flue.
Clearances to combustible materials must be at least
75mm.
The condensate may be allowed to run back into the
boiler. A condensate drain at the base of the flue
system is not required.
Fig 6.1
Point where flue passes
through weather surface
(Note 1,2)
Clearance to flue outlet
A
At or within 600mm of the
ridge
At least 600mm above the
ridge
B
Elsewhere on a roof
(whether pitched or flat)
At least 2300mm
horizontally from the
nearest point on the
weather surface and;
a; at least 1000mm above
the highest point of
intersection of the chimney
and the weather surface;
or
b; at least as high as the
ridge
C
Below (on a pitched roof)
or within 2300mm
horizontally to an
openable rooflight, dormer
window or other opening
(Note 3)
At least 1000mm above the
top of the opening
D
Within 2300mm of an
adjoining building, whether
or not beyond the
boundary (Note 3)
At least 600mm above the
adjacent building.
Notes
1) The weather surface is the building external surface, such as
its roof, tiles or external walls.
2) A flat roof has a pitch less than 10°.
3) The clearance given for A or B, as appropriate, will also apply.
Clearances recommended by Grant Engineering
Limited in accordance with British Standards and
Building Regulations. Also refer to section J of either
the England and Wales or Irish building regulations for
comprehensive details on flue systems.
NOTE
!
A
Figure 6.1
BC
D
6 Flue system and Air Supply

18
6.3 Flue components & assembly
6.3.1 Combined fan box & flue starter. The boiler is
supplied with a combined fan box & flue starter connector
that comes packed inside the boiler combustion chamber.
The unit comes complete with exhaust flue fan, draught
stabilizer and a connection to take the Grant „Black‟ flue
system. The draught stabilizer must not be boxed or
obstructed from operation in any way. Also fitted is a clean
out hatch to allow removal of any ash that may have
dropped down the flue system. The clean-out hatch should
be fully closed during normal operation. See section 10
servicing.
The flue connector is fitted with a neoprene gasket for
connection to the boiler. The neoprene gasket is to
accommodate a low temperature wet flue system that is
achieved on the condensing boiler. The attached wiring
harness is for flue fan along with the connection for the
wash system.
When fitting the flue system to the boiler the gasket seals
supplied must be fitted to the flue inner liner at every joint.
A condensate drain at the base of the flue is not required
as the flue connector is designed to allow the condensate
run back into the boiler.
6.3.2 Flue System. The „Black‟ flue system is a twin wall
fully insulated flue which reduces the possibility of freezing
in the flue on condensing boilers. The flue also has a high
corrosion resistance suitable for solid fuel.
No horizontal section should be used or no elbow
greater than 45° should be used as these can cause a
build up of ash and condensate in the flue. Also all flue
joints must have a seal fitted on each joint of the inner
liner.
Failure to maintain a clean flue can result in the
emission of flue gases into the dwelling or damage
from fire in the flue. See section 10.3 Cleaning the
Boiler & Flue
6.3.3 Joining components. The joint is locked by rotating
the upper section clockwise. To secure the joint, the locking
band supplied with the female end of all components must
be used. To allow alignment, there are no locating flutes on
the female section of the elbow. For this reason these joints
MUST be secured using the locking band. All flue joints
must have a lip seal gasket fitted on the bead of the
projecting liner spigot of every joint. The lip seal should be
fitted dry and lubrication applied to the internal of the socket
into which it is to be assembled.
6.3.4 Adjustable length. An adjustable flue length allows
adjustment from 75mm up to 250mm. Assembly is achieved
by fitting the adjustable length over the proceeding pipe.
Remove insulation as necessary and secure when desired
length is achieved using joint band supplied. The adjustable
section is not load-bearing, therefore adequate support
must be provided immediately above.
6.3.5 Support components. The weight of a chimney
system is considerable and requires independent support.
No weight should be taken by the appliance. On internal
systems the weight is held by using a support plate and
clamp fixed on top of the first floor/ceiling joist. A fire-stop
plate is also required fixed to the ceiling below. In a normal
house, when passing through the second floor the only
requirements is two fire-stop plates because the system is
adequately supported at first floor level.
Wall brackets and roof brackets are not load bearing and
give lateral support only. Wall brackets should be fitted
every 3m and at any offset to ensure the system is rigidly
supported.
Where the flue is free standing above the roof and its height
exceeds 1.5m beyond the last support or the roof a guy wire
bracket must be used and every 1.5m thereafter.
Alternatively a height of up to 4m can be achieved
unsupported with the use of an extended locking band at
the joint immediately below every joint above the roof.
Adjustable Pipe 75 - 250mm-
Part no. WP/ADJ250
Internal diameter 125mm. External diameter 180mm
Complete with locking band. Telescopes over pipe below.
Minimum engagement should be half the diameter.
This component is NOT load-bearing.
WARNING
!
WARNING
!
Ø125
Ø180
75 - 230

19
Straight Pipe
DN21009
Nominal
Length
Effective Length
Code Number
1000
960
WP/EXT1000
500
460
WP/EXT500
333
293
WP/EXT333
200
160
WP/EXT200
Internal diameter 125mm. External diameter 180mm
Locking band
Part no. WP01
Internal diameter 125mm. External diameter 180mm
This item is supplied with pipes, bends, tees and terminals
30° Bend
Part no. WP/30
Internal diameter 125mm. External diameter 180mm
45° Bend
Part no. WP/45
Internal diameter 125mm. External diameter 180mm
Ø125
Ø180
EFFECTIVE LENGTH
66
57
Ø125
Ø180
30°
79
Ø125
Ø180
70
45°

20
Double 30° Bend and straight pipe length
960 Eff pipe
A
1061
B
542
460 Eff pipe
A
628
B
292
293 Eff pipe
A
483
B
208
160 Eff pipe
A
368
B
142
Viton Seal
Part no. WP02
Internal diameter 125mm.
ø125mm Wall Band (50mm)
Internal/external Code WP/WB50
External diameter 180mm.
Roof Support
Code WP/RS
External diameter 180mm.
Fire stop plate
Code WP/FP
External diameter 180mm.
B
A
Ø125
Ø180
EFFECTIVE LENGTH