INSTALLATION, OPERATING and SERVICE MANUAL
Contents
1. SVO 0 TID OU TH SNL AGE EH ONV TT DL 5 NI ONY 030200290 SAV SION MUNI FP 3 J E ENTE SI AIHA BIS _ LYLSINNH 0n SYNE 08 7 NLYN E UL Qp SIH E Dy SENT S wm mm lt lt 7 gt E 1158 TII r XD sgg px mc q Q Lr Q am ly rela gt 1 214 RE du m a ee ad peg epee TEE E 1 9 A vm Bm 4 WS 3873 j M M NTE Y S1 7H DB NA 01 WOH SIATA m wet AOTEA OL AH gt AES Md SAIA pe X08 P LAND 12 060 e H th SAAN2. JIM U 1 V Y m BN pet Y EN NH BAN 979071 TAMNIH Wiring diagram explained DISCONNECT ALL POWER TO THE FURNACE BEFORE PROCEEDING 2 disconnect and remove draft fan 3 1 connect the supplied power cord wires part 2200114 to the wires in the draft fan J Box and ground unhook both black wires from the Honeywell R8225B Relay 4 connect the two black wires from the R8225B Relay to the two middle wires supplied from the NPB terminal block Refer to Figure 4 5 connect the black wire from the draft fan J Box to the black wire from the Interlock Control White Rogers 8A05A 4 6 Figure 3a NPB Wiring Diagram for WB Series Furnaces Comb Control For connection with the blue wire from the electric section when Fan Limit installed with the Newmac Electric section Madels E10 to E25 Blue NPB POWER CABLE Red Black wire for connection with black wire from 120V service Black or red wire from electric section White wire for connection with 120V Supply white wire from 120V service o um or white wire from electric section White Yellow Transformer 120 24 I White Yellow Yellow p Black Terminal Block Jumper Factory Wired 120 V ee Field Wired 24V Wiring diagram explained DISCONNECT ALL POWER T
3. TO PROVIDED ROHERTSHAW RS 22100 THERMOSTAT Wiring for BL 160 Boiler Model To TT comectors on side of draft fan box 7 Figure 5 NPB System General Assembly PROXIMITY SENSUR FEE SAFETY TEMPERATURE SENSOR a 2 7 CONTROL PELLET CHUTE PHDTUSENSUR GATE BURNER COVER COSS BURNER GRATE COMBUSTION FAN P lt CLEANING AUGER COVER AUGER MOTOR HOPPER CAPACITY FLEXIBLE FEED HOSE a APPROX 400 Ibs AUGER TUBE 12 Figure 6 NPB Pellet Hopper Auger Switch Tob Auger Switch Box AUGER BUX Figure 7 Complete NPB System with CL Series O CONTROL AND SETTINGS Figure 8 Programmable Control 2 4 at t im um c TABLE 1 CONTROL CONFIGURATION W NOR Prompt Element ge 1 Retractable mounting feet 2 Screw terminal block for the power supply 3 3 LCD display 4 lines 18 characters ee 4 Screw terminal blocks for discrete analog 7 inputs 3 2 M 8 5 Relay output scre
4. 3 for low speed To manually test the cleaning grate you must simultaneously press and hold down buttons 4 amp 2 for the forward direction and buttons 4 amp 3 for the reverse direction Always wait a couple seconds between changing directions to allow for the capacitor to lose its dwelling charge IMPORTANT While running in the forward direction make sure not to run too far to cause binding of the motor The cleaning grate should always be run in the reverse direction until the limit switch shuts it down prior to initial start up or subsequent testing when it has been manually run FUEL PELLETS Pellet fuels are put into 3 categories in terms of ash content Premium at 1 or less Standard at 2 or less and all others at 2 or more When using higher ash content pellets more frequent ash removal scraping and cleaning of burner may be required Higher ash content pellet may also provide less Btu s per pound The Burner should normally burn 6 12 mm diameter fuel pellets which come either in 40 Ib 16 kg bags or are supplied by bulk delivery truck If you have a bulk storage container you should follow the recommendations to ensure that the quality of the pellets does not deteriorate Never use pellets which do not meet manufacturers recommendations Damp pellets must never be used and should be disposed of immediately The pellets can be made from different materials The most common material is wood but there are suitable alterna
5. Figure 22 NPB Hopper Chain Set Up Auger Tube Chain can be attached to suppart chain or to a ceiling support Chain ta support Lid when open HPPER LID Chain to support Auger Tube AUGER TUBE 19 TABLE 3 FAULT DIAGNOSIS auger not running FAULT CAUSE ACTION 1 Feed tube sensor has 1 Let cool opened due to temperatures 2 Manually reset thermodisc OVERHEAT FAULT of 170 F or more 3 If flexible feed hose has 2 Not enough draft melted replace 3 Feed rate too high 4 May need to increase draft 5 Adjust feed rates 1 Wrong start feed 1 Change start feed 2 Broken ignition element 2 Replace igniter IGNITION FAULT 3 Blocked feed chute 3 Clean out chute 4 Photo cell dirty or broken 4 Clean or replace photo cell 5 Make sure auger is feeding pellets 1 Pellet hopper is empty 1 Fill hopper with pellets 2 Auger and or chute are 2 Clean out blockage FUEL FAULT blocked 3 Clean or replace photo cell 3 too heavy a feed rate 4 Adjust feed rate 4 photo cell dirty or broken 5 make sure auger is running 5 properly The function of the included ash scraper is for cleaning off the pellet grate NOTE Never attempt to clean the pellet grate while burner is running or power is turned on TABLE 4a SUGGESTED FEED RATES PER MODEL FOR PREMIUM PELLETS MODEL CL 86 96 CLC 90 100E WB 100 WFA 70 WAO CL 115 170 BC 160 High Burn On 42 42 70 70 60 90 90 High Burn O
6. QO DO 1 22 2 7 2 Prg 17222 1 0 1 922 ni 0 5 W7 48 15 Figure 12 NPB Low Fire Feed Rates Menu four shows the low fire feed rates which are manually adjustable The suggested feeds rates per model are shown in Tables 4a and 4b located at the back of this manual ee 23 45 BBCDEEFG QO 6969 69 CO CO 69 69 69 69 69 690 60 CO Inputs 11 18 2NDC Analog or SR2 20180 Low Fire Rote 60 000 Btu 24KW Auger Un 00035 Auger tt 00045 CE A CK e gt Outputs 58 Relay BA SO DO OO OHO VOO OO DO OH 2 1 5 2 2 22 2 12232 12 d 13 5 WI Figure 13 NPB High Fire Feed Rates Menu five shows the high fire feed rates which are manually adjustable The feed rates low and high will be factory set according to the furnace model 1234588CDEFB 69 069 69 Co 69 G9 60 69 69 Inputs 1 18 24NDC Analog 2410 582 820180 High Fire Rate 110 000 Btu 38KW Auger 00070 Auger tt 00040 IE REDE v A gt Outputs UL 08 Relay 99 990 99 99 99 96 OD DO 1 2 1 2 1 2 I 2 v 52 e doa 422 12 d Im 13 5 b WI Figure 14 NPB Overheat Fault Menu This Fault Menu will appear if the feed tube sensor reaches 170 F and will remain until the temperatu
7. TO WOOD AMIN WIRING DIAGRAM FUR CONECTION TO AN DIL OR GAS HITLER BURNER WITH FRE AND POST PURGE MIST HAVE THE POWER FRON TERNINAL 3 IN THE NENMAL CONTROL THE PRE AND PIST PURGE VIRE FRN TE AAR aww 1 4 CER 2 2 IHAN Figure 4 NPB Control Wiring SENSIR RIGHT SIDE VIEN IF PALET BIRNER PROIXINITY SENSIR PHOTOCELL LDER EAR LIMIT SVITTH HPFER LID SWITCH Wenu Rig Inc R 100 000 L Verslan 4 3 2 Y B 36 PE 99 9 Go Se 99 9 9 E E E LS TS DIS PG ie Md 2 vem ED RAFT FAN 25215529 1201 ANGER CINELTIIN GND LINEAR CLEANING HE GEAR Ej zm mena l ma CFTR Figure 4a NPB Thermostat Wiring Robertshaw RS2210C First Stage Heat Figure 4b NPB Model Thermostat Wiring Wiring for WB WFA and WAU Models Robertshaw BS2210C PROVIDED ROBERTSHAW The rnos vol RS 2210C THERMOSTAT e 9 5 Wiring tor CL series Models To the black wires af the Honeywel 82258 Relay 9 on back af the CL series eu B n amp 9
8. h g MJ BTU eff eff 19 7 11 4 high 14 76 3 92 0 06 121 977 82 4 100 7 21 7 11 3 med high 10 39 2 12 0 03 78 547 78 8 92 1 21 7 11 2 med low 7 99 1 04 0 04 53 050 71 1 80 9 22 7 11 1 low 6 06 0 078 0 02 35 666 65 0 71 7 21 TABLE 5 NPB PARTS LIST 4110239 4120526 4120532 4120517 4120518 FIREDOOR ASSEMBLY FIREDOOR HEAT SHIELD FIREDOOR FRAME FIREDOOR HANDLE COMPLETE AUGER COVER BURNER COVER 4080150 4080159 4060443 2020041 ee BURNER ASSEMBLY ES Gi LINEAR GEAR MOTOR 2080113 BURNER GASKET 2040003 COMBUSTION FAN 2080114 2080115 2080116 2020040 4060441 4120520 FEED TUBE GASKET LEFT SIDE COVER GASKET FIREDOOR GASKET AUGER MOTOR AUGER WELDED AUGER ASSEMBLY 2090089 2010097 4160212 2180020 2010056 2010100 2090088 IGNITER THERMOSTAT NPB CONTROL 4080166 1150056 2190100 3130022 4120527 4120538 AUGER COLLAR AUGER TUBE FLEXIBLE FEED HOSE BAFFLE CL CL HEAT SHIELD WB HEAT SHIELD 2010101 RELAY 2210051 4120529 4120530 4120519 2090087 22 MANUAL BURNER SCRAPER BOX SIDE COVER HOPPER FEED ASSEMBLY PROXIMITY SENSOR PELLET BURNER LIMITED WARRANTY Newmac Mfg Inc extends the following limited warranty for Newmac Pellet Burners Subject to the conditions exclusions and limitations set forth below Newmac warrants to the original owner of the Pellet Burner that it will
9. to desired levels according to the furnace model or owners preference See TABLES 4a amp 4b for recommended settings HEATING The feed rates are factory set but may require adjustments to attain desired temperature rise The typical temperature rise should be 75 F plus or minus 5 F The unit is designed for a maximum temperature rise through the furnace of 85 F at a maximum external static pressure of 0 50 inches of water column However due to the wide range of static pressures in duct systems it is the responsibility of the installer to verify that the temperature rise does not exceed 85 F To measure the actual temperature rise insert a thermometer and note the temperature of the warm air supply at a point at least 24 inches upstream from the heat exchanger surface and the temperature at the return air grill and take the difference Air temperature rise can be lowered by increasing the blower speed lowering the feed rate or increasing undersized supply and return air free area The furnace will not operate properly and its life will be decreased if insufficient air quantity passes over the heat exchanger Similarly too much air during heating mode resulting in a temperature rise of less than 65 F may cause heat exchanger degradation due to condensation FEED SYSTEM INSTALLATION Using the auger feed system and hopper assembly supplied insures that the feed system is installed in the correct position See Figures 5 6 and 7 For prope
10. FURNACES BOILERS INSTALLATION OPERATING and SERVICE MANUAL THE INSTALLATION OF THE UNIT SHALL BE IN ACCORDANCE WITH THE REGULATIONS OF THE AUTHORITIES HAVING JURISDICTION SUPPLEMENTARY AND NPB CONTROL INSTRUCTIONS HEAD OFFICE MARKETING PRODUCTION WAREHOUSE Newmac Mfg Inc Newmac Mfg Inc DEBERT AIR INDUSTRIAL PARK 430 SPRINGBANK AVE SOUTH 208 LANCASTER CRESCENT WOODSTOCK ONTARIO P O BOX 9 DEBERT 182 NOVA SCOTIA BOM 160 PHONE 519 539 6147 PHONE 902 662 3840 FAX 519 539 0048 FAX 902 662 2581 EMAIL newmac newmacfurnaces com LA WEB SITE newmacfurnaces com 3 p NOTICE HOMEOWNER T SGS READ AND SAVE THESE INSTRUCTIONS 156156 2210051 March 2013 Subject to change without notice Printed HOMEOWNER INFORMATION Keep this manual so that it is accessible to technicians and future needs Read this manual carefully before putting the pellet burner into service Follow this manual and its instructions carefully and do the recommended management and maintenance If you have any questions your Newmac dealer will be happy to answer them for you DESCRIPTION The NPB is intended to be mounted through the fire door of Newmac wood burning furnaces and shall be fired by wood pellets The enclosed auger feeds the fuel from a separate storage hopper A two stage heat thermostat controls the burner via the first and second stage call for heat that starts and stops the burner automatically The burn
11. O THE FURNACE BEFORE PROCEEDING disconnect and remove draft fan connect the supplied power cord wires part 2200114 to where the draft fan wires were connected connect the supplied jumper across the wood thermostat connector Figure 3b NPB Wiring Diagram for WAO Series OIL FURNACE WOOD ADD ON FURNACE NEWMAC AY VIPIM 4 E HEAT 10 FROM EH THE 4060306 1 PREN DAM Prk 2100112 PLATE PEL Ar 15 GAD FUP ATE CM PEN 10 FP OL FIPE IITIN PIPA EE O ATE CDU 49 10 MN 10 RES 10 ALO FROM FOH AME mr RUNE VIFE MLI 041 04 DL SVMPELLET 12002011 SEPTEEEP 2011 Figure 3c NPB Wiring Diagram for 160 Boiler PANEL TERMINAL 1 TERM 2 2 CTRL CONTROL PANEL WIRING manere WT SLY FENIN 17 2 WIRE 4 SEE VENT WIRING E EO 5 NOTE QUANTITY OF NINBERED TERMINAL NAY 0 NOT BE EXACTLY AX SHIN HEATING ZINE CONNECTIONS Hc 0 1 O we ZONE VALVE CONNECTIONS av a y REFER
12. be baffles 2 damage resulting from a failure to install operate or maintain the pellet burner according to the installation and operating instructions and labels furnished with the pellet burner failure to install the pellet burner according to local building codes shipping or improper handling abuse misuse continued operation with damaged corroded or failed components accident or incorrectly performed repairs over firing corrosion environmental conditions inadequate ventilation negative pressure or drafting caused by tightly sealed construction insufficient make up air supply or handling devices such as exhaust fans or forced air furnaces or other such causes use of fuels other than those specified in the operating instructions installation or use of components or accessories not supplied with the pellet burner or authorized and approved in writing by Newmac Mfg inc j modification of the product not expressly authorized and approved by Newmac Mfg Inc in writing k interruptions or fluctuations of electrical power supply to the pellet burner 3 noise caused by minor expansion contraction or movement of parts 4 the pellet burners capability to heat a desired space information is provided to assist the consumer and the dealer in selecting the proper product for the application consideration must be given to product location and configuration environmental conditions insulation and air tightness of the struct
13. ct CSA output Date Run Category Ibs hr g h 9 eff eff 31 8 11 4 high 17 58 2 93 0 02 130 815 79 6 94 8 30 8 11 3 med high 10 9 2 07 0 03 73 300 69 0 77 9 30 8 11 2 med low 8 79 1 64 0 03 60 307 71 3 79 5 29 8 11 1 low 6 81 1 37 0 03 42 324 65 8 72 0 CL 86 96 RESULTS Burn Particulate Particulate PREMIUM Rate Emissions Emissions direct direct CSA output Date Run Category Ibs hr g h g MJ BTU eff eff 11 7 2011 4 high 14 57 2 21 0 02 118 603 78 3 94 3 12 7 2011 3 med high 9 75 2 02 0 03 65 359 68 3 77 6 13 7 2011 2 med low 8 65 1 75 0 03 56 408 66 9 75 5 17 8 2011 1 low 6 39 0 81 0 02 36 769 61 2 66 6 Burn Particulate Particulate STANDARD Rate Emissions Emissions direct direct CSA output Date Run Category Ibs hr g h g MJ BTU eff eff 28 6 2011 4 high 13 96 2 86 0 03 113 674 78 7 94 3 29 6 2011 3 med high 10 3 2 84 0 04 75 967 75 3 85 4 30 6 2011 2 med low 8 74 1 81 0 03 57 222 68 4 75 8 14 7 2011 1 low 7 31 1 35 0 03 45 182 65 5 71 5 WAO RESULTS Burn Particulate Particulate PREMIUM Rate Emissions Emissions direct direct CSA output Date Run Category 16 g h g MJ BTU eff eff 26 7 11 4 high 13 96 1 76 0 02 105 263 77 4 91 9 27 7 11 3 med high 8 93 2 1 0 04 59 843 72 0 81 7 27 7 11 2 med low 6 77 1 16 0 03 40 906 66 5 73 6 28 7 11 1 low 6 39 1 52 0 04 35 309 61 8 67 3 Burn Particulate Particulate STANDARD Rate Emissions Emissions direct direct CSA output Date Run Category 16 g
14. emove the ash from the firebox using provided shovel or proper vacuum by putting it into a metal container e Replace the baffle and pellet grate and close the fire door e Once the feed tube is put back in place the power may be connected and the burner checked for proper operation e Depending on the grade of pellet this procedure may require more or less frequency Establish a routine and follow it ASH REMOVAL A good quality pellet has no more than 0 5 ash content As a result the ash will need to be emptied at 3 to 4 week intervals depending on usage Pellets with higher ash content will require the ash to be emptied more frequently Shut the burner down using the thermostat and wait for the burner to complete it s cool down cycle Wait at least another hour for the burner and surrounding surfaces to cool down Ashes should be placed in a metal container with a lid The closed container of ashes should be placed on a non combustible floor or on the ground well away from all combustible materials pending final disposal If the ashes are disposed of by burial in soil or otherwise locally dispersed they should be retained in the closed container until all cinders have thoroughly cooled NOTE Ashes usually contain live dormant coals which may burn for many hours after a recognizable flame has disappeared Use extreme caution when handling and disposing ashes No other waste shall be placed in this container HOMEOWNER CHECKLIST Ke
15. enever the cleaner is not fully back in position and the auger will not run 123 4 OB D ER DO 955906 9 0909 9 69 C2 9 NIC Inputs 11 18 IB IG 24VDC Analog 24VDC SR2 82018 CLEANER IS RUNNING Hi 08 Relay 8A OO 99 OH 2 111 2 1 2 1 8 12 Gl 5 6 Ny 58 Figure 20 NPB High Fire Running Menu This Menu will appear only when the NPB is in running mode and second stage heat is called for dere 12348 68 59 60 60 60 69 69 69 69 69 69 60 60 69 69 69 Inputs 11 18 18 16 Analog or 24VDC SR 2018 Running High Fire Ph Cell Read 00255 Un Tine 00070 Uff Tine 00040 9209060 Outputs Gi 08 Relay 8A OD DO pei 1702 2 22 1 2 Il 12 12 i 2 M 5 7 IB 18 Figure 21 NPB Low Fire Running Menu This Menu like Fig 20 will appear only when the NPB is in running mode and only if first stage heat is called for pus OH G9 C2 G9 C9 G2 C2 GO Inputs 11 18 IB 24VDC Analog or 2410 SR2 20180 Running Fire Ph Cell Read 00255 Un Tine 00032 tf Tine 00045 Ono OOo 6 Y gt Outputs 18 Reloy
16. ep area around pellet burner clean and clear of combustibles Use only dry wood pellets DO NOT burn garbage gasoline oil or any other combustible liquids Remove ashes as directed Watch for soot in smoke pipe clean regularly Clean furnace heat exchanger regularly Always observe the minimum clearances to combustible materials See the furnace service manual Do not store solid fuel within the allowable clearances or within the space required for ash removal Establish a routine for storage of fuel and care of the appliance Figure 1 Newmac CL 86 96 with NPB 6 BAFFLE HEAT SHIELD Figure 2 NPB Fire Door 5 9 o Y 1 HEAT INNER LINER N DINETAIL ANET FAR Figure 3 NPB Wiring Diagram for CL Series Furnaces 7079 73 SWAIN 25076 TENASNOH HLTA 859179 SLINI NO ONY MAOIN OL 83459 ATH 0102 IN BI 250
17. er has an on off power switch on the left side of the burner A programmable relay system controls the feed rates and supervises the burner functionality The pellets are ignited with a hot rod heater when there is a call for heat The start procedure is fully automatic in several steps to provide a fast and almost smoke free ignition The burner shuts down completely when the thermostat is satisfied and after a short cooling phase is ready for the next heat cycle A self cleaning scrapper keeps the burning grate clean and free of debris for fast and easy start ups The cleaning cycle can be set to clean prior to start up at intervals dependant on the pellet type CONSTRUCTION The construction and choice of material are made with a long life time in mind The firing zone of the burner is made of stainless high temperature steel grate and 2 plate steel The burner is a gravity fed burner in which the auger delivers pellets from the hopper to the top of the feed tube PELLET BREAK In the lower part of the pellet chute there is a gate that works as a break and places the fuel in the proper place for ignition and combustion SAFETY FUNCTIONS The NPB fulfills all existing safety requirements including overheat protection on the feed tube that turns the burner off if the temperature reaches 170 F photo cell that supervises the flame chute gate and feed tubes that provide burn back protection safety switch which will not allow the auger to
18. f incidental or consequential damages so these limitations may not apply to you This warranty gives you specific rights you also may have other rights which vary from state to state or province to province The duration of any implied warranty is limited to the duration of the warranty period specified herein 23 INSTALLER RETAILER INFORMATION NAME COMPANY Signature of the Installer The homeowner should telephone ___ for a service call or for additional information APPLIANCE INITIAL TEST AND SERVICE INFORMATION MODEL INSTALLATION DATE FURNACE SERIAL NUMBER PELLET BURNER SERIAL NUMBER PELLET BURNER SETTINGS AS TESTED Set Photocell Reading Start up Feed Time sec Ignition Time sec Clean Cycle setting Low Fire Rate settings Auger On time sec Auger Off time sec High Fire Rate settings Auger On time sec Auger Off time sec Start Feed setting sec Flue Draft 02 Flue Gas Temp C02 Burner Feed Rate high low Temperature Rise CUSTOMER INFORMATION Name Address Postal Code City Phone Date 24
19. ff 20 20 40 40 38 20 20 Low Burn 20 20 35 35 35 35 35 Low Burn Off 30 30 45 45 43 35 35 NOTE Feed rates shown above are premium pellets less than 196 ash while below are standard pellets greater than 1 but less than 2 ash TABLE 4b SUGGESTED FEED RATES PER MODEL FOR STANDARD PELLETS MODEL CL 86 96 CLC 90 100E WB 100 WFA 70 WAO CL 115 170 BC 160 High Burn On 40 40 60 60 50 90 90 High Burn Off 30 30 35 35 52 25 25 Low Burn On 20 20 35 35 25 35 35 Low Burn Off 40 40 60 60 50 35 35 NOTE For the EPA models the internal secondary air baffles must be removed for proper burner operation NOTE For a retrofit into a 7 flue the included stack reducer should be installed if needed CSA B415 1 TEST RESULTS Premium Pellets used are those with Ash content less than 196 while the Standard Pellets used are those with Ash content less than 2 but greater than 1 20 WB 100 Results Burn Particulate Particulate PREMIUM Rate Emissions Emissions direct direct CSA output Date Run Category Ibs hr g h 9 eff eff 25 8 11 4 high 14 67 2 04 0 02 113 044 76 2 89 2 24 8 11 3 med high 10 17 1 93 0 03 72 404 73 0 82 5 24 8 11 2 med low 7 96 1 82 0 03 48 004 64 0 69 9 23 8 11 1 low 6 16 1 16 0 03 38 328 66 1 72 0 Burn Particulate Particulate STANDARD Rate Emissions X Emissions direct dire
20. n needed The cleaning will be dependant on the amount of usage and pellet type being used Have a qualified technician check the complete burner operation at least once a year Cleaning of the heat exchanger flue pipe chimney and draft inducer if used is especially important at the end of the heating season to minimize corrosion during the summer months caused by accumulated ash CLEANING For best performance keep the burner and furnace clean CAUTION Be careful of hot parts on the burner and furnace Hot ash can reignite when collected Dispose of the ash outside in a covered metal container e Disconnect the power supply to the pellet burner e Make sure that the burner has shut down and cooled off for at least one hour This will make it a cooler place to work and there will be no residual pellets burning in the pot to create smoke during the cleaning operation e Remove the flexible feed hose for ease of opening the fire door and getting into the firebox e Open the fire door to allow scraping of the grate e With the provided scraper scrape all remaining ash from the back of the grate off the front into a metal container e Remove the pellet grate and scrape any remaining debris off into a metal container e With a suitable vacuum vacuum out all ash from inside the burner which may have falling through the grate e Using the provided scraper or brush scrape down all the firebox surfaces A proper vacuum may also be used e R
21. operate free from defects in material and workmanship under normal conditions and use as described in the operating instructions supplied with the pellet burner during the warranty period described below Newmac Mfg Inc will at its option repair or replace any product covered by this warranty that is determined to be defective in material or workmanship Period The warranty period begins on the date of original installation 1 Burner components warranted for five 5 years include the burner box stainless steel burner body steel feed tube hopper auger tube 2 Mechanical components which are warranted for three 3 years include the auger shaft shaft bearing shaft coupler cleaning scraper and grate 3 Electrical components that are warranted for two 2 years include the control relay blower auger motor power supply cleaning motor igniter switches thermo disc and photocell Conditions This warranty applies only to the Newmac Pellet Burners which 1 areinstalled operated and maintained as recommended in the Newmac Pellet burner user s manual 2 remain atthe site of original installation 3 have not had any unauthorized alterations after leaving the factory 4 the registration form has been completed and returned to Newmac Mfg Inc within 30 days from date of purchase Exclusions This warranty does not cover the following 1 consumable and normal wear items including without limitation gaskets paint flexible feed tu
22. ou the current photo cell reading the initial start up feed time and how long the current ignition cycle is From this menu you can manually adjust the photo cell reading required to start the soft feed cycle It is factory set between 25 and 35 above the Photo Read reading before the first call for heat s Loo A o Bet I BOE mox DO 00909 69 69 59 09 069 60 2ANUC Inputs 1l 18 IB 1 24 0 Analog or 24VDC SR 20180 Set Ph Cel 00030 Photo Read 00000 Start Up 100000 Igniter 00000 0959550 Outputs 01 08 Relay BA DO OO OO 00 1 2 2 rg 1 2 1 2 12 10 13 17 INS Figure 11 NPB Cycle Count Menu three shows the cycle counts the Start Feed setting and the Clean Cycle setting From this menu you can manually adjust the Start Feed setting which is factory set at 40 and recommended to keep it between 35 and 45 Depending on the grade of pellet the cleaning cycle should be between 1 and 5 lower for poorer grade pellets que EPG 59 G9 69 69 G9 09 9 9 69 69 Inputs 11 18 IB 16 24 0 Analog or 24VDC 592 20180 Running Count Cycle Count 10000 Start Feed 00040 Clean Cycle 00003 O X9 C V Menu DK Outputs N6 Relay DO OO 009
23. r Hopper and Auger set up see Figure 22 The feed auger and hopper are designed to maintain an auger angle of approximately 45 degrees The flexible feed hose should be at least 12 inches in length The auger should also be placed so that it sits a little to the side of the pellet chute of the burner This will prevent pellets from entering the burner if burn back should occur and the feed hose burns off as part of safety The start dose shall be approximately 40 seconds to maintain consistent and correct ignitions This is factory set and may be adjusted by a technician if required SET UP PROCEDURE Refer to Figures 1 5 amp 7 Remove existing fire door and frame from your furnace If installing on a CL series insert the 6 stainless steel baffle by resting it on the side stabilizers and pushing it to the back of the firebox See Figure 1 Attach the supplied heat shield to the front of the furnace See Figure1 Mount the NPB fire door and frame on the Newmac wood burning furnace or boiler Make sure to put the gasket on the door before installing the burner The NPB will come as one unit already put together Mount the burner through the opening in the door and four bolts The burner can be held in place on the four bolts with the four nuts and washers provided The feed tube can be turned to the desired angle for the feed system to be connected 0 The hopper lid switch needs to wired to the control as per Figure 4 1 The cover need
24. re drops 40 F and the Thermodisc is manually reset The burner is inoperable while this menu appears on the control Wepre Tom RSA 175 90590909 CO Co CO 2AVDL Inputs 11 18 18 15 24AVDC Analog 24VDL SR2 20180 OVERHEAT FAULT Refer to Manual or Contact Installer SAGA RE e gt Outputs 08 Relay BA SO DO DO DO OQO VA 2 1 3 2 1412 L 222 j 2 12 14 2 2 13 5 WI B 16 Figure 15 NPB Fuel Fault Menu This Fault Menu will appear if a fuel fault occurs and will remain until the problem is resolved Refer to Table 3 in the manual to DO 0909 9 69 69 9 69 09 69 69 0 9 2ANDC nputs 1 18 2NUC Anolog or 24VDC SR2 20180 FUEL FAULT Refer to Manuol Contact Installer OCC Oe _ Menu Qutputs OL DB Relay BA 952 GG Oo GG Iu qw 2o opu poe 2 2072 01 w 13 A 5 06 NX a8 8 6 Figure 16 NPB Ignition Fault Menu This Fault Menu will appear when an ignition fault occurs and will remain until the problem is resolved Refer to Table 3 in the manual ee L243 4 5 68 Cp FR QO 60609 69 69 69 69 69 Co Co 69 69 69 Inputs 11 18 2ANDC Analog or SR2 820180 IGNITIDN FAULT Refer to Manual or Contac
25. run while the hopper lid is open flexible feed hose that melts off and prevents the pellets from entering the burner in case of burn back or overheating e proximity sensor to prevent feed tube from plugging NPB LOCATION The NPB is mounted through the NPB fire door on Newmac wood burning furnaces and boiler See Figures 1 and 2 ELECTRICAL CONNECTIONS The NPB model is connected through the existing 120 V draft fan control box as well as the NPB thermostat being wired to ensure only one combustion type oil or pellets may fire at any given time See Figures 3 3a 3b 4 4a and 4b THERMOSTAT The NPB model requires a two stage heat thermostat to control high and low burn rates The Robertshaw RS2210C is a recommended and supplied thermostat Refer to Figure 4 4a and 4b for thermostat connection In case of power failure or the furnace limiting the thermostat will default to a 68 degree F setting if without power and battery backup for more than 40 seconds With battery backup provided 2 AA batteries the thermostat will maintain settings previous to power failure or limiting FAN amp LIMIT CONTROL The NPB furnace model uses only the limit side of the fan amp limit control NPB CONTROL OPERATION AND FURNACE SET UP The NPB control operates on 24V DC Refer to Figures 3 3a 3b 3c 4 4a and 4b The High and Low feed rates are factory set They can be field adjusted by a service technician to increase or decrease the feed rates
26. s to be attached before the power feed system and thermostat can be hooked up to the control 12 Once the cover is attached and power is on the control should be manually tested Ph OO Be IMPORTANT The feed auger should be run by itself until the pellets flow at a constant rate This can be done by connecting the burner power cord directly into the auger motor power cord This may take up to 20 minutes MANUALLY TESTING CONTROL Using the navigation keys see Figure 8a you can scroll through the six menus and manually adjust certain aspects of the burners program such as the feed rates Pressing button 1 first from the left left arrow lets you scroll through the menus while pressing button 2 down arrow reverses the direction of the scroll sequence To adjust a setting such as the low feed rate first scroll to the appropriate menu using button 1 To program you press the white button 6 furthest to the right together with button 4 right arrow The value available to be changed will flash To change the desired value use button 2 to decrease the value or button 3 up arrow to increase the value To jump between different variables within the same menu you use button 4 The changed value can be saved by pressing the menu ok green button 5 Refer to Tables 4a and 4b for factory settings To manually test the control fan you must simultaneously press and hold down buttons 1 amp 2 for high speed and buttons 1 amp
27. t Installer OO OQ Ob V Outputs 08 Relay SO Cc SO OO i 2 i 2 ro i 2 i 2 In 6 07 UB 2 l 13 In Figure 17 NPB Hopper Lid Not Closed Fault Menu This Menu will appear if the hopper lid is not closed properly on the lid switch and the auger will not run To 12345 6BCDEFG DO 60 60 9 69 9 69 59 69 60 60 60 60 69 59 Inputs 18 IB IG 2AVDC Analog or 24VDC SR2 82018 hopper Lid is not Closed Properly Ono o HO a 7 Hi 06 Relay 8A OOD OH OD OH OH OH 12 1222 2 2 1 72 1 2 1 2 2 Gl B 5 6 N7 58 17 Figure 18 NPB Feed Tube Plugged Menu This Menu will appear if pellets build up the feed tube and cause the Proximity Sensor to go off This will result in the pellet burner going in to shut down mode and will not restart till the photocell in satisfied there is no longer flame present ie gt 12345 6BCDEEE DO 096026969 6 59 6909 HOO Inputs 11 18 IB db 24VDC Analog or 24 00 SR2 820180 FEED TUBE PLUGGED REFER TO MANUAL OR CONTACT INSTALLER Menu OK Outputs Qi GG OO OH OH 2 1 uA 12 12 98 12 AS 12 12 10 B M 5 6 17 58 Figure 19 NPB Cleaner Is Running Menu This Menu will appear wh
28. tives on the market The raw materials have different properties which give them both advantages and disadvantages as a pellet fuel The important factors are the energy value the ash content the volatile matter content the environmental impact and price The majority of the disruptions that can arise due to poor fuel quality are the results of poor production handling and intermediate storage before the fuel reaches the end user With high levels of fine chips the deficiency is caused by the manufacturing process and by separation during storage at the loading site The occurrence of sintering in the ash is due to silicate impurities and cannot be ascertained prior to combustion Damp pellets may arise in connection with intermediate handling and transport If possible check when you purchase the pellets that they are clean dry and have not broken down into small particles or chips Damp pellets must be disposed of immediately APPROVED FUEL SPECIFICATIONS Fuel Density 47 58 lb ft 600 750 kg m Energy Content 7600 8700 Btu lb 4 9 5 6 kWh kg Size Diameter 4 2 6 12 mm Size Length max 1 3 8 35 mm Moisture Content max 12 Ash Content Weight0 5 2 Fines Content Weightmax 3 Ash Melting Temperaturemin 2000 F 1100 C NOTE The main power must be turned off and disconnected before servicing the burner The burner should be inspected weekly and cleaned appropriately whe
29. ure 5 additional or unusual utility bills incurred due to any malfunction or defect in the pellet burner 6 labour charges travel costs transportation or delivery costs involved with the repair or replacement of defective component parts o 79o0oc5 Claim or service procedure Contact the dealer who sold you the product If that dealer cannot provide the warranty or service contact the distributor that they purchased the product from to find an alternate dealer and proceed with service or warranty Claims must be made within the warranty period Travel and shipping charges for parts are not covered by this warranty Limitations of Liability Repair or replacement in accordance with the provisions of this warranty will be the owner s exclusive remedy for and will constitute Newmac Mfg Inc sole obligation under this warranty under any other warranty express or implied or in contract tort or otherwise No employee agent dealer or other person is authorized to give any warranty on behalf of Newmac Mfg Inc TO THE EXTENT ALLOWED BY LAW NEWMAC MFG INC MAKES NO OTHER WARRANTY EXPRESS OR IMPLIED INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE NEWMAC SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES HOWEVER CAUSED WHETEHER BY DEFECT IN THE PELLET BURNER OR ANY PART THEREOF WARRANTED HERE UNDER OR BY THE NEGLIGENCE OF ANY PERSON Some states and provinces do not allow exclusions or limitation o
30. w terminal block toea E E 6 Slot for backup memory or PC connection 22 92 67 6694 42 cable J lt 1 7 Shift key 8 Menu OK key for selection and confirmation 9 Navigation keys or after configuring Z pushbuttons Figure 8a Function Buttons TuS L234556BCDEFG TABLE 2 FUNCTION BUTTONS QQ 59009090 9 69 69 69 60 9 69 69 AVIC Inputs 11 18 16 1 Button 1 left arrow Analog or 24VDC SR 82018 2 Button 2 down arrow Newnoc Mfg Inc NPB 3 Button 3 up arrow 60 000 110 000 Bt Moneta aed 2 4 Button 4 right arrow 5 Button 5 MENU OK Y A Output m Relay 6 Button 6 Shift key GG OH OO QO 99 JO 00 1 2 1 52 2 1 272 1 22 12 12 12 12 IB 5 56 07 14 Figure 9 NPB Title Menu When you first turn on the power you will see this information on display To scroll between menus press button 1 left arrow See Figure 8a pe BeBe AE TE ue 62 lt 9 0 9 69 69 D 24V0C Inputs 18 IB 10 24v0C Analog or 24VDC SR2 B201BD Mfg Inc NPB 60 000 110 000 Btu Version 4 3 12 O JO 0 Ou Outputs Q1 08 Reloy DO OO Go 599 VAO 1 72 17 2 2 CA 1 2 1 2 10 13 5 17 INS Figure 10 NPB Running Status Menu two shows y
Download Pdf Manuals
Related Search