INSTALLATION, OPERATING and SERVICE MANUAL
Contents
1. Fig 128 NEWMAC CL SERIES WIRING DIAGRAM WITH AIR CONDITIONING FAN amp LIMIT CONTROL E HONEYWELL L4064R 54 BLUE BLUE FAN LIMIT DFSW ea HONEYWELL J BOX RELAY ea Reesor WENN TT DRAFT FAN CABLE F RUE DETECTER IF SUN S B MAIN J BUX a P g N E NORMALLY LIED 20 VAC 60 HZ 15 SUPPLY POWER SUPPLY m CABLE i L1 BACK J Hu DESY DRAFT FAN SWITCH L2 WHITE 2 5 L GROUND BLALK BECKETT AFG BLRNER JUMPER g n Yel low gBy B LMT ga E EZTE go D pes Y RED 5 gg 4 eo BLACK L1 WHITE A AR HN L2 nr BURNER BELT DRIVE BLACK LU WHITE PRIMARY BLOWER MOTOR EEEN r m BLOWER WIRING Y Y HARNESS aS E Nc e SOLID FUEL ALTERNATE FUEL THERMOSTAT FUR 2 SPEED MOTOR CPTION RED O HEAT COOL THERMOSTAT WHITE RODGERS 150 1 HONEYWELL 187F REQUIRES 02. Fig 10 NEWMAC CL SERIES STANDARD WIRING DIAGRAM mE MINE 9 4 54 DFSW DRAET FAN BLUE HONEYWELL BLUE FAN LIMIT RELAY RE225B g DRAFT FAN D CABLE T T BLRNER 24 V GND WIRE FLAME DETECTER CIF EQUIPFED ig 120 VAL BO HZ 15 A SUPPLY MAIN J BUX mi ea NORMALLY E d m N C NORMALLY CLOSED L1 BLACK 12 12 WHITE 2 n pz 5 DFSW DRAFT FAN SWITCH GROUND WHITE BLACK 7799 E BECKETT AFG BLIRNER JUMPER 2 L E Yellow Je DM 3 ggg T M Yellow LIMIT t 1 Paws RED At BLACK L1 WHITE i T BELT DRIVE BLACK xX BLOWER MOTOR mer L z WHITE BLOWER WIRING i Za HARNESS i ER gt l WHITE FOR 2 SP D MOTOR OPTION RED 50 0 FLEL ALTERNATE FUEL ct THERMOSTAT THERMOSTAT BURNER HONEYWELL T822D HONEYWELL Te220 MOTOR WHITE RODGERS LF30 RODGERS LFIO 120 V WIRING 24V WIRING zz Z EWMAC AVA COMBINATION ILABLE IN SEVERA 0 OUTPUT AND FUEL SOUR EFERS TO UNITS EQUIPPE RNERS SOLID FUE MODELS AND COAL ON NLITPPED WITH HONEYWELL ONTROL TERMINALS EWMAC RB405N IS A DIRE HITE RODGERS 8A05 4 L MODE CE A D WITH
3. Loading Door LPA Lower Primary Air uo9 aoe FIG 14A ELECTRODE SETTING FOR BECKETT FIG 14B ELECTRODE SETTING FOR RIELLO FIG 14 FIG 14D BURNER INSERTION RIELLO SLEEVE POSITION E gt Setback Gasket Riello BF3 Riello Burner End Cone Protector i Part No 2030016 Rielo aor FIG 14E DIMENSIONAL RELATIONSHIPS FIG 14A 14D BECKETT RIELLO A 1 8 5 32 B 7 16 13 64 1 16 5 64 to 7 64 2 1 3 8 a E 7 7 8 7 1 2 27 FIG 15 CLC 90 100 WOOD OIL COMBINATION FURNACE ASSEMBLY FIG 15B PARTS LIST ITEM NO PART NO DESCRIPTION ITEM NO PART NO DESCRIPTION 1 4120203 Blower Section Side Panel 17 5400060 Riello Burner 2 4120314 Fan Partition Panel 17 2110126 Beckett Burner 3 4120315 Blower Section Small Panel 18 4060010 Brick Rack 4 2180002 Filters 16 x 25 x 1 2 19 4120414 Furnace Section Base Panel 5 5300012 Slide Plate Assembly 20 5110006 Split Brick 1 4 X 4 12 X 9 Box of 6 6 2040001 50 CFM Draft Fan 21 2080004 Front Gasket 7 4060461 Secondary Air Slide Assly 22 4120359 Furnace Section Front Panel 8 See Door Assly Diagram 23 4120218 Furnace Section Side Panel 9 See Door Assly Diagram 24 4120104 Furnace Section Back Panel 10 S
4. L MAY OTHER R8405 G CT FURNACES ARE CERTIFIED LS ACCOROING LTERNATE FUEL OIL OR GAS R TO WDDU S FOR UNITS C INTERLOCK 0 W 0 LACEMENT FOR QD WIRE COLORS MAY DIFFER WHITE WHITE VALVE REFER TO BURNER amp CONTROL INSTRUCTIONS CL WIRING OITAGRAM STANDARD 0903201 1 prt 22 RED YELLOW GROUND VHITE IGNITOR RIELLO F3 ELIRNER e CABLE AIR CONDITIONING The following thin line boxed sections are excerpts from NFPA 90B Standard for Installation of Warm Air Heating and Air Conditioning Systems 4 1 4 Air Cooling Equipment Mechanical refrigeration used with air duct systems shall be installed in accordance with ANSI ASHRAE 15 Safety Code for Mechanical Refrigeration 4 1 5 Furnaces Used with Cooling Units 4 1 5 1 Combination units in which a refrigeration coil is provided shall have the refrigeration coil located downstream from the heating furnace or the coil shall be located parallel to the heating furnace Exception Where the heating furnace is specifically approved for installation downstream from the coil 4 1 5 1 1 When the heating furnace is located upstream from the coil the coil shall be designed or equipped so as not to develop excessive temperatures and pressures In those cases where the coil is located parallel to the hea
5. tightly sealed wood heaters get perhaps 50 Notice that the percentage efficiency goes up as the combustion process becomes more and more controlled The roaring fire is a complete waste of fuel The best situation is one where the combustion chamber is gas tight This allows a controlled fire that toasts the wood and puts the right quantity of wood gas in the right place and at the right temperature for optimal combustion and heat transfer The NEWMAC COMBINATION OIL AND WOOD FURNACE toasts the wood to charcoal and the charcoal burns to dust leaving a minute amount of residue From the above heat values it can be seen that a cord or Hickory wood is equivalent to 248 22 30 0 cents litre worth of oil over twice as much as you would pay for a cord of wood Without taking into account all the free wood that is available EFFICIENT WOOD HEATING cuts your heating costs in half 20 1 MAINTENANCE AND OPERATING BULLETIN Regarding Multifuel and Solid Fuel Burning Heating Units The following are some suggestions with reference to the above MAINTENANCE In addition to periodic cleaning it is most important that the unit be cleaned thoroughly at the end of each heating season Both the primary and the secondary heat exchangers should be given extra attention with a steel scraper or brush This will help to prevent rust and corrosion during the high humidity summer months Also if the firedoor is left open it will allow for air to c
6. FIG 6 Oil burner end 24 Flue Pipe 18 Wood door end 48 Top of Supply Plenum 6 One side 6 Supply Plenum and takeoff ducts to 6 from furnace 6 Other side walkway 24 Duct beyond 6 from furnace 1 2 Floor non combustible In USA next 3 3 balance 1 Return Air is otherwise certified to be installed as per CSA B139 Clearances Unlined Joist Space may be used for the Return Air as there is no radiation in the Return Air section Effective August 2008 Refer to Canadian Building Code COMBINATION FURNACE INSTALLATION Check with provincial state or local codes concerning clearances chimney requirements and other installation procedures before installation Some codes may vary from the requirements set forth in this manual To ensure the furnace is on a level foundation and above any possible dampness a cement pad is recommended It is important that the top be level Install as close to the chimney as possible so that a minimum of pipes and elbows may be used If unit is installed in an enclosed area furnace room ventilation must be provided for the burner minimum of one square inch for every 1 000 BTU 1 The NEWMAC COMBINATION FURNACE may be installed with the supply or return air on either side The units leave the factory with the return or cold air on the right when viewed looking at the oil burner end If it simplifies the duct installation to have the supply air on the opposite side remove the installed pan
7. HEATING SYSTEM AND NEVER LEAVE PAPER OR RAGS AROUND THE UNIT 12 HEATING PLANT Give your Heating unit the proper care and attention The use of the furnace as an incinerator is not recommended Heating unit flues should be kept clean for economical operation Dampers are set by installation technicians and should not be changed Free ventilation must be permanently provided in the room where the burner installation is made CONTROLS The operation of the burner is normally controlled by room thermostat which may be set for any temperature desired usually 70 F higher or lower temperature is desired the indicator should be moved to the proper point on the scale To shut down burner at any time turn main switch to off position SUMMER SHUT DOWN When burner is not to be used during the summer months turn off burner main switch If the heating unit room is damp protect burner against dirt and moisture with light cover SAFETY SHUT OFF An emergency oil shut off valve should be installed as required by local ordinance Always keep the valve shut off if the burner is shut down for an extended period of time SERVICE If burner fails to run when the thermostat or other operating control is calling for heat see that the main switch is turned on and that fuses are not blown Be sure there is oil in the supply tank and that the electric service to the building has not been temporarily interrupted Press button on burner control box and if b
8. Species Approx Wt BTU Per Air Equivalent Value 2 Cost at 70 0 Cost at 80 0 Cost at 90 0 Per Cord Dried Cord Heating Oil Litre cents cents cents Hickory 3595 30 600 000 827 4 579 18 661 92 744 66 Hard Maple 3075 29 000 000 784 6 549 22 627 68 706 14 Beech 3240 27 800 000 752 4 526 68 601 92 677 16 Red Oak 3240 27 300 000 738 7 517 09 590 96 664 83 Yellow Birch 3000 26 200 000 709 2 496 44 567 36 638 28 Elm 2750 24 500 000 662 8 463 96 530 24 596 52 Soft Maple 2500 24 000 000 649 2 454 44 519 36 584 28 Tamarack 2500 24 000 000 649 2 454 44 519 36 584 28 Cherry 2550 23 500 000 635 5 444 85 508 40 571 95 Ash 2950 22 600 000 611 4 427 98 489 12 550 26 Spruce 2100 18 100 000 490 1 343 07 392 08 441 09 Hemlock 2100 17 900 000 484 1 338 87 387 28 435 69 Aspen 1900 17 700 000 483 2 338 24 386 56 434 88 White Pine 1800 17 700 000 462 8 323 96 370 24 416 52 Basswood 1900 17 000 000 459 6 321 72 367 68 413 64 Note To change litres to US gal multiply by 0 264 For the least amount of wood handling the wood with the highest heat content is most desirable An open fireplace can actually refrigerate a house because it sucks in so much cold air which is only partially used for combustion A carefully designed fireplace makes use of perhaps 10 15 of the heat available most still going up the flue The well constructed potbellies get perhaps 20 25 and the automatic draft regulated
9. a corrosive atmosphere such as a concentration of acids or halogenated hydrocarbons The installation and operation of the unit in such an environment will be considered as gross misuse and all warranties will be automatically invalidated 3 heating unit must not be modified away from its published design and or specifications without prior written authorization for such modification from Newmac 4 The heating unit must be correctly sized to operate at its designed capability 5 The heating unit must be correctly fueled to operate within its designed function 6 The heating unit must be maintained and cleaned at regular intervals and in accordance with instructions contained in the Newmac owner s manual 7 Failure to comply with all the above stated qualifying conditions will render the Newmac Warranty null and void in its entirety 8 This warranty is the only warranty made by Newmac and furthermore Newmac does not authorize any person or company to change or alter the conditions under which this warranty is provided Newmac does not authorize any person or company to provide any other warranty on its behalf 9 For routine service requirements contact the dealer who installed the equipment originally or an alternate qualified and registered heating dealer or electrician 10 As previously stated herein Newmac does not assume responsibility for costs of delivery or labour charges involved in the replacement of defective
10. attached This shall not preclude the attachment to a plenum or duct of small devices such as humidifiers specifically listed for such use Motors and electrical wiring and equipment shall comply with section 4 2 CONVERSION TO 4 TONS A C 1 2 HP Motor Recommended Use existing motor pulley 7 X 34 Blower Pulley Recommended Standard is 8 39 X 1 2 Blower Belt required for 7 pulley See A C wiring diagram with Honeywell 8405A Relay or equivalent Install a By Pass damper or blast as per sketch Typical A C Coil Installation A minimum supply duct free area of 180 square inches must be maintained at all times during heating the cycle A minimum return duct free area of 250 square inches must be maintained at all times during heating the cycle A C coils installed above heat exchanger should be located over oil section A C coils installed above heat exchanger should be located as high as possible and no less than 12 inches above the top of the heat exchanger A C coils must not be located on return air side Ensure condensate from coil does not drip onto heat exchanger surfaces Condensate drip trays must be metal Ensure duct sizes are as specified in Installation Operating and Service Manual Increased air flows may require more frequent air filter maintenance Emerson 1 2 h p Single Speed Belt Drive Motor p n 2020003 Blower pulley 7 X 34 p n 2240002 39 X 1 2 Blower Belt p n 2240039 Honeywell 8405A fan cente
11. chimney Average flue gas temperatures can be increased by minimizing the length of stovepipe connecting the stove to the chimney This of course will also decrease the energy efficiency of the system and it is often true that measures which decrease creosote formation also decrease heating efficiency For instance stoves which have energy efficiencies due to their relatively good heat transfer e g the Sevca lange 6303 and double barrel stoves are more likely to have chimney creosote problems precisely because they do such a good job extracting heat from the flue gases Generally creosote is inevitable and must be lived with Any kind of chimney deposit decreases the system s heating efficiency Soot and dried creosote accumulations have a significant insulating effect less of the heat in the flue gases transferred into a house through dirty stovepipes and chimneys The most annoying problem can be creosote dripping from a stovepipe or chimney and the most dangerous problem is chimney fires during which the creosote or its pyrolyzed residue burns Creosote dripping can usually be eliminated Joints in vertical segments of stovepipe will not leak if at the joints the smaller crimped ends always stick down into the receiving end Smoke will not leak out of the joints due to this direction of overlay Since this is not the usual orientation for stovepipe a double male fitting may be necessary at some point to connect the 18 stovepipe
12. newspaper crumpled up in the bottom of the firebox on top of the minimum requirement of 2 of sand ash or firebrick Add some small kindling and light the fire When the fire starts add some larger pieces of kindling or wood until you have a good fire The idea is to ultimately end up with a good bed of ash and coals which helps to maintain a good controllable fire When reloading the firebox there will be a build up of ash and coals from the previous fire Rake the coals mixed with ash to the front of the firebox which places the coals at the front Load in your wood and the fire should light in a few minutes When the firebox gets full of ash within two inches of door level some morning before loading the firebox push or rake the coals to the rear of the firebox Remove the ash from the front of the firebox using the shovel supplied for this purpose Refer to Maintenance section on Page 15 for proper removal of ash instructions When the ashes only are removed from the front rake the coals from the back to the front Load in desired amount of wood and the fire will again be burning in a few minutes The fire burns best when the ashes and coals are 3 to 4 below the fire door level Return wood thermostat in main living space to desired setting For safe operating procedure refer to the Notice label on the furnace 13 TYPES OF COMBUSTION AIR FOR WOOD HEATING Unlike older airtight heating appliances low emission furnaces have more than
13. one location and control for supplying combustion air into the firebox These additional air inlets allow for near complete combustion of wood gases and particulates It is important to understand how these three different air supplies work 1 PAC PRIMARY AIR CONTROL A 2 SAC SECONDARY AIR CONTROL 3 LPA LOWER PRIMARY AIR C PRIMARY AIR starts the fire and controls the burn rate Opening or closing this air supply regulates how hot the furnace will burn Primary air is supplied by the following an adjustable slide plate to vary the burn rate and sliding the plate to the Left is a hotter fire Use the Primary Air Control PAC slide plate knob on the left side of draft fan to control the burn rate Always start the fire with the PAC set on high and leave it on high until the secondary flames continue to burn at the rear of the firebox below the baffle then adjust the PAC to a lower setting to the right Adjust the PAC accordingly when refueling An established hot coal bed requires less Primary Air to restart a fresh load of firewood The Primary Air Control PAC also called COMBUSTION AIR is normally set in the center between maximum and minimum The Thermostat also controls the amount of primary air entering the unit by turning on the draft fan and adjustment of slide plate A Turn up the thermostat for 10 to 20 minut
14. tall plume of flame and sparks can be seen rising from the top of uncapped chimneys The most effective way to suppress a chimney fire is to limit its air supply although both water and salt are sometimes suggested if a relatively airtight stove is the connected appliance This is easily done by closing the stove s air inlet dampers if all the stovepipe and or chimney joints are tight and if no other appliance is connected to the same flue In a properly designed and maintained chimney the only potential hazard related to chimney fires is ignition of the building s roof or surroundings due to sparks and burning embers coming out of the top of the chimney A spark arresting screen can decrease but not eliminate this possibility but spark screens themselves are often not suitable for use with wood fuel because they can become clogged The chimney itself and the stovepipe when properly installed are intended to withstand an occasional chimney fire without danger of ignition of their surroundings During a chimney fire one ought to check the roof and surroundings and possibly wet down critical areas If the chimney may not be up to safety standards one should also keep a close watch on all surfaces near the chimney Some people start chimney fires fairly frequently as a means of chimney cleaning This deters very intense chimney fires and the small ones which do happen are always under a watchful eye Under some circumstances this practice may b
15. when there is a power failure Metal connecting ducting from the warm air plenum should be used OIL FIRED BLOCKED VENT SWITCH MODEL WMO 1 Refer to the Newmac and Field Controls Instructions enclosed in the WMO 1 package Do not use the WMO 1 Blocked Vent Switch with the Newmac SVS Sealed Vent System When installed on the chimney vent or on the appliance burner plate according to these instructions the manually reset WMO 1 blocked vent switch is designed to shut off power to the oil burner if the hot flue gases in the chimney vent connector pipe back up sufficiently to activate it The WMO 1 switch is required on new Newmac oil fired and combination furnaces or boilers installed in Canada It must be installed by a qualified installer in accordance with the manufacturer s installation instructions Electrical wiring must be in accordance with applicable codes and the Canadian Electrical Code Before leaving the appliance check that the WMO 1 switch and its cover are tightly secured Installation on the Burner Plate combinations Figs 5A and 5B 1 See Fig Remove the 5 8 diameter plug in the burner plate Cut or file a hole in the rigid fibreglass insulation behind the 5 8 hole in the burner plate large enough that the WMO 1 securing nut will seat against the back of the burner plate Remove one of the securing nuts from the tube of the WMO 1 assembly Tighten the remaining nut onto the tube as far as possible 2 See Fig 5B Wi
16. 0 F The condensation may then be thick and sticky like tacky paint or tar Creosote may be found almost anywhere in a wood heating system from the top of the chimney to the insides of the loading door itself Creosote which remains in a chimney after its initial formation may later be significantly modified both in physical form and chemical content The water and the more volatile organic compounds tend to evaporate leaving the more tar like substances behind If these are subsequently heated by the flue gases from a hotter fire this usually happens they themselves are further pyrolyzed to the same final solid product that wood is carbon The physical form is usually flaky and often shiny on one side Partially pyrolyzed deposits can have a bubbly appearance The flakes do not adhere strongly to a stove pipe and thus are easy to brush off some of the other forms will not budge even under the action of a stiff wire brush The amount of creosote deposited depends mostly on two factors the density of the smoke and fumes from the fire and the temperature of the surface on which it is condensing Highest smoke densities occur when a large amount of wood in relatively small pieces is added to a hot bed of coals and the air inlet damper is closed Here there is considerable pyrolysis of wood but little combustion and little air to dilute the smoke In practice creosote generation is higher during low power overnight smoldering burns Smoke densi
17. 1 Insulator 13 Door Latch 6 Glass Gasket 14 Washer 7 5 MM Ceramic Glass 8 x10 15 V4 Hex Nut 8 Glass Gasket 16 Lag Bolts 4 29 FIG 17 1A BECKETT BURNER EXPLODED ASSEMBLY AF GEB TIF FIG 17 1B BECKETT BURNER PARTS LIST N ITEM iB DESCRIPTION NO z BECKETT NEWMAC z 1 5877 2090024 X Burner Housing Assembly 2 3709 X Air Shutter 3 3492 X Air Band 4 3493 X Escutcheon Plate 8 21844U 2060012 X Pump Clean Cut A2EA 6520 51843U X Strainer amp Gasket 10 21755U 2090065 X Valve Coil Suntec Part No 3713824 7 21877U 2090072 X Valve Stem 51573 2090058 Suntec Pump c w Solenoid Valve 51843U Strainer amp Gasket 21755U Valve Coil Suntec Part No 3713824 Valve Stem Includes 2 O Rings Suntec Part No 3773578 Solenoid Valve Repair Kit Suntec Part No 991375 9 21807 X Valve cordset 11 2256 Pump Nozzle Port Fitting 12 5394 Connector Tube Assembly 13 21805U 2020012 X PSC Drive Motor 3450 RPM 14 2999U 2090056 Blower Wheel 16A 7456U 2090069 X Primary Relay Honeywell R7184B 16B 7457U 2090067 Primary Relay Honeywell R7184P 17 5770 X Junction Box Kit 18 51771U 2090064 X Electronic Ignitor 14 000 Volt 20 7006U 2010006 X Cad Cell C554A1455B Honeywell 21 3384 X 3 3 8U Static Plate 22 5153633BK 2090039 X Blast Tube c w Welded Flange AFG 7 7 8 2110007 X Endcone F4 2110009 Endcone F6 24 2090022
18. 1147 SUBBASE TI VALVE EE IDNITUR 1 A MERE SIS i REFER TO BURNER amp CONTROL INSTRUCTIONS 24V WIRING CODLING CONTACTOR eee RIELLO F3 nee RA Uu Stu l TRANSFORMER RELAY WIRE COLORS MAY DIFFER RiWO yG N D 24 V COIL NEWMAC COMBINATION FURNACES ARE CERTIFIED ES N A AND AVAILABLE IN SEVERAL MODELS ACCORDING YELLIN TO OUTPUT AND FUEL SOURCE ALTERNATE FUEL D YELLOW REFERS TO UNITS EQUIPPED WITH OIL OR GAS TE RODGERS A RIND lt gt BURNERS SOLID FUEL MAY REFER WOOD DN S ER WUE SOME MODELS AND COAL ON OTHERS FOR LINITS Saeed UR BLACK STRIPE EQUIPPED WITH HONEYWELL RBAOSC INTERLOCK CONTROL TERMINALS R C G D H EL WIRE AC W R 0B032011 prt 25 FIG 13 FLUE GAS AND COMBUSTION AIR PATHS Primary Air Secondary PA L EXHAUST GASE Air NN Pd ira 771 16 X 1 FILTERS q 1 kA S Air Filters 25 Jj N mes ff Thermostat Controlled Main Primary Air 26
19. ANT e This furnace is tested to CSA B366 1 and UL391 e This furnace must be installed according to CSA Standard B365 Installation Code for Solid Fuel Burning Appliances and Equipment and CSA Standard B139 Installation Code for Oil Burning Equipment in Canada This furnace must be installed to NFPA211 Standard for Chimneys Fireplaces Vents and Solid Fuel Burning Appliances and 1 Standard for the Installation of Oil Burning Equipment in the US e solid fuel side of this furnace is designed to burn wood only unless equipped with grates thus allowing the burning of coal Burn anthracite coal only e Proper flue draft must be maintained to allow combustion gases to flow freely out the chimney e ONLY ULC 5629 650 or masonry chimney is acceptable e IN USA DO NOT CONNECT THIS UNIT TO A CHIMNEY SERVING ANOTHER APPLIANCE DANGER RISK OF FIRE OR EXPLOSION FOR SAFE OPERATION Load fuel carefully or damage may result Do not load solid fuel higher than the firebrick or cast liner Do not use chemical or fluid fire starters On combination units Do not attempt to light a fire when there is oil vapour present Minimum flue draft 03 W C Maximum flue draft 05 W C Do not burn garbage manufactured fire logs gasoline naptha or crankcase oil or other inappropriate materials Keep the furnace doors tightly closed except for refueling and cleaning Maintain all door seals in good condition To maintain f
20. CATION AND THE OFF POSITION IS CLEARLY MARKED KEEP THE SPACE CLEAR AROUND THE APPLIANCE WITHIN THE SPECIFIED CLEARANCES TO COMBUSTIBLES ENSURE THE SUPPLY OF COMBUSTION AIR TO THE APPLIANCE IS NOT OBSTRUCTED OR CUT OFF MAINTAIN PROPER VENTILATION OF THE APPLIANCE AREA MAINTAIN FREE AIR FLOW THROUGH THE RETURN AIR REGISTERS CONTACT SERVICE PERSONNEL BEFORE REMODELLING CONTACT SERVICE PERSONNEL FOR ANNUAL SERVICE AND MAINTENANCE CONTACT SERVICE PERSONNEL FOR AIR FILTER REPLACEMENT CONTACT SERVICE PERSONNEL BEFORE AND AFTER EXTENDED PERIODS OF APPLIANCE INOPERATION THE BURNER IS FULLY AUTOMATIC IN OPERATION ALL ADJUSTMENTS SHOULD BE MADE BY A QUALIFIED TECHNICIAN DO NOT PUSH THE RESET BUTTON MORE THAN ONCE CAUTION DO NOT ATTEMPT TO START THE BURNER WHEN EXCESS OIL HAS ACCUMULATED WHEN THE APPLIANCE IS FULL OF VAPOUR OR WHEN THE COMBUSTION CHAMBER IS VERY HOT CAUTION DO NOT TAMPER WITH THE APPLIANCE OR CONTROLS CALL YOUR SERVICE PERSONNEL DO NOT USE GASOLINE CRANKCASE OIL OR ANY OIL CONTAINING GASOLINE ALWAYS KEEP THE OIL SUPPLY VALVE SHUT OFF IF THE BURNER IS SHUT DOWN FOR AN EXTENDED PERIOD OF TIME DO NOT START THE BURNER UNLESS THE BLOWER ACCESS DOOR IS SECURED IN PLACE NEVER BURN GARBAGE OR PAPER IN THE HEATING SYSTEM AND NEVER LEAVE PAPER OR RAGS AROUND THE APPLIANCE FURNACES ONLY 32 INSTALLER INFORMATION The homeowner should telephone COMPANY for
21. X Electrode Assembly 8 31517 2110015 X Ceramic Heat Shield 2110016 X Ceramic Heat Shield Holder 3416 2080051 X Flange Gasket 51770 2090061 Field Controls AirBoot 5880 2090044 X Low Firing Rate Baffle 5941 X Adjusting Plate Assy 2100131 X Nozzle Delavan 0 75 X 70 A 2100128 X Nozzle Delavan 0 85 X 709A 30 FIG 17 2A RIELLO EXPLODED ASSEMBLY See FIG 14D for location of Riello End Cone Protector No 49 FIG 17 2B F3 RIELLO BURNER PARTS LIST DESCRIPTION Rielo 2090043 _ O ring pump cover 21 3007802 2060007 Pump 202018 Motor 201045 Photocell 2010048 Primary control 530 SE C Primary control w 24V TT Universal mounting flange 2080058 Mounting gasket NotUsed _ Not Used Manual Air Shutter 2090041 Capacitor 12 5 Uf Fan 40 C3948874 2090051 Blast Tube Assembly 49 2030016 Blast Tube Protector Optional 3007568 Bleeder 3006925 Valve Stem C7001013 Parts Bag 50 C5830011 2010034 24V Relay Switching for Riello Item 50 not used if Item 26B Primary control w 24V TT used 31 m s 11 12 13 14 15 IMPORTANT HOMEOWNER INSTRUCTIONS AN EMERGENCY POWER SWITCH IS REQUIRED TO BE INSTALLED IN A CONVENIENT LOCATION AT A SAFE DISTANCE FROM THE BURNER THIS SWITCH INTERRUPTS THE ELECTRICAL SUPPLY CIRCUIT TO THE APPLIANCE MAKE SURE YOU ARE AWARE OF ITS LO
22. a service call or for additional information APPLIANCE INITIAL TEST AND SERVICE INFORMATION MODEL INSTALLATION DATE DATE 1 FUEL INPUT 2 FUEL PRESSURE PSIG 3 DRAFT BREECH 4 DRAFT OVERFIRE 5 NOZZLE ANGLE PATTERN 6 CO PERCENT 7 BURNER MODEL 8 FLUE GAS TEMP F 9 ROOM TEMP F 10 SMOKE DENSITY N 11 FUEL GRADE N 12 STATIC PRESSURE IN WC BONNET 13 AIR TEMP INLET F 14 AIR TEMP OUTLET F 15 AIR TEMP RISE F 16 LIMIT CONTROLS FUNCTIONING PROPERLY 17 PRIMARY CONTROL A SHUT OFF TIME FLAME FAILURE B SHUT OFF TIME IGNITION FAILURE 18 PULLEY TURNS OPEN 33 NEWMAC MULTI FUEL AND SOLID FUEL HEATING UNIT LIMITED WARRANTY Subject to the following provisions Newmac Mfg Inc Newmac warrants the heating unit to the original owner under normal use and repair against defects in workmanship and materials for a period of one calendar year from the date or original installation Blower motor controls and or any other electrical or mechanical components not manufactured by Newmac are not warranted by Newmac but are warranted for a period of one year from date of original installation by their respective manufacturer In addition to this comprehensive unconditional one year new product warranty Newmac further warrants the heat exchanger for an additional nine calendar years fr
23. aced on a noncombustible 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 Establish a routine for the storage of fuel care of the appliance and firing techniques Check daily for creosote buildup until experience shows how often cleaning is necessary Be aware that the hotter the fire the less creosote is deposited and weekly cleaning may be necessary in mild weather even though monthly cleaning may be enough in the coldest months Have a clearly understood plan to handle a chimney fire INSPECT FLUE PIPES FLUE PIPE JOINTS AND FLUE PIPE SEALS REGULARLY TO ENSURE THAT SMOKE AND FLUE GASES ARE NOT DRAWN INTO AND CIRCULATED BY THE AIR CIRCULATION SYSTEM SEMI ANNUALLY Draft Fan oil motor with 20 non detergent oil if oil cups provided ANNUALLY Burner Motor and Blower Motor oil with 20 non detergent oil if oil cups provided In the spring after the furnace is shut down for the summer clean the heat exchanger of all soot ash and creosote accumulation remove all ashes clean the flue pipe and clean the chimney The baffles should be removed to allow a thorough cleaning and scraping of the heat exchanger see Fig 8B KEEP THE FIREDOOR OPEN APPROXIMATELY 2 TO INSURE MOISTURE REMOVAL DURING SUMMER 15 NOTICE IMPORT
24. component parts 11 Newmac shall not be responsible for any consequential damage however caused whether by a defect in the heating unit or any part thereof warranted hereunder or by the negligence of any person 12 This warranty is not effective unless the warranty registration card is properly filled out with all of the required information and received at Newmac s factory at the address below within 30 days from the installation date NOTE Keep this warranty certificate and the instruction manual for future reference mm To register your warranty please complete form below detach and mail to Mfg Inc Box 9 Lancaster Cr Debert 5 BOM 1G0 ___ LIMITED LIFETIME WARRANTY REGISTRATION Owner s Name Date of Installation Address of Installation Dealer s Name Dealer s Address Furnace Serial Number Furnace Model Number 34
25. cover Remove the two mounting screws for the thermodisc temperature sensor Carefully pull the sensor to one side Using a suitable soft brush or cloth carefully clean any soot from the surface of the sensor and the inside of the 5 8 diameter tube Replace the sensor and secure with its mounting screws Check that the wiring is in good condition and secure Check that the 5 8 diameter tube and its securing nuts are tight Replace the cover and tighten the mounting screws Check the operation of the WMO 1 switch as described above Troubleshooting If for any reason the WMO 1 switch shuts the appliance down during operation the cause of the shut down should be investigated and corrected before resetting the switch and restarting the appliance The blockage switch is reset by pushing the square red button until it clicks SEO BrO NS o9 AONE to Deo FIG 5A FIG 5B zum View Port Viewport WMO 1 5 8 hole 1 Burner Plate Securing Nut Securing Nuts Tube Horizontal appliance junction box Connect WMO 1 at except CL series Burner Plate CL series combination furnaces Connect WMO 1 at the burner control junction box Burner FIG 6 FLUE PIPE CONNECTION amp MINIMUM INSTALLATION CLEARANCES T Floor joist See N Chimney Cleanout Note Duct beyond 6 1 2 Insulated Thimble In USA ne
26. e reasonable but generally it is a risky method to keep a chimney clean There is always some danger of a house fire but in addition any chimney fire is wearing on a chimney the high temperatures increase the corrosion rate of metals and the thermal expansion of masonry materials encourage crack formation and growth Chemical chimney cleaners are available Opinions on their effectiveness vary but apparently when used regularly and as directed they work and do not damage chimneys The usual chimney cleaning method is the oldest human energy and some kind of mechanical tool A stiff wire brush a heavy chain perhaps in a bag hung with a rope and worked up and down from the top of the chimney and very small brushes have all been used Professional chimney sweeps are also reappearing Some people clean yearly other after every few cords of wood burned but there are so many factors influencing creosote build up that such generalizations are not appropriate in most particular cases In new installations or when changes occur such as a different stove the chimney should be checked frequently after 2 weeks then after a month then after another 2 months etc until it is clear how frequently cleaning is usually needed The preceding is an excerpt from THE WOODBURNERS ENCYLOPEDIA published by Vermont Crossroads Press Inc Dec 1976 19 WOOD IS A SAFE CLEAN AND ECONOMICAL FUEL
27. ee Door Assly Diagram 25 4060001 Heat Exchanger 11 2240003 Blower Pulley 8 x 34 26 LPA Slide Assly 12 2040105 G9 2 Delhi Air Circulating Twin Blower 27 2010017 Fan amp Limit Control 12 BC 916 916 2 Airdex Air Circ Twin Blower 28 2010050 Transformer Relay 13 4120323 Blower Section Access Panel 29 3100741 Baffle 2 piece 14 4120403 Blower Section Base Panel 30 4060461 Secondary Air Assly 15 2030004 Corbel Combustion Chamber 31 2080110 Door Frame Insulator 16 5110003 Full Brick 2 V X 4 v X 9 Box of 10 2240040 Standard 40 Belt for 8 Pulley 28 AN Fig 16 Standard Firedoor Breakdown 2 AET 9 6S Dr 028303 9 0 4120508 Firedoor Shield 8 2080002 Dovetail Set 1 2160001 Door Pins 2 9 3160455 Liner 2 4120507 Firedoor Assly Less Frame 10 3160456 Air Chute 3 5300009 Firedoor Handle Complete 11 2120008 Bolts 4 3160362 Inner Panel 12 Latch Part of 5300009 5 12080111 Insulation 13 Washer Part of 5300009 6 3160366 Spacer 14 Hex Nut Part of 5300009 7 2080017 Insulation Fig 16B Optional Glass Firedoor Breakdown 1 1 Door Pins 2 9 Glass Retainers 2 Firedoor Assly Less Frame 10 Dovetail Gasket Set 3 Firedoor Handle Complete 11 20 GA Metal Plate 4 Inner Panel 12 Air Chute 5
28. el and install it on the other side 2 After placing the heat exchanger on the proper side of the pad assemble the blower section to the heat exchanger section by lining up the prepunched holes and metal screwing together 3 Install the oil nozzle in the burner firing assembly and check to make sure adjustments are according to Fig 14 Install the oil burner by mounting it on the burner mounting plate Check to make sure the oil burner tube is aligned with the hole in the combustion chamber 4 Install junction box fan limit control draft fan and thermostat as in Fig 7 Note recommended setting FIG 2 THERMOSTAT HEAT ANTICIPATORS HONEYWELL T822 WHITE ROGERS IF30 In order to prevent short cycling the heat anticipator in the thermostats must be set at 4 amps as indicated in the diagrams below WARNING The heat anticipator will BURN OUT IF 25 volts are applied directly to thermostat by shorting out primary control during testing or incorrect wiring If this happens the warranty on the thermostat is void FIG 3 FAN AND LIMIT CONTROLS Settings Fan off 95 F Fan on 130 F High limit 180 F SLALE PLATE FAN DFF INDICATUR FAN TERMINAL FIXED LIMIT SETPDINT LIMIT TERMINAL PULL AUTO FAN ON INDICATUR LINE LINE ES MANUAL FAN SWITCH EQUIPPED PRT JUMPER NOTE For constant fan operation push the MANUAL AUTO swi
29. em is installed in the house If these or other indications that infiltration air is inadequate additional combustion air should be provided from the outdoors DUCT INSTALLATION The plenums and warm air supply ducts must be constructed of metal To prevent excessive noise and temperature rise limit the minimum return air duct size to at least 250 square inches in Because the unit may be used as a gravity furnace when the power is off the following is recommended 1 Locate the furnace as centrally as possible in the home so the best warm air distribution may be enjoyed 2 Usean extended plenum central duct at least one size larger than called for in National Warm Air Standards 3 Use a minimum pipe size of six inches in diameter in runs and in no case smaller than five inch diameter 4 Slope extended plenums and runs as much as possible to facilitate gravity flow of warm air IMPORTANT FIG 4 MINIMUM DUCT SIZES Model Return Air Supply Air Static Pressure CLC90 100E 250 sq in 180 sq in 20 W C The above chart gives the MINIMUM free area duct size The supply air extended plenum should be 8 10 feet out from the furnace with the sizes shown in the chart then gradually transitioned to the end of duct system If the plenum is lower than 24 inches high increase the duct size proportionately HUMIDIFIER Install humidifier in the return air plenum This prevents possible damage due to excessive temperatures
30. es after reloading for a good start then turn down to desired temperature It is very important to keep the secondary flames burning to maximize heat output and minimize air pollution so some experimentation will be necessary because each installation is different Wood moisture content will also affect the amount of time that a unit will need to burn on high after each reload SECONDARY AIR allows the furnace to burn clean This preheated air enters the upper firebox just below the baffle plate This superheated air mixed with the wood gases and flames ignites reaching temperatures in the 1100F to 1600F range Without Secondary Air these volatile gases would exit the furnace unburned as creosote smoke particulates and high levels of Carbon Monoxide increasing pollution and greatly decreasing efficiency Heat comes from burning the wood gases not the wood which itself turns into black charcoal after the gases are all released and then to grey ashes Secondary air increases a furnaces efficiency by approximately 4096 greatly reducing the amount of wood required for a heating season up to 1 3 less wood SECONDARY AIR SLIDE B is located on the right side of the draft fan NEVER ATTEMPT TO BURN YOUR FURNACE WITH THE SECONDARY SLIDE IN THE CLOSED POSITION AS YOUR FURNACE WILL BURN POORLY AND DIRTY AND PRODUCE CREOSOTE SAC amp LPA Slide Plates must be OPEN at all times when burning wood and may be CLOSED only when the Oil Burner is fired as th
31. for every 1 000 BTU must be provided Use a chimney suitable for solid fuel which must be kept free of accumulations of soot and ash Accumulations of soot and ash not only create a fire hazard but cause poor efficiency In case of a soot fire move all thermostats to their lowest setting close the barometric draft regulator and call the fire department OIL BURNER OPERATING INSTRUCTIONS GENERAL CARE This burner is fully automatic in operation All adjustments have been carefully set and should not be changed Keep burner free from excess dirt and moisture Any oil leaks however small should receive immediate attention The oil filters should be cleaned once a year by the service man The motor should be given a few drops of light oil two or three times a year if oil cups are provided No other parts require lubrication FUEL The supply tank should be kept at least one quarter full Outside underground storage tanks if not equipped with a special gauge are gauged by stick Recommended grade of fuel No 2 Furnace Oil CAUTION 1 2 3 4 5 DO NOT USE GASOLINE CRANKCASE OR ANY OIL CONTAINING GASOLINE DO NOT TAMPER WITH THE UNIT OR CONTROLS CALL THE SERVICE TECHNICIAN Do not attempt to start burner when excess oil has accumulated when the heating unit is full of vapour or when the combustion chamber is very hot Do not start the burner unless the blower access door is secured in place DO NOT BURN GARBAGE OR PAPER IN THE
32. he stovepipe and chimney thus decreasing the system s energy efficiency Creosote formation may also depend on the type of wood burned and on its moisture content Dry hardwoods have a reputation for generating the least creosote but the quantity can still be very large No kind of wood eliminates creosote formation For a given smoke density near a surface the cooler the surface the more creosote will condense on it The phenomenon is very similar to water vapor condensing on the outside of a glass of ice water on a humid day except for an inversion condensation occurs on the inside of a chimney especially when cold air outside makes the inner chimney surface relatively cool A stovepipe chimney outside a house on a cold day will be wet on the inside with creosote including a lot of water virtually all the time A well insulated pre fabricated metal chimney has the least serious creosote problems its insulation helps maintain higher temperatures on its inner surface and its low heat capacity allows it to warm up very quickly after a fire is started Masonry chimneys frequently accumulate deposits at the beginnings of fires and their interior surfaces take a longer time to warm because the construction is so massive Any type of chimney which runs up the outside of a house is more susceptible to creosote problems than the same type of chimney rising in the houses interior due to the cooling effect of the colder outdoor air on the exterior
33. hermostat on combination furnaces is generally set about 5 F to 10 F 3 C to 5 C lower than the solid fuel side When the solid fuel thermostat is calling for heat the draft fan is on If the fuel has been depleted and cannot keep the temperature up the oil burner thermostat brings the oil burner on The NEWMAC COMBINATION FURNACE has a relay that stops the draft fan when the oil burner comes on making the oil fuel side efficient and making the furnace operate safely 11 10 a By means of slide plate A above the firedoor you can control the amount of combustion air allowed into the fire box The position of slide plate A will vary with heat requirement as well as size and type of wood being burnt Slide plates B and C should be open when burning wood For added efficiency when heating with oil only close all three slide plates and adjust your solid fuel thermostat to its lowest temperature setting b FURNACE LABEL ILLUSTRATION Draft Slide A Draft Slides B and C DRAFT CONTROL DRAFT CONTROL SOLID FUEL OIL ONLY OIL ONLY SOLID FUEL MAXIMUM MINIMUM CLOSED CLOSED MAXIMUM 4 4 4 4 For safe operating procedures for solid fuel burning refer to the notice label on the furnace The furnace room must have adequate air for combustion If the unit is in a confined space on square inch of free air access
34. ide of the chimney absorb the various products of incomplete combustion and form creosote When green wood is burned the exhaust gases carry a high moisture content in addition because of the heat required for evaporation these gases are cooler and more likely to condense than would be the case with dry wood Charcoal may be formed more readily if the unit is overcharge particularly in milder weather With overcharging too much wood in unit the draft fan will be off a greater percentage of time coals will be formed which will become covered with ash in turn will smother the coals to form charcoal Any coals in the furnace should be stirred before more wood is added to it The preceding is an excerpt from a document prepared by the Nova Scotia Energy Council and the Nova Scotia Research Foundation Corporation 17 CREOSOTE AND CHIMNEY FIRES Wood combustion is never perfectly complete Wood smoke almost always contains some unburned gases and a fog of unburned tar like liquids Some of these materials will condense out of the flue gases onto any surface which is not too hot The condensation is usually dark brown or black and has an unpleasant acrid odor It is called creosote If condensed on a relatively cool surface such as an exterior stovepipe chimney the creosote will contain a large amount of water along with the organic compounds and will thus be very fluid Water is usually absent if the condensation occurs on surfaces hotter than 15
35. irculate through the units 2 a OPERATION When burning with wood the minimum setting for the manual draft slide should be in the center This is the slide knob beside the combustion fan above the firedoor The closed position is for when burning with oil for a prolonged period to obtain maximum efficiency and the open setting is for initially starting a wood fire Do not attempt to burn the solid fuel in the spring or fall when temperatures are mild This will cause the unit to be shut down for extended periods at a time and will form creosote and soot In the Multifuel units two or three times a week burn the oil fuel for an hour or so This will help to keep the unit clean of creosote build up In the Solid Fuel units burn the fuel at maximum draft with good dry wood for an hour or so once or twice a week This will help to prevent creosote build up During the off season in order to dry out the humidity in the unit fire the furnace once a month for at least 30 minutes The multifuel unit use the oil side The solid fuel furnace build a fire with dry wood The above details if adhered to will extend the longevity of your furnace and provide many years of warm comfortable heat 21 FAN amp LIMIT CONTROL
36. is will increase oil burner efficiency DO NOT LET THE COALS ASHES BUILD UP ANY HIGHER THAN HALF WAY UP THE FIRE BOX LINER POWER FAILURE In case of prolonged power failure first turn off power supply to furnace then remove the blower access door and air filters The draft fan will be off to control combustion air adjust slide plates for more or less air accordingly Turn power switch back on after filters are reinstalled DO NOT CHARGE the firebox higher than half way up the liner as overheating may result 14 SAFETY Whenever a loading door is opened it always should be cracked slightly before fully opening to allow oxygen to enter and burn any combustible gases that are present Failure to do this could result in sudden ignition and explosion of the unburned gases when the door is opened A furnace should never be filled with excess fuel so that the flue gas exit is in anyway blocked or impeded Burning wood generates carbon monoxide If the flue gas exit is blocked the carbon monoxide can be forced out of the furnace into the room with possible fatal consequences The furnace should be used only with chimney systems that provide a strong reliable draft MAINTENANCE Failure to follow these instructions may result in poor efficiency excessive corrosion of the heat exchanger and the possibility of a creosote fire DAILY Check ash level daily and remove as required see Monthly section for instructions BI WEEKLY Furnace hea
37. l FURNACES amp BOILERS INSTALLATION OPERATING and SERVICE MANUAL NEWMAC COMBINATION FURNACE CLC 90 100 E The installation of the unit shall be in accordance with the regulations of the authorities having jurisdiction 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 N4V 1B2 NOVA SCOTIA BOM 160 PHONE 519 539 6147 PHONE 902 662 3840 FAX 519 539 0048 FAX 902 662 2581 EMAIL newmac newmacfurnaces com S HOMEPAGE newmacfurnaces com ow 2e HRAI aces 2 NOTICE HOMEOWNER cour READ THESE INSTRUCTIONS SAVE THESE INSTRUCTIONS fe Farmed CERTIFIED 2210039 April 2012 SGS Subject to change without notice Printed COMBINATION FURNACE MODEL CLC 90 100 E It is the responsibility of the consignee of the unit to examine the packages for damages and if found to note the same on the Carrier Bill of Lading PACKAGE 1 Heat exchanger with end panels and side panel installed filters draft regulator accessory carton brick rack 8 split brick in firebox PACKAGE 2 Blower section with blower installed blower belt attached PACKAGE 3 Oil Burner box with oil burner primary relay cell and nozzle PACKAGE 4 Firebrick 20 full brick Accessory Carton Wire harness fan limit control solid fuel and
38. nd providing there is sufficient draft in Canada amended April 2011 The installation must conform with the regulations of the local authorities having jurisdiction with the applicable Electrical Code and C S A Standard B139 The Installation Code for Oil Burning Appliances and Equipment and with the regulations in C S A Standard B365 The Installation Code for Solid Fuel Burning Appliances and Equipment when pertaining to supply air plenum clearances and flue pipe installation The flue pipe must be black 24 ga pipe minimum Caution The flue collar is sized so that a trade size flue pipe fits snugly inside it Joints in flue pipes including the connection at the appliance and the chimney shall have at least 30mm 1 3 16 overlap Flue pipe connections must be secured with at least 3 metal screws or an equivalent mechanical means and be made tight in accordance with good practice The flue pipe shall have joints arranged so that condensation from the chimney will drain towards the appliance and not have longitudinal seams located on the underside in horizontal runs The flue products may contain carbon monoxide particularly when the wood fire is being starved for air made to burn at slow rate Therefore the flue pipe must seal tight and must not be inserted into the return air stream of the circulating blower Wood storage should conform to local bylaws and should not be within the appliances minimum clearances for combustible surface
39. oil burner thermostats junction box with relay transformer mounted blower motor and pulley draft fan package Instruction Manual FIG 1 GENERAL INSTRUCTIONS BTUH BTUH MODEL BECKETT INPUT OUTPUT NOZZLE PUMP p s i INSERTION CLC90E AFG NM502 105 000 89 000 75 70 A 100 7 7 8 CLC100E AFG NM502 119 000 98 000 85 70 A 100 7 7 8 BTUH BTUH 1 MODEL RIELLO INPUT OUTPUT NOZZLE PUMP p s i INSERTION CLC90E 40 F3 10 BT 111 000 95 000 0 65 60W 150 7 1 2 CLC90E 40 10 BT 111 000 95 000 0 65 60AB 150 7 1 2 CLC100E 40 F3 10 BT 119 000 102 000 0 75 60W 130 7 1 2 WOOD PERFORMANCE DATA Avg particulate emissions 0 035 g MJ Avg particulate emissions 1 69 g hr Avg efficiency based on delivered heat 83 17 96 Min heat output from CSA B 415 emission test 34 544 Btu Max heat output from CSA B 415 emission test 108 368 Btu Avg efficiency based on HHV High Heat Value of fuel and stack loss method 72 95 Avg efficiency based on LHV Low Heat Value of fuel and stack loss method 78 56 Min overall heat output rate based on stack loss method 27 985 BTU Max overall heat output rate based on stack loss method 103 507 BTU The stated efficiency is based on the higher heating value HHV of the fuel ELECTRICAL DATA Avg electrical power consumption 0 183 kw Electrical Supply 115 vac 60 HZ 1 ph less than 12A Minimum Clearance From Combustible Surfaces See
40. om date of original installation and in accordance with the declining table as set out below THE NEWMAC EXTENDED CONDITIONAL HEAT EXCHANGER WARRANTY PROGRAM Warranty protection calculated from date of original installation Owner Warranty Owner Replacement Protection Charge First full year 100 0 From year one through year two 80 20 From year two through year four 60 40 From year four through year six 50 50 From year six through year eight 40 60 From year eight through year ten 20 80 From year ten and over 0 100 NOTES 1 Owner Replacement Charges are expressed as a percentage of the replacement retail price prevailing at the time of replacement purchase 2 Newmac is NOT responsible for Labour charges generated by removal of malfunctioning component and re installation of replacement component Freight charges generated by any form of transportation of replacement component Any applicable sales tax generated by the purchase of replacement component Corrosion is not covered under warranty regardless of cause com General Conditions and Limitations 1 The heating unit must be installed by a qualified licensed installer with the Newmac installation instructions The heating unit must also be installed in accordance with all applicable codes and the National Warm Air Heating and Air Conditioning Association Standards or generally accepted equivalent standards 2 The heating unit is NOT designed or intended for use in
41. ontent of about 15 percent and kiln dried wood may have a moisture content of less than 10 percent when it is fresh from the kiln What causes wood to rot When wood is cut it is very susceptible to the growth of fungi which converts the wood to water carbon dioxide and heat just as does a fire This rotting decreases the wood s energy The fungi are most productive when three conditions are met the temperature is between 60 F and 90 F the wood s moisture content is above 30 percent and ample oxygen is available Thus wood does not rot appreciably when it is dry in the winter or when it is submerged in the water but it should not be allowed to lie on the ground during the summer How can rotting be prevented When the wood has been cut into stovewood lengths and split it should be piled outside during the months of June July and August Two poles should be placed on the ground to serve as rails to keep the firewood off the moist ground and the wood should be piled up in such a way that it is well exposed to the sun and the wind The moisture content of the wood will drop until it reaches equilibrium with the ambient weather conditions When the relative humidity is 60 percent the equilibrium moisture content is about 11 percent When the wood has reached this equilibrium moisture content it is said to be air dried Around mid August it should be placed under cover so that it will not reabsorb moisture from the rain and sn
42. ow before it is used Why this concern about allowing the wood to dry Green or wet wood is undesirable for several reasons Green or wet wood tends to mildew and rot which causes a significant reduction in the thermal value When green or wet wood is burned it may take 20 to 25 percent of the thermal value of the wood heat to evaporate and drive off the moisture which is contained Green wood does not burn easily and in order to keep the fire burning it is often necessary to add a lot of fuel and provide excessive draft thereby decreasing the efficiency of the unit The excess air needed for combustion must be heated and it escapes up the chimney wasting heat that should be used to heat the house What is creosote Wood smoke almost always contains some unburned gases and a fog of unburned tar like liquids Some of these materials will condense on the inside of the chimney just as steam condenses on any cold surface This condensation is a black tacky fluid when first formed When it dries it is flaky and shiny Creosote has approximately the same thermal value as fuel oil Not only does it reduce the effective size of the chimney but an accumulation of this material constitutes a serious fire hazard Does green wood cause creosote Yes Indirectly green wood does cause creosote The exhaust gases cool as they rise up the chimney If the temperature falls below the dew point any moisture contained in these gases will condense on the ins
43. r transformer relay p n 2010015 Honeywell 8285A fan center transformer relay p n 2010041 Honeywell 8239B fan center transformer relay p n 2010059 The unit must be installed in accordance with the National Warm Air Heating and Air Conditioning Association Standards or generally accepted equivalent standards Consult appropriate provincial state or local codes Regulations governing installation requirements may vary from the ones presented here 23 FIG 11 TYPICAL COIL INSTALLATION SET COIL AS HIGH AS POSSIBLE IN PLENU A C COIL METAL OR STEEL DRIP TRAY PIVOTING OR F amp L SLIDING DAMPER SOLID FUEL SECTION OIL SECTTIN ACOIL 14072006 PRT FIG 12 AIR CONDITIONING INSTALLATION W634D Sub base 5 N RH w Y R Ww Connect to Air Connect toR amp W gt y Conditioning on raneto ey Transformer Relay Starter e For Air Conditioning For Air Conditioning remove the oil thermostat and replace with a T834A Thermostat with a Q634D Sub base In junction box on furnace x Connect to Power Supply 5 5 and from Blk to Combination 5 If not used Control _ ew tape up Connect to Black from fan Motor and Blue from Combination Control 24
44. rnace door THIS DAMPER SHOULD BE CLOSED FOR NORMAL OPERATION 3 Do not load the fire box higher than half way up the firebrick or cast liner SOOT FIRE Close all sources of air that can reach the fire through the furnace and draft regulator Insure the draft fan above the fire door is turned off Do not attempt to take the flue pipes down until the fire has been completely extinguished RUNAWAY FIRE This can be caused by too high a flue draft or excessive fueling 1 Close all sources of air to the furnace Insure draft fan is turned off 2 Set the barometric draft regulator wide open to reduce draft The excessive heat caused by a runaway fire may damage the furnace safety controls Their operation should be checked before the furnace is returned to service After a soot or runaway fire inspect chimney connection and chimney 16 PREPARATION OF WOOD Once have my wood at home how do prepare it for burning The wood must be cut to length to suit the firebox of the stove furnace or fireplace in which it is to be burned An 8 log may be cut into four six or eight pieces depending on the desired length Splitting the wood greatly facilitates drying and reduces the wood to a more manageable size How much moisture is contained in wood Many softwoods have a moisture content in the vicinity of 55 percent when they are freshly cut The popular hardwoods have moisture contents of about 45 percent Air dried wood has a moisture c
45. rward off right amp left side mounting clip A Remove the secondary air assembly 1 through the firedoor Installation To install repeat the procedure in reverse order Ensure pin 3 is bent down on both ends to secure the secondary air assembly in the furnace FIG 9 Motor and Blower Assembly BE_T ORIVE BLOWER MOT OR ADJUSTMENT 140 211 1 PRT MOUNTING MOTOR If motor is equipped with oil caps rotate motor in mounting base so oil caps are up BELT TENSION When adjusting the proper pulley setting make certain that the belt is able to flex at least one inch without movement of the motor pulley The belt should be just tight enough to avoid slippage Align pulleys with straight edge ITEM NO PART NO DESCRIPTION ITEM NO PART NO DESCRIPTION 1 2040105 G9 Twin Circulating Blower c w 8 Pulley 10 2040141 Blower Motor Mounting Bracket 2 2240003 8 x 34 Blower Pulley 11 2120027 5 16 x 34 Sq Head Screw 3 2240001 14 x V Variable Speed Motor Pulley 12 2150001 5 16 Washer 4 2240040 40 x 7 Belt 13 2130002 5 16 Nut 5 2130010 Motor Adjustment 14 2130002 5 16 Nut 6 2140002 34 x Hex Cap Screw 2 15 2130010 Motor Adjustment 7 Motor Frame 16 2130011 Motor Adj Leg Rubber Foot 8 2150004 Ya Washer 17 2020002 1 3 HP Belt Drive Blower Motor 9 2130003 Ya Hex Nut 10 COMBINATION OPERATING INSTRUCTIONS When the installation is complete set both burner and solid fuel thermostats
46. s as shown on Page 1 Do not store fuel within the space required for fuelling ash removal and other routine maintenance operations This furnace must be installed by a qualified furnace service person COMBUSTION AIR Where fans are used in the fuel storage area they should be installed so as not to create negative pressure in the room where the solid fuel burning appliance is located OUTSIDE COMBUSTION AIR Provision for outside combustion air may be necessary to ensure that fuel burning appliances do not discharge products of combustion into the house Guidelines to determine the need for additional combustion air may not be adequate for every situation If in doubt it is advisable to provide additional air Outside combustion air may be required if 1 the solid fuel fired appliance does not draw steadily experiences smoke roll out burns poorly or back drafts whether or not there is combustion present 2 existing fuel fired equipment in the house such as fireplaces or other heating appliances smell do not operate properly suffer smoke roll out when operated or back draft whether or not there is combustion present 3 anyofthe above symptoms are alleviated by opening a window slightly on a calm windless day 4 the house is equipped with a well sealed vapor barrier and tight fitting windows and or has any powered devices which exhaust house air 5 there is excessive condensation on windows in the winter or 6 aventilation syst
47. speed must be adjusted by means of the following With the oil burner operating place a thermometer in the warm air supply place thermometer so that it cannot see the heat exchanger and measure the temperature after the unit has been operating for at least 5 minutes Be sure the blower door is closed measure the return air at return air grill If the difference is less than 75 F slow the fan speed by opening the motor pulley or if it is greater than 75 F close the pulley In the majority of cases the fan must be slowed By means of the motor adjustment bracket adjust the motor so that the belt may be deflected approximately one inch This adjustment is important as a tight belt causes excessive fan bearing wear it uses more electricity and it is noisy If the above instructions are followed continuous air circulation can be comfortably accomplished without the added expense of a two speed motor simply by using the manual fan switch on the face of the combination control Before loading the solid fuel firebox turn the thermostat up to insure that the draft fan is on after the fire is established set thermostat to desired temperature IMPORTANT Learn how to load your solid fuel box with wood so as to maintain a comfortable home temperature The amount of fuel required depends upon your home s heating requirements A small and intense fire is preferable to a large smoldering one to reduce the amount of creosote deposition The oil burner t
48. t exchanger and flue pipe The complete heat exchanger and flue pipe should be thoroughly inspected for creosote deposits ash buildup etc See pages 17 amp 18 for more detailed information on creosote Creosote or ash deposits must be removed by scraping and or brushing the deposits from the heat exchanger surfaces the baffle may have to be removed see Fig 8B An industrial vacuum cleaner may be used to assist in the removal of such deposits A complete cleaning must be done immediately at the end of each heating season If this is not done condensation from the summer months or any other source will mix with the ash or creosote and cause corrosion of the heat exchanger Corrosion is not covered under warranty Chimney The chimney should be inspected for creosote buildup Chemical chimney cleaners are not recommended as they could damage the furnace heat exchanger and flue pipe One of the most efficient methods to clean a chimney is to lower a stiff brush chimney brush tied to a heavy weight down the chimney on a rope Work the brush up and down the chimney to scrape the accumulated creosote and soot off the chimney walls Remove the residue from the cleanout at the base of the chimney MONTHLY Ashes must be removed on a minimum of a monthly basis depending on the ash build up Ashes should be placed in a metal container with a tight fitting lid and other waste shall not be placed in this container The closed container of ashes should be pl
49. tch on button to MAN position 5 Connect wiring as in Fig 10 All models 6 Install the oil storage tank or tanks according to the instructions supplied by the manufacturer of the tank and the appropriate regulation for the location of the installation 7 Install brick in firebox according to Fig 8A and baffles according to Fig 8B 8 Install motor and belt on circulating blower according to Fig 9 9 Do not use a manual flue pipe damper with this furnace Optimal draft should be controlled by means of the supplied barometric draft regulator adjust to a 03 to 0 5 draft at the chimney see page 11 paragraph 5 for correct installation 10 Caution If this furnace is used as a replacement for an existing furnace make sure there is a minimum of 6 clearance above the warm air plenum as far as 6 feet out from the furnace Beyond 6 feet there must be a minimum of 1 2 clearance This furnace must be connected to a chimney approved for wood burning appliances ie ULC S629 Canada and UL103 US Newmac recommends an 7 round or 7 square chimney flue inside dimension It is the responsibility of the installer to ensure there is sufficient draft in all cases Draft should be between 0 03 and 0 05 ins wc No other appliance should be connected to this chimney flue for installations in the US No other appliance should be connected to this chimney flue unless the installation conforms to clause 5 of B365 a
50. th the WMO 1 assembly outside the burner plate insert the threaded tube end into the 5 8 diameter hole in the burner plate re install the first securing nut onto the tube on the inside of the burner plate Tighten securely CAUTION Disconnect the electrical power supply before wiring the WMO 1 assembly 3 See Fig 5 Using suitable AC90 flexible BX conduit or equivalent wire the WMO 1 switch in series with the appliance limit circuit Connect at the burner junction box 4 Check the operation of the WMO 1 switch before leaving the appliance The WMO 1 switch is reset by pushing the square red button WMO 1 Blocked Vent Switch Check Note take appropriate precautions this test can produce soot smoke and fumes The appliance should not be left unattended during the test With the appliance shut down block the vent pipe at the downstream chimney side of the barometric damper Start the appliance The WMO 1 switch should stop the oil burner in less than 10 minutes After the test turn off the appliance and let it cool Remove the blockage from the vent pipe Reset the WMO 1 switch by pushing in the square red button until it clicks Ensure that the appliance is in a safe condition Maintenance and Cleaning The WMO 1 switch assembly should be checked and cleaned at least once a year and after any time the switch has shut off the burner Cleaning procedure Switch off the electrical power to the appliance Remove the WMO 1
51. ties are least when combustion is relatively complete which tends to be the case when the amount of excess air admitted to the wood burner is high Leaky stoves open stoves and fireplaces typically have the least creosote problems One way to lower the average smoke density in an airtight stove is to use less wood each time fuel is added and or to use larger pieces of wood In either case the air supply need not be turned down so much in order to limit the heat output and combustion is likely to be more complete Of course if less wood is added stoking must be more frequent A related procedure to limit creosote is to leave the air inlet moderately open after adding wood until the wood is mostly reduced to charcoal and then close the inlet as much as desired This will promote complete combustion during pyrolysis when the creosote compounds are being formed but there will be a significant heat surge while the gases are burning Extra air can also be added to the flue gases in the stove pipe this is what the Ashley creosote inhibitor does But the net effect of adding dilution air is not obvious or necessarily beneficial Dilution air will decrease the smoke density but it will also decrease its temperature These effects have opposing influences on creosote formation The National Fire Prevention Association states that dilution air increases chimney deposits In any case the cooling effect of dilution air does decrease the heat transfer through t
52. ting furnace dampers or other means to control flow of air shall be adequate to prevent chilled air from entering the furnace section If the dampers are manually operated means shall be provided to prevent operation of either unit unless the damper is in the full heat or cool position Adequate means shall be provided for the disposal of condensate and to prevent dripping of condensate on the heating element 4 1 5 2 Furnaces including duct furnaces may be installed downstream from the evaporative coolers or air washers provided that condensate will not fall into any portion of burners pilots or burner carry over arms and provided that the heating element is made of corrosion resistant material such as stainless steel ceramic coated steel or an aluminum coated steel in which the bond between the steel and the aluminum is an iron aluminum alloy Air washers operating with chilled water which delivers air below the dew point of the ambient air at the appliance are considered as refrigeration systems 4 1 5 3 The capacity of the blower shall be adequate to overcome the external static pressure imposed by the combined heating and cooling units at the air throughput required for heating or cooling whichever is greater 4 3 6 Accessory Equipment Material used in the construction of accessory equipment attached to or installed in a supply or return system shall comply with the requirements for the materials of that portion of the system to which it is
53. to the bottom of the scale Close the supply switch and turn the solid fuel thermostat above room temperature The draft fan should operate If this fails to happen check a power supply b voltage on secondary side of control relay transformer c correct wiring hook up d correct voltage at fan motor If a to d check OK the fan is defective Open the line switch turn the solid fuel thermostat to its lowest setting and the oil burner thermostat above room temperature Remove the air bleed plug from the pump refer to Diagram attached to pump a open oil supply valve b place a container in position to catch foam c close the line switch and after pure oil is emitted open the line switch and replace bleed plug d close the line switch and the oil burner should run normally after a few seconds Adjust oil burner air control so that a 1 or less smoke is arrived at by means of a smoke test Close all three slide plates when doing the smoke test see paragraph 10 of this section If a smoke tester is not available slowly close the air adjustment until the fire becomes smokey Slowly open the air adjustment until there is a small amount of smoke on the flame tips By means of the barometric draft regulator adjust to a 03 draft at the chimney This must be done by means of a draft meter The maximum draft is not to be more than 05 as damage can result to the furnace when used as a gravity unit The test must be made be
54. to the stove a prefabricated chimney or a rain cap Special drip proof adapters are available for connecting some sizes of stovepipe to Metalbestos brand prefabricated chimneys Common types of stovepipe elbows can leak creosote due to their swivel joints rigid and accordion type leak proof elbows are available Horizontal or gently sloping joints between horizontal pipes and or fillings are the most difficult to seal against dripping A good high temperature sealant can sometimes help but is no guarantee The joint must also be snug and well secured with sheet metal screws If all joints are made leak proof then the creosote will generally drip into the stove where when the fire is hot it will be burned Chimney fires occur when the combustible deposits on the inside of a chimney burn The deposits may be raw creosote pyrolyzed creosote or soot Ignition requires adequate oxygen which is usually available and sufficiently high temperatures the same conditions as for the ignition and combustion of any fuel Chimney fires are most likely to occur during a very hot fire as when cardboard or Christmas tree branches are burned or even when a stove burns normal wood but at a higher than normal rate A crackling sound can often be heard at the beginning of a chimney fire As the intensity of the fire rises the stovepipe will sometimes shake violently air will be very forcefully drawn in through the stove and the stovepipe may glow red hot A
55. tween the flue collar on the furnace and the draft regulator A flue gas analysis should be made with all three slide plates closed see paragraph 10 of this section the unit adjusted so that between a 8 and 10 CO is registered The combination fan amp limit switch is thermally operated The limit side is connected in series to the power supply to the oil burner Because of blower failure dirty filters or some other cause the present limit will interrupt the power supply to the burner If the limit switch shuts the unit down it may be because of a common fault not enough return air supply or a supply air grill being covered by a rug The load side of a limit also supplies power to the transformer relay If the unit goes off on limit the draft fan will shut off The fan side of the combination control is adjustable with fan on and off fingers If the furnace fan has been adjusted to deliver a 75 temperature rise difference between return air and supply air a setting of fan on 130 and off at 90 100 F is comfortable The temperature rise in accomplished by speeding up or slowing down the fan by means of the adjustable pulley on the fan motor Maximum temperature rise is 75 F on CLC 90 100 E The motor pulley is factory set but should be adjusted to give a 75 F temperature rise at a 20 W C or 25 W C static pressure air resistance in duct work Since most home duct work does not have resistance of the value the fan
56. urnace efficiency and prevent soot fires clean the heat exchanger flue pipes and chimney at the end of each heating season to minimize corrosion during summer months and as frequently as required during the heating season to prevent soot accumulation The furnace flue and chimney must be in good condition These instructions also apply to a draft inducer if used Turn off power to the furnace when cleaning the furnace and flue e Do not store fuel or combustible material within the furnace clearances e Do not use salt wood driftwood gathered from the seashore WB WG amp WFA models the return air ducts are to be metal not wooden WARNING TO PREVENT DAMAGE AND RISK OF FIRE e Do not set the flue draft above 05 W C as the fire could burn out of control e f equipped do not open the furnace door slide plate damper during normal operation e Furnaces with grates must have ashes removed daily e Furnaces without grates require a minimum of 2 of sand or ash in the bottom of the fire box CAUTION HOT SURFACES e Keep children away e Do not touch during operation SPECIAL PROCEDURES POWER FAILURE 1 Turn off power supply to furnace remove the blower access door and air filters for better air circulation If the furnace is in an enclosed area furnace room open the door to the room Turn power switch back on after filters are reinstalled 2 If equipped to control the fire open the slide plate damper in the fu
57. urner still fails to start call the service person A periodic inspection of the burner is recommended BURNING WOOD OPERATING INSTRUCTIONS When installation is complete turn on the power switch and turn the thermostat above room temperature Check to make sure the forced draft fan above the fire door is operating when the thermostat is set above room temperature The draft fan should be off when thermostat is set below room temperature The maximum draft is not to be more than 05 as damage may result to the furnace when operated as a gravity unit The motor pulley is factory set but should be adjusted to give an adequate temperature rise under most conditions However because of various temperatures that can result from burning wood the blower speed can be adjusted by the motor pulley The temperature rise is the difference in temperature between the hot air plenum and the cold air plenum and under no circumstances should the temperature rise be more than 80 F 27 F NOTE Before loading the fire box turn the thermostat up to insure that the draft fan is on This provides an air curtain to avoid smoke roll out during loading and fans the coals to assist the ignition process of your new fuel It also helps to promote when there is inadequate draft After the fire is established set the thermostat to desired temperature To start the fire turn up the thermostat to Maximum setting to turn ON Forced Draft Fan Place some
58. xt 3 3 balance 1 Fastening E All sides of flue pipe 18 One side 6 Other side walkway 24 E 24 a 4 H Furnace J FIG 7 CONTROL LOCATIONS Mound Conte el Brocket Fiver wih Edge Pieri TS Fight Hand Setup Alternate Blower Posiltons T Left Hond Seiup from Mart Sie 39 Fight Hand Setup Side Right Side Setup Setup FIG 8 FIREBOX INSTALLATION PROCEDURE WITH STAINLESS STEEL FRONT Clips are welded to inside of firedoor opening 1 Place 4 row of firebrick firebox as shown 4 split 10 full 2 Place top row of firebrick in firebox as shown 4 split 10 full 3 Insert top frame into the clips with frame setting 1 top of bricks FIG 8B BAFFLE AND SECONDARY AIR SYSTEM REMOVAL amp INSTALLATION PROCEDURE CLC90 100E CLIT OUT FOR SECONDARY AIR SYSTEM 28032011 PRT Removal Gain access through firedoor Lift right side secondary air baffle 2 off pin D Ensure pin D clears hole E Remove through firedoor Repeat for left side baffle Remove pin 3 by bending one side up to straighten Slide pin 3 out of mounting hole C of bracket F Slide secondary air assembly 1 back out of bracket Tip front of secondary air assembly 1 down towards firedoor Slide secondary air assembly fo
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