Wood Pellets Burner

Bio comfort
100 step modulated
Woody Generation

EN 303-5 approved by DTI (Danish Technological Institute)

Approved for pressure expansion
Energy class AA
 Manual
NBE pellet system
INSTALLATION GUIDE FOR COMFORT BOILER

Comfort Opop
Height 1050mm 850mm
Width 700mm 380mm
Depth 700mm 560mm
Chimney 130mm 130mm
Forward flow 1 1/4“ 1 1/4“
Back flow 1 1/4“ 1 1/4“
Lining 1/2“ 1/2“
Efficiency 93,3% 89,7% Dragex
Draught stabilizer
General guidelines:
The boiler should be installed by an authorized fitter and must
be installed in accordance with work supervision publication 42
( Danish ) covering equipment working with water.
The outlet duct should be no longer than 1m,
and should be fitted with a cleaning door.
The chimney draught should be at least 5 PA and should be stable,
a draught stabilizer should always be installed.
If combustion gases condense in the chimney (wet ash)
install a draught stabilizer in the chimney, or open the flue
(the flap inside at the back of the boiler)
as wide as possible to increase the temperature of the smoke.
The boiler must be spanned with a bypass to ensure the back flow is al-
ways kept above 55 degrees.

Installing the burner into the Comfort boiler:

1. Install the burner on the side of the boiler
(there should be no shield on the burner, when using the comfort boiler ).
2. Fit the controls either into a cabinet or on the wall.
3. Install the overheating safety cut off into the pocket on the side of the boiler, and connect the
controls so that the overheating safety cut off will cut the power if the boiler overheats.
4. Install the heat sensor on the forward flow, either in the pocket or by the sensor on the for-
ward flow. (The sensor must be insulated to the forward flow.)
5. Fit the pipe on the drop shaft (this must be the pipe that comes with the Comfort boiler).
6. Fit the hopper and auger so that the pipe slopes.
(PELLETS MUST NOT GET STUCK IN THE PIPE.)

Diag. Example of installation

 Manual
NBE pellet system
BOILER INSTALLATION GUIDE H418—H4160

Installing into boiler:

1. Check that the burner is undamaged.
2. Fit the burner and tighten it firmly using the two wing nuts supplied.
3. Ensure that the burner is in a horizontal position and all connections are tight.
4. Fit the cover and the plug.
5. Wire up the overheating safety fuse following the electrical wiring diagram.

Outer auger:
6. Install the auger through the opening over the burner.
7. Ensure that the pipe slopes enough to allow the pellets to fall into the burner.

When using for the first time:

8. Make sure there are enough pellets by the entrance to the outer auger.
9. Force-start the auger by holding down the UP button by the power input point.
10. If the pellets fall into the combustion chamber, turn off again by pressing DOWN.
Then restart the burner using electrical ignition.

Turning off the alarm:

11. If the alarm goes off or the burner will not start, switch the burner off and on again
using the ON/OFF switch on the control box.
 Manual
NBE pellet system
SETTING BY WEIGHT

Unplug the burner and force-run

the auger until pellets start to come out of it,
continue for 15 minutes.

Then weigh the amount of pellets

after 360 seconds and enter the result
into the controls as the capacity
of the auger.

Once again plug in the burner

and start it.
 Manual
NBE pellet system
USER GUIDE

Current operation Various sensor readings

Boiler temperature
Smoke temperature (special apparatus)
Temperature of mechanical stoker
Current performance
Oxygen % (special apparatus)
Current light in combustion head
Press SET and the display will show SETUP for standard settings.
The UP button is used to increase the setting and for force-running the auger
( hold for longer than 5 seconds ).
The DOWN button is used to decrease the setting and switch the controls on/off
( hold for 10 seconds ).
.

Temperature BOILER TEMPERATURE

Setting the required boiler temperature.
Auto combustion The burner sets the performance higher or lower depending
Man. combustion on the figure entered (set point).
At 10 degrees over this figure the burner will begin to pause or turn itself off.
Timer
PAUSE DIFF. TEMP
Cleaning / power The setting defining how far the boiler temperature must drop below the desired
value before the burner restarts.
O2 Control

SCREW CAPACITY
Temperature After setting the auger performance in 360 seconds the control will
Auto combustion automatically calculate the amount of pellets in low steam and high steam,
pellets in pause , and pellets for ignition
Man. combustion Under normal conditions these numbers will be correct.
Timer To increase combustion, set the value DOWN.
Cleaning / power
To reduce combustion, set the value UP.
O2 Control
CHIMNEY DRAUGHT
With a strong chimney draught the ventilator performance will be higher,
At low steam and during pause.
If the amount of chimney draught is increased,
the automatic calculation sets more pellets in low steam and during pause.
The smaller the chimney draught and the greater the back pressure of the boiler,
the lower the value must be.
The greater the chimney draught and the lower the back pressure of the boiler,
the higher the value must be.

YES/NO
Switching automatic calculations on/off.
If automatic calculation is on, only the auger performance can be set.
 Manual
NBE pellet system
USER GUIDE

Temperature PELLETS LOW

Setting the amount of pellets for low performance.
Auto combustion Should be set so there is a flame when running 10% power.
Man. combustion
PELLETS HIGH
Timer Setting the amount of pellets for full performance.
Should be set so that combustion is powerful when running at 100% power.
Cleaning / power
O2 Control PAUSE PELLETS
Setting the amount of pellets for during lag.

If in doubts about the settings, use the automatic calculation program.

Temperature STARTS / DAY

Setting daily operating cycles.
Auto combustion Switches the pellet burner on and off at set periods.
1 is one start each 24 hour.
Man. combustion 6 is one start each 4 hour.
Timer If this function is activated, the operating cycle is turned on.

Cleaning / power PERIOD TIME

Setting the running times using the clock.
O2 Control The time should be set sufficiently in advance to allow the burner to reach normal
operating temperature at the set time.

NEXT START
Switches on after a certain length of time; this is used when the boiler needs to be
turned on without anyone actually being present, e.g. at 4.00 in the morning.

CLOCK
The clock correctness depends on the feed from the power station.
The clock is calibrated every time when you set it,
and should match after 1-4 settings.
WARNING
The clock does not contain a battery and will lose its settings if there is a power
cut. Therefore always switch off using the ON/OFF button on the regulator.

Temperature CLEANING INTERVAL

Sets how often the burner should be cleaned.
Auto combustion If you often heat on low load, the interval can be reduced to 5 minutes,
with 5 seconds of cleaning.
Man combustion
Timer CLEANING TIME
Set the cleaning time.
Cleaning / power The shorter the intervals the shorter the time should be.
O2 Control
MINIMUM POWER
Setting minimum performance.
If the pellet burner always works on low load and is having some difficulties,
the minimum performance can be increased so the burner occasionally turns off.

MAXIMUM POWER
Setting maximum performance.
If the pellet burner rapidly reaches a high temperature,
the maximum performance should be reduced.
 Manual
NBE Pellets Systems
Betjenings vejledning.

ONLY TO BE ADJUSTED
IF THERE IS A LAMBDA CONTROL MOUNTED ON THE BOILER. !!

O2% MIN POWER

The amount of excess oxygen in the smoke at low performance.
Temperature Sets the amount of fuel so that the excess oxygen is at the required amount.
Auto combustion If the pellet burner smokes at low performance, set a higher percentage of oxygen.
If the photo sensor has problems recognizing the ignition, this could be caused by
Man. combustion the ignition being too weak; set a higher value to increase the feed.
The flame should be yellowish.
Timer
Cleaning / power O2% MAX POWER
The amount of excess oxygen in the smoke at full performance.
O2 Control Sets the amount pellets so that the excess oxygen is at the required amount.
If the pellet burner smokes at full performance, set a higher percentage of oxygen.
If the flame is angry and sputtering, set a lower percentage of oxygen.

OFF / DISPLAY / ON
Turns oxygen regulation on/off.
Oxygen regulation set to ON –
The burner sets the amount of pellets to suit the required percentage of oxygen.
Oxygen regulation set to DISPLAY –
You can read the percentage, but the burner does not set the amount of pellets.

The tighter the boiler, the more you get from oxygen regulation.
It is recommended to fit the chimney with a draught stabilizer,
this will reduce the draught and cut the amount of air flowing back into the boiler.

EXTENDED SETUP (Press the SET button for 6 seconds.)

Ignition
PELLETS
Pause Run Setting the amount of pellets for ignition.
O2 Sencor
PERIOD
Fine tune Setting maximum ignition duration.

PID regulation POWER %

Setting performance of electrical ignition.
Temp. alarm
FIRE LIMIT
Setting amount of light required to interrupt ignition.

Ignition MAXIMUM MINUTES

Maximum pause time,
Pause burner will then ignite electrically.
Oxygen
BLOWER %
Fine tune Ventilator speed during pause.
PID regulation
Temp. alarm
 Manual
NBE Pellets Systems
Betjenings vejledning.

Ignition GAIN
Sets how much oxygen regulation should regulate when activated.
Pause Run
O2 SENSOR TUNE
O2 sensor Calibration of oxygen sensor to ensure it gives accurate readings.
Fine tune Hold the exhaust gas oxygen sensor in the air and calibrate it to give it a reference
value to the air (21% oxygen).
PID regulation WARNING! The oxygen sensor must be warm!
Temp. alarm

Ignition MIN. POWER

Corrects the calculation program at low feed,
Pause Run used in special conditions causing a difference in calculations.
O2 sensor
MAX. POWER
Fine Tune Corrects the calculation program at full feed,
used in special conditions causing a difference in calculations.
PID regulation
Temp. alarm

Ignition P - GAIN
Shifts performance in relation to deviation from required temperature.
Pause Run
O2 sensor I - GAIN
Shifts performance in relation to the time the pellet burner
Fine tune deviated from the required temperature.
PID regulation D - GAIN
Temp. alarm Shifts performance in relation to the temperature trend of the boiler.

Ignition BURNER TEMP. MAX

Indicates the maximum temperature the burner can reach; protects against back
Pause Run combustion.
O2 Sensor BOILER TEMP. DIFF.
Fine Tune Indicates the maximum deviation from the set point temperature of the boiler before
the burner triggers the alarm to signal a temperature drop caused by an error, etc.
PID regulation
Temp. alarm
 Manual
NBE pellet system
EXTENDED SET-UP GUIDE

SETTING THE CONTROLS

The controls work in 100 step modulation and change these step automatically.

If you use the automatic calculation program after measuring the performance of the auger,
no further setting should be necessary.

Setting pellets at low and full load…

During normal everyday use it is recommended to occasionally check the combustion and assess the flames.
Whenever the heating pellets are changed (size or length of pellets, etc. …),
the dosing rate of the auger will also change, which will affect combustion.
(However, if the burner is equipped with oxygen regulation, the burner will regulate this automatically.)

If there is a big flame on low load (10-30% performance)

(Dark, or black tips) or the ash is black.
In this case fewer pellets are required at low load.
(Reduce the chimney draught or reduce the pellets low )

If there is a big flame on full load (70-100% performance)

(Dark, or black tips) or the ash is black.
In this case fewer pellets are required at full load.
(Increase the performance of the auger or reduce the pellets high.)

If there is a weak flame on low load (10-30% performance)

(Small flame and sputtering stars) or the ash is light grey.
In this case more pellets are required.
(Increase the chimney draught or set the pellets low higher).

If there is a weak flame on full load (70-100%)

(Small flame and sputtering stars) or the ash is light grey, with dark pellets.
In this case more pellets are required.
(Reduce the performance of the auger or set the pellets high higher.)

The pellet burner must not smoke, but must be sealed tight.
(Take care that smoke does not mingle with condensed steam.)

Correct combustion normally results in dark grey ash,

although this can vary slightly depending on the type of pellets used.
White and light ash in the boiler means excess air.
Having the boiler set up correctly has a great effect on the economy of burning wooden pellets

Fuel type
The boiler is set up for wooden pellets Ø 5-8mm,
which do not burn to cinders!! ( Hard ashes )
 Manual
NBE pellet system
CLEANING GUIDE

When cleaning, turn off the burner…

Turn off the controls (hold the on/off button down for 10 seconds)
and let the burner cool down for about 3 minutes,
when it is completely switched off the burner is ready to be cleaned.
Unplug the burner, remove the cover and the drop shaft,
and unscrew the burner from the boiler before continuing.

The burner should be cleaned regularly and whenever necessary.

This will ensure that the burner runs as economically as possible.
The more suitable the boiler you have and the better the pellets you use,
the longer the intervals between each cleaning session.

The boiler…
Clean the ash out of the boiler and brush off
all the surfaces to remove any deposits.
Be very careful of the ash in the backflow valve
and the chimney pipe.
The chimney-sweeper DO NOT CLEAN
the chimney pipe, you must do this yourself …
An old vacuum cleaner or ash bucket are
especially suitable,
as the ash does not normally contain carbon particles or tar.

Combustion heads…
Remove the ash and any cinders from the grate.
Remove any remnants of pellets from underneath the grate.
Wipe the flame indicator.
Ensure there is nothing in the ventilator.

VERY IMPORTANT!!!
THE COMBUSTION HEAD WILL
B BE DAMAGED IF THE GRATE IS
N NOT POSITIONED CORRECTLY!!!

Pellet hopper…
As the pellets you put in the hopper contain detritus,
the hopper should be completely emptied from time to time.
The more detritus there is in the hopper, the less the auger feeds,
which can interfere with the settings cause the burner to cut out.
The frequency with which you empty the pellet hopper depends entirely on the angle inside of the hopper
and the quality of the pellets you use.

Restarting after cleaning…

Reassemble the pellet burner and ignite it (hold the on/off button down for 10 seconds),
at which point the burner will start automatically. DO NOT FORGET to replace the cover,
to ensure that the temperature of the combustion chamber is measured correctly.
 Manual
NBE pellet system
TROUBLESHOOTING

Problem Cause Solution

ALARM 1. Cinders/ash in the combustion head. Clean the combustion chamber!
HOT DROP SHAFT 2. Ash in the boiler, smoke pipe and chimney. Clean the boiler, smoke pipe and chimney!
OR BACK SMOKE 3. Backflow valve installed incorrectly in the boiler. Rectify or remove the backflow valve panel in the boiler!
4. No draught in chimney. Strip the insulation in the smoke pipe, raise the chimney!
5. Performance too high (kW) in proportion to boiler. Contact your dealer!
6. Defective sensor. Change the heat sensor on the printed circuit board!
7. Air flow wrong. Contact chimney-sweep or NBE!

ALARM 1. Burner grate not fitted correctly. Check the burner grate.
FAULTY IGNITION 2. Ash/cinders in the combustion head. Clean the combustion chamber!
3. Damp pellets. Change supplier/storage!
4. Ignition not fitted correctly. Fit into quadrangular holder.
5. Defective ignition. Change ignition/ignite manually!
6. Excessive chimney draught. Install a draught stabilizer in the chimney.
7. Photo sensor is faulty/covered in soot. Clean/change the sensor.
8. Blocked ventilator. Clean the ventilator and check that it works.

ALARM Boiler temperature has not exceeded 35 degrees after 2 Low burner performance.
LOW BOILER hours of operation, or has dropped below Check pellet feed/ventilator!
TEMPERATURE 35 degrees when running. Check that the temp. sensor is on the boiler.

ALARM 1. Plug on the burner is not fitted correctly. Check the plug on the burner !
PLUG NOT FITTED 2. Dirt in the plug. Clean any pellet reside from the plug.
3. Faulty sensor. Change the sensors (photo/temperature).

Control display is black 1. Boiler overheated Reset overheating fuse!

2. Control fuses broken. Change the fuses. Check for short circuits!
3. Contrast button not set on controls. Set contrast button.

Burner ejects HFI relay 1. Ignition faulty. Change Ignition/ignite manually!

2. Faulty cables. Check cables and plug on the burner.
Check condition of burner.

Burner goes out on “LOW STEAM” 1. Fuel supply instable. Check there is no sawdust at the entrance to the auger.
Weak flame 2. Pellets remain in pipe. Check the slope of the auger.
3. Low feed is set too low. Check that the auger drops into the combustion chamber.
4. Chimney draught estimated wrongly. Increase chimney draught and watch LX indicator at low
5. Amount in auger measured incorrectly. performance.
Measure the auger again for 360 seconds.

Burner goes out on “PAUSE” 1. Pellets supply instable. Check there is no sawdust at the entrance to the auger.
Weak flame 2. Pellets remain in pipe. Check the slope of the auger.
3. Chimney draught is set too low. Check that the auger drops into the combustion chamber.
4. Chimney draught too strong. Watch LX indicator during pause.
Increase chimney draught.
Install a draught stabilizer in the chimney.

Excessive pellet consumption / 1. Combustion set incorrectly. Check that the ash is dark grey!
boiler will not reach required tem- 2. Chimney draught too strong. Measure the chimney draught / install a draught stabilizer.
perature 3. Backflow valve installed incorrectly in the boiler. Check boiler, install backflow valve.
4. Bad boiler /low efficiency/ insulation. Measure smoke temperature, insulate the boiler!
5. Combustion chamber working too hard. Reduce performance of combustion chamber.
6. Damp pellets/poor quality. Use efficient pellets.

Boiler and burner are clogged up / 1. Too many pellets. Increase auger performance in calculation program.
black. 2. Lag set incorrectly. Reduce chimney draught.
3. Blocked ventilator. Clean the ventilator!

Support: www.pelletsburner.net
 Manual
NBE Pellets Systems
ELECTRICAL WIRING DIAGRAMS
 Manual
NBE Pellets Systems
WARANTY

All products purchased from NBE are naturally covered by the applicable Danish purchasing law.
Products come with a two-year warranty valid from the date of receipt.

However, this does not cover the exhaust gas oxygen sensor, electrical ignition or the combustion grate.
These are considered to be replaceable parts.

The warranty only covers production and material faults.

If there is a fault with goods under warranty,
NBE will send a replacement part for repair at no cost to the purchaser.
The purchaser shall install the replacement part himself.
If NBE offers to repair a defective part, the purchaser shall send it to NBE, who will repair it and then return it.
The warranty becomes void if the fault is caused through circumstances caused by the purchaser, by accident,
or by improper use of the goods, incorrect cleaning, chimney condition, as well as circumstances unrelated to
NBE. In addition to this the warranty becomes void upon improper use of the boiler, for example by using fuel
not approved by NBE. The warranty does not cover parts such as the exhaust gas oxygen sensor, electrical igni-
tion and combustion grate. The purchaser is obliged to check the goods immediately upon receipt. If on the
basis of this inspection the purchaser would like to make a claim to the effect that the delivery was inadequate
or somehow at fault, the customer must immediately file the claim with NBE without delay. Goods can only be
returned upon agreement with NBE. To the extent that NBE is liable to the purchaser, the responsibility of
NBE is limited to direct damage, i.e. damage to connected equipment, and indirect damage, for loss of earn-
ings, operating losses, connection costs, etc.
responsibility:
NBE accepts no responsibility as a result of the purchaser’s legal relations with third parties.
All orders are accepted with the exception of force majeure, such as war, civil unrest, natural catastrophes,
strikes and lockouts, breakdown in the supply of raw materials, fire, damage to NBE or its supplier network,
breakdown in transport facilities, bans on import or export or any other event which prevents or restricts NBE
from supplying its goods.
In the case of force majeure, NBE may choose to either cease trading in full or in part, or to supply the contrac-
tual goods as soon as the obstacle preventing normal delivery has passed. In the event of force majeure,
NBE is in no way responsible for any damage caused to the supplier as a result of its failure to deliver.
We do not vouch for printing errors, price adjustments, changes in the exchange rate, sold-out goods or changes
to specifications in products such as the manual.
It is the purchaser’s responsibility to have the equipment registered with the appropriate offices; any disputes
between the authorities and the purchaser do not relate to NBE and are not its responsibility.
Upon request the following documents can be issued:
12. Exception to pressure expansion from Work Supervisor.
13. Declaration of conformity.
14. DTI type approval (Danish Technological Institute).
15. Printed circuit board diagrams.
This material is also available at www.nordjysk-bioenergi.dk.
 Manual
NBE Pellets Systems
INSTALLATIN OF OXYGEN EQUIPMENT

Installation of oxygen equipment

Install the exhaust gas oxygen sensor into the boiler (Diag.1)
and ensure it will be in good contact with the flue gases,
e.g. into the smoke outtake or the front doors.
It is important that the installation is airtight.
Attention – it must be possible to remove it.
Then disconnect the power and remove the lid on control box.
Fit the exhaust gas oxygen sensor cable to the four terminals
(marked with blue, Diag.2).
The color is on the printed circuit board.

Diag.1 (Controls, exhaust gas oxygen sensor).

Install the enclosed chip (marked as a black square, Diag.2).
The little dot at the top of the chip must point in the same direction
as the markings on the printed circuit board holder.
(facing away from the screw terminals).

THE CHIP MUST NOT BE TURNED THE WRONG WAY

THIS WILL DAMAGE IT!!!

Fit the lid back on the control box.

Connect the power to the controls and wait about 15 minutes for the exhaust gas oxygen sensor to warm up.
You can now calibrate it. Find the oxygen regulation in the menu and select DISPLAY.
Switch to the extended menu and calibrate the oxygen and the sensor.
Note: the exhaust gas oxygen sensor must be held in the air.
The burner will continue without having regulated the pellets , but the percentage of oxygen will appear on the
display. Fit the exhaust gas oxygen sensor back into the boiler and spend a little time detecting the percentage
of oxygen at LOW LOAD and FULL LOAD, which is when your burner fires at its best.
There should be a powerful flame at FULL LOAD (100%) and a slightly weaker one at LOW LOAD (10%).
Note that the tighter the boiler is and the smoother the chimney draught, the more accurate the oxygen percent-
age measurements will be.
It is always recommended to install a draught stabilizer into the chimney
together with oxygen regulation.
When you have found the optimum percentage of oxygen, go into the menu below O2 and select YES,
then enter the percentage of oxygen detected into O2 MIN POWER and O2 MAX POWER.
The controls will then automatically set the auger times into PELLETS LOW and PELLETS HIGH.
If you want more powerful combustion, set a lower percentage of oxygen.
If you want weaker combustion, set a higher percentage of oxygen.

Diag. 2
 Manual
NBE Pellets Systems
MOUNTING THE PELLET HOPPER
 Manual
NBE Pellets Systems
EXCEPTION FOR PRESSURE EXPANSION

NBE
Jannich Hansen
Brinken 10
DK 9830 Oester Vraa
Landskronegade 33
2100 Copenhagen
Telephone 39152000
www.arbejdstilsynet.dk
Your contact JH
Our ref. 20030027413
Our contact.
G.Agersnap
Direct telephone
0045-3915265915

Re: Use of burner to burn wooden pellets type Woody, Scotte, Bio-comfort and
Boink in boiler equipment in relation to smaller, closed facilities in compliance with Work
Supervisor Regulations for Hot-water Heating Systems. (publ. 42/1980 para 4)

With regard to your query of 1 September 2006 concerning the use of the burner to burn wooden
pellets type Woody, Scotte, Bio-comfort and Boink in boiler equipment in relation to smaller,
closed facilities with pressure expansion, we can report that the Work Supervisor has perused the
submitted materials and can declare that the burner for wooden pellets type Woody, Scotte, Bio-
comfort and Boink can be installed in the heat facilities listed in paragraph 4 of the Work Supervi-
sor publication no. 42/1980, Regulations for Hot-water Heating Systems.

It is assumed that the boiler contains the requisite amount of water and that the entire heating fa-
cility is designed in exact compliance with the instructions given in publication 42/1980, and also
that the electricity supply will only be connected to a boiler with a fitted and connected thermostat
with the appropriate overheating safety fuse which must be manually reconnected after activation.

All heating in the boiler must take place by means of the pellet combustion chamber, and only
fuels listed in the instructions may be used. Otherwise the equipment must be installed with an
open expansion (compare paragraph 2 in publication 42/1980).

This decision is based on the enclosed instructions and diagrams, Test Report no. 300-ELAB-
0741, as well as the Power Dropout Test with readings recording the build-up of heat in the boiler
if the power supply to the equipment is interrupted.

Best regards,

G.Agersnap