BRULA BRULA NEO Quick guide

BRULA NEO
The next generation of professional
combustion control
Installation and service instructions
Note:
Guarantee claims shall be forfeited if these installation and service instructions are
not observed.
- Subject to technical changes and errors -
Dated: March 2018 BRULA GmbH
Weidacher Str. 17
87471 Durach, Germany

BRULA NEO service instructions
Dated 03/18
Page 2 of 52
Contents Page
1General information............................................................................ 4
1.1. Information on installation..................................................................... 4
1.2. Scope of supply and accessories ......................................................... 5
1.3. System components for the BRULA NEO ............................................ 5
1.4. Accessories .......................................................................................... 6
1.5. BRULA NEO functional description ...................................................... 7
2Safety instructions ............................................................................. 8
3Design and installation ...................................................................... 9
3.1. Installation and connection of the display............................................. 9
3.1. Flue gas temperature sensor.............................................................. 11
3.2. Installation and connection of the control system............................... 12
3.3. Connector coding................................................................................ 14
3.4. Installation of the cable housing ......................................................... 15
3.5. Connection of the motor ..................................................................... 16
3.5.1. Motor cable .................................................................................... 17
3.6. Connection of an S-USI II control system .......................................... 18
3.7. Other connections and displays ......................................................... 19
3.7.1. Refill signal .................................................................................... 19
3.7.2. Room temp. sensor ....................................................................... 19
3.7.3. Status LED..................................................................................... 19
3.7.4. Data LED ....................................................................................... 19
3.7.5. 24V bridge ..................................................................................... 19
4Startup ............................................................................................... 20
4.1. Self-test............................................................................................... 21
5Menu structure and display............................................................. 22
5.1. Menu structure.................................................................................... 22
5.2. Main menu .......................................................................................... 23
5.3. General operation of the display......................................................... 24
6Statistics............................................................................................ 24
7User menu ......................................................................................... 25
8Service Menu..................................................................................... 28
8.1. Fireplace insert ................................................................................... 28
8.2. Parameters ......................................................................................... 28
8.3. Relay Menu......................................................................................... 28
8.4. Doorswitch Menu ................................................................................ 31
8.5. Motor Menu......................................................................................... 31
8.6. Overview............................................................................................. 31

BRULA NEO service instructions
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8.7. Test..................................................................................................... 31
8.8. Factory setting .................................................................................... 32
8.9. Saving user data................................................................................. 32
8.10. Loading user data .......................................................................... 32
8.11. System ........................................................................................... 32
9BRULA app........................................................................................ 33
10 Sample circuits ................................................................................. 34
10.1. Controlling the accumulator change pump.................................... 34
10.2. Blocking the extractor fan .............................................................. 35
10.3. Switching on the smoke extractor.................................................. 35
10.4. Switching the SESAM door lifter ................................................... 36
10.5. Activating the external air flap ....................................................... 36
11 Closed-loop control characteristics ............................................... 37
12 Parameters ........................................................................................ 38
12.1. Description of the parameters: ...................................................... 38
13 Appliance list / fireplace .................................................................. 41
14 Repairs............................................................................................... 42
14.1. Replacing the motor ...................................................................... 42
14.2. Replacing the flue gas sensor ....................................................... 42
15 Guide.................................................................................................. 43
16 General warranty conditions ........................................................... 45
17 EU Declaration of Conformity ......................................................... 48
18 Notes.................................................................................................. 49

BRULA NEO service instructions
Dated 03/18
Page 4 of 52
1 General information
You have decided in favour of a BRULA fireplace insert accessory - thank you
for your confidence in our company.
These installation and service instructions provide details on the installation and
start-up of the combustion control system.
Details on operation of the combustion control can be found in the BRULA NEO
operating manual
Important information is printed in bold. Important information and safety
instructions are printed in red and bold - always comply with these points.
Before using the appliance, please read the entire operating manual.
The combustion control system is pre-set to the nominal thermal output of the
delivered fireplace. Information concerning the nominal heat output and the
wood feed quantity can be found in the operating manual of the fireplace.
1.1. Information on installation
Please consult your district master chimney sweep before assembling and
installing your fireplace. He will advise you on building regulations, will check
the suitability of your chimney, will commission your fireplace and will issue the
operating licence for your fireplace.
When installing and operating the fireplace insert and connecting it to the
chimney, make sure that you comply with the national and European standards,
the country-specific and local directives and regulations as well as the fire
regulations for your state (in Germany only) and the Technical Rules of the
Stove and Hot Air Heating System Trade (TROL).
All work on the electrical installation may only be performed by an authorised
specialist company. All equipment must be switched off at the main switch
before performing work on it.

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1.2. Scope of supply and accessories
Scope of supply:
 1 x Control system with plug connectors
 1 x Power cable for the control system
 1 x Display unit in black or white
 1 x Display cable, 5 metres
 1 x Wall socket for the display
 1 x Motor cable, 2 metres with connectors
 1 x Flue gas temperature sensor, 5 metres (thermocouple Type K)
 1 x Room temperature sensor, 2 metres
 1 x Throttle valve with motor to control the combustion air
 BRULA NEO operating manual (for the customer)
 BRULA NEO service manual (for the fireplace fitter)
1.3. System components for the BRULA NEO

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1.4. Accessories
If needed, all conduits can be extended using normal copper cable, but this
does apply to the cable on the flue gas temperature sensor. Here, a
special compensating line MUST be used.
•5m flue gas sensor extension cable (Item No. 1013221)
•10m extension cable for flue gas sensor (Item No. 1013222)
With appliances that circulate water, if the circulating pump is to be controlled
by the BRULA NEO, at least two or ideally 3 PT 1000 sensors should be ordered
at the same time. This is the only way of ensuring that the "Differential
temperature" function and control of the circulating pump can be implemented
together with the BRULA NEO.
•Temperature sensor PT1000 (Item No.. 1013765)
Length 3 metres, incl. immersion sleeve with a G1/2" external thread
•Plug housing for the pump cable, for additional insulation (Item No.
1047657)
If the control system housing of the NEO is to be protected in a special manner,
a dust protection box measuring 210 x 160 x 80 mm can be obtained in which
the control system can be installed. ATTENTION: The cable housings (see 3.4)
must be removed, otherwise the control system will not fit inside.
•Dust protection box for BRULA NEO (Item No. 1013792)

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Dated 03/18
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1.5. BRULA NEO functional description
The basic configuration of the BRULA NEO combustion control system
consists of the control unit, the display, a flue gas temperature sensor and a
motorised throttle valve for the combustion air. The control is only suitable for
fireplaces that burn split logs.
At the start of combustion, the BRULA NEO MUST be activated by
pressing the screen so that the throttle valve opens. The control works
without a door contact switch and detects opening of the door during operation
via a drop in temperature on the flue gas sensor, i.e., automatically. After
closing the door, the control switches, after a short holding time, back to
controlled operation.
Depending on the prevailing flue gas temperature, the control system adjusts
the throttle valve using the motor until the correct quantity of combustion air is
directed into the appliance. The time for adding fuel is displayed with a visual
as well as an audible signal.
The control system remains active until the flue gas temperature has dropped
to about 50°C and then it returns to Standby mode.
In the event of a power failure, the throttle valve automatically moves into a
position in which the fireplace can continue to be operated. Until power is
restored, or until the fire is extinguished, no further interventions or measures
are required.
Throttle valve
Actuator with
spring return
Flue gas temperature sensor
Display
control unit
BRULA NEO
230V AC
Mains connection

BRULA NEO service instructions
Dated 03/18
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2 Safety instructions
•At the start of combustion, the BRULA NEO MUST be activated by
pressing the screen so that the throttle valve opens. A fire may only be
ignited if the throttle valve (air slider) is at 100
•The BRULA NEO combustion control may only be used in combination with
a wood-fired fireplace.
•Only fireplaces which are ordered with this combustion control system and
that are appropriately prepared from the factory can be combined with the
BRULA NEO.
•The combustion control system cannot be retrofitted!
•The maximum ambient temperature for the electrical components is 50°C.
Measures must be taken by the customer to ensure that this temperature
is not exceeded.
•The total electrical installation of the individual components may only be
conducted by an authorised specialist company.
•All electrical installations are to be carried out as per the VDE regulations
(e.g. VDE 0105, VDE 0116, VDE 0100, etc.) and the technical connection
conditions of the local power company.
•All equipment must be switched off at the main switch before performing
work on it.
•The cables must be laid so as to allow maintenance work to be performed
and the individual components of the BRULA NEO to be replaced without
any problems.
•Building moisture and condensation are to be avoided as these can result in
corrosion and failure of the electrical components.
•The connecting cable of the flue gas temperature sensor can only be
extended with a special compensation cable!
•The specified factory settings which are required for the safe operation of
the combustion control may not be changed.
•The installed wires on the fireplace insert must not be pulled. Outside the
fireplace insert, these must be installed so that no tensile forces and no
compression, chafing or shearing points are created.

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3 Design and installation
The design of the cladding must be such so as to enable access to all the
installed components at all times. This concerns the exhaust gas temperature
sensor, the connections, the motor and sensor wires and the control.
The control system should ideally be positioned behind an air grille in the stove's
cold area or in an adjacent room.
It is recommended to secure the socket to the BRULA NEO separately or with
a switch (on site). As a result, the system can be easily switched off in the
summer or for maintenance purposes.
The maximum ambient temperature at the installation location of the
control system must not exceed 50°C!
3.1. Installation and connection of the display
The installation site must be selected so that the maximum permissible
ambient temperature of 50°C is not exceeded and that this component is not
exposed to direct heat radiation when the fire is lit.
For the display cable, an empty tube is preferred with an internal diameter of
at least 18 mm, long enough to reach as far as the wall socket provided.
Break-throughs are laser-cut into the top, bottom and back of the wall socket.
Retaining lugs

BRULA NEO service instructions
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The minimum dimension for the break-through in the wall is (W x H x D):
139 x 82 x 31 mm.
The wall socket must be installed absolutely horizontally in the wall so that the
front edge of the socket is at precisely the same level as the wall coating that
is installed subsequently. Only then will the installed display be flush with the
wall, without any gaps.
If the socket is not plastered in absolutely horizontally or too deep, it is
possible to adjust the position and installation depth of the display. There are
adjustable retaining tabs to the left and right of the wall socket, these are lined
with M4 washers. If the side parts of the socket are positioned too far inwards,
the washers must be removed and the tabs should be screwed on directly.
Initially on one side only and if necessary on both sides.
When inserting the display, the outer glass surface should never be
pressed on. Only ever press on the 4 corners of the actual screen in
order to avoid breaking the glass.
Once the socket has been plastered in and adjusted, the cable is inserted into
the back of the display. Ensure that the stop hooks on the connector click into
place, locking the connector in position. The cable must be routed without any
tensile forces, protected against shearing, crushing and chafing points.
To unfasten the plug connection, press down on the stop hook and pull the
connector out of its bushing backwards.
Stop hook
Spring clip

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The display is then pushed into the wall socket from the front. There are 2 spring
clips on the side of the display that engage in the recesses in the adjustable
retaining tabs.
3.1. Flue gas temperature sensor
The flue gas temperature sensor should, as far as possible, be fitted after the
combustion chamber, i.e., in the flue gas pipe of the burnout. For this, a M10
thread must be cut at the designated point.
Example
With thin-walled flue gas pipes, 2 M10 washers MUST be placed on the
sensor connection otherwise the thread of the sensor does not engage
and this point is not tight.

BRULA NEO service instructions
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3.2. Installation and connection of the control
system
All connections are identified with text on the control system housing.
Switching off the 'add
more fuel' signal
S-USI II *
Motors with spring
return
Servo motor without
spring pull
Flue gas temp.
sensor
Ambient sensor
Water sensor 3
Water sensor 2
Water sensor 1
Door contact 2
Door contact 1
Status LED
(option with stoves)
Display
LED data
24V bridge
Relay 3 (free)
Relay 2 (free)
Circulating
pump control
LED
Power supply
Earth
connection
* To the S-USI II interface, see 3.5

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Dated 03/18
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The external components are connected directly to the control system
connectors. A separate motor cable must be used for the motors. Also for
coupling to a Spartherm S-USI II differential pressure control system, a separate
cable must be used.
Pay attention to the polarity of the following connectors:
"Flue gas sensor" and "throttle valve" These are marked on the image with
crosses. These terminals are also marked separately. With the flue gas sensor,
e.g. the wire colours (green and white) are also printed on the terminal
designation.
With the ambient temperature sensor, the polarity is irrelevant, i.e. the wires can
be connected up in any desired order. If the wires get swapped over, this has
no adverse effects.
For the connection and installation of PT 1000 sensors on water applications,
we advise orienting yourself on the following assignment:
PT1 = Boiler sensor, in the heat exchanger of the fireplace
PT2 = Heat storage function, top
PT3 = Heat storage function, bottom
The assignment of sensors can also be modified retrospectively on the control
system.

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Dated 03/18
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3.3. Connector coding
Whenever the control system is installed in an electrically conductive
housing, e.g. a stove, the cabinet of the appliance must be connected to
the earth connection (PE) of the control system. On stoves, a
corresponding earth cable is supplied with the appliance and is already
connected up.
These 4 plug connections (power cable, pump, relay 2 and relay 3) are larger
than all the other plug connections. This is to prevent confusion. Furthermore,
they are coded with red plug-in bridges, i.e. each connector only fits into its
intended bushing. Never try to plug one of these 4 connectors into a
bushing for which it is not intended. The control system could get
damaged irreparably.
Coding pins
Pump cablePower supply

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Dated 03/18
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3.4. Installation of the cable housing
With fireplace inserts, the control system is usually open, inside the stove
masonry. Here, the cable housings must be installed.
The power cable is equipped with a cable housing as standard.
The pump connection can also run on line voltage if the corresponding relay
function has been activated. For this, a separate cable housing and a cable tie
are supplied with the unit. This cable housing MUST be installed on the
pump cable (provided by customer) to protect against direct contact. With
stoves, the cable housing is not needed. A cover plate protects against direct
contact.
First connect the wires to the connector. Then install the connector in the lower
half dish of the cable housing. Then guide a cable tie through the pre-drilled half
dish and guide it around the cable. Tighten down the cable tie and then clip it to
the upper half dish.
ATTENTION:
If the relay outputs 2 and 3 are connected to line voltage, cable housings must
also be fitted to them. These can be ordered quoting Item Number 1047657.
For further instructions, please refer to chapter 10.

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3.5. Connection of the motor
If the motor is connected to the wrong bushing, it will not work correctly
and there is a risk of explosion. The fireplace must never be operated like
this!
The BRULA NEO is equipped with an external throttle valve. The electrical
motor connection is on the THROTTLE VALVE bushing. These external throttle
flaps have an integrated spring return that releases the entire cross section in
the event of a power failure.

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3.5.1.Motor cable
A motor extension cable is used between the control and motor. The polarity of
this cable cannot be reversed, i.e. it can only be connected up in one position.
Motor cables are always assigned in the same way:
Motor
cable
Extension
cable
Terminal name
in plug
connector
Terminal name
for THROTTLE
VALVE
white
grey
N
0-10V
black
black
PE
GND
red
Brown
l
24V
If the motor cable is too short, it can be extended with a copper wire measuring
3 x 0.75 mm² to a length of about 10 metres. For other lengths, please consult
BRULA. Ensure that the wires are connected up correctly.

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3.6. Connection of an S-USI II control system
The BRULA NEO offers the option of connecting to the Spartherm low pressure
monitor S-USI II.
The S-USI II is a differential pressure monitor which compares the negative
pressures in the gas flue pipe and in the installation room of the fireplace. If the
negative pressure in the installation room is greater than the draught in the
chimney, flue gases could be drawn into the installation room. The S-USI II
identifies this condition and switches off the appliance that is creating a vacuum
in the installation room (ventilation system, extractor fan or similar).
It is possible to connect the S-USI II to the BRULA NEO using a special
connecting cable. In the NEO user menu, you can call up an S-USI II screen
that shows the prevailing operating statuses and the differential pressure in
Pascal.
The standard connecting cable between NEO and S-USI II is 10 metres long
and can be ordered by quoting SAP number 1056300. Other cable lengths are
available on request.
Switch box on an S-USI II
The user is informed of the
prevailing operating status
of the system by two-
coloured LEDs.

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Dated 03/18
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3.7. Other connections and displays
3.7.1.Refill signal
As well as connections for the S-USI II, there is a jumper (bridge connector) on
the board. This connects 2 contact pins together. If the jumper is removed, the
acoustic signal sensor is disabled permanently. We urgently advise leaving the
jumper connected. All sound settings (including muting) can be initiated in the
user menu by display or by app.
3.7.2.Room temp. sensor
For this, the room temperature sensor is connected. The connection cable is
about 2 metres long. We recommend rolling out the sensor wire completely and
positioning the sensor outside the stove masonry. The actual measured point is
the small thick section at the end of the wire.
If the sensor is not connected or is defective, no measured value is displayed.
Instead, all that appears are three horizontal dashes ( - - - ).
3.7.3.Status LED
An LED for checking the functionality of the control can be connected directly
here without a series resistor. The LED works in the following manner:
OFF: Control system is in standby mode, fireplace is off
ON: Control system working in feedback control mode OR
is currently open, performing a self-test in the direction
of 100%
SLOW FLASHING: The time for adding fuel has been reached
FAST FLASHING: The door is open, the appliance has overheated or an
external component is malfunctioning
3.7.4.Data LED
A small red LED is mounted directly on the control unit board, beside the display
bushing. While this is lit or flashing, operating voltage is being provided and the
processor is operational for data processing purposes.
3.7.5.24V bridge
A wire bridge must be
mounted here. If this is
missing, the control
system cannot work.

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Dated 03/18
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4 Startup
At the factory, the BRULA NEO combustion control system is pre-set to the
respective fireplace if ordered at the same time. Failing this, the control system
must be adapted to suit the fireplace which involves it being configured
appropriately.
The following tasks must be completed before the BRULA NEO can enter
service:
1. Fireplace must be installed properly and connected to the chimney. Inlet
airways must not be angled or sealed.
2. On appliances with circulating water: Appliance must be filled, bled and
properly connected to the water supply. Accumulator charge pump
installed. The thermal drainage safety device must also be connected
up.
3. Flue gas sensor fitted on the fireplace insert.
4. Flue gas sensor and throttle valve connected to the control
5. If the accumulator charge pump is to be activated by the BRULA NEO,
a PT1000 sensor must be placed in the fireplace insert and another
PT1000 sensor must be placed above in the buffer storage unit and
both connected to the control system, at PT1 or PT2. In addition, relay
1 must be set to the "Differential thermostat" function. The cable to the
pump must be fitted with a cable housing, and must be connected to
the "Pump out" bushing. Details of this can be found in chapter 10
"Relay functions / Pump connection"
Now the self test can be carried out.
At the start of combustion, the BRULA NEO MUST be activated by
pressing the screen so that the throttle valve opens.
For this the screensaver must already be active, i.e., in the case of doubt
wait a little (max. 2 minutes) until the screensaver is active. With the air
slider on the main menu of the display, 100 MUST be shown as otherwise
a fire cannot be ignited.