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PB-1525 Wood Pellet Burner System: Installation and Operation Manual
Rev 1.0, OCTOBER 2011

Page 56 of 67

Burner Servicing

Burner servicing (other than regular cleanout of the burn chamber as
described in this manual) is authorized to be performed by Pellergy

Certified Installation Professionals only. Any alteration performed by a
non-Pellergy trained individual voids the warranty. Burner failures caused
as the result of improperly performed service or installation by non-trained

individuals voids the warranty.

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Summary of Contents for PB-1525

Page 1: ...ERATION MANUAL Product P N Pellergy PB 1525 Serial Number ________________ Wood Pellet Burner System REV 1 0 OCTOBER 2011 16 Railroad Street Barre VT 05641 802 659 4866 www pellergy com www mywoodpell...

Page 2: ...ion 26 System Operational Description 27 System States 27 System Setup 35 Filling the Conveyor 38 Setup of the Start Feed Value 40 Setup of the Burner Firing Rate 42 Setup of the Initial Combustion Bl...

Page 3: ...latory compliant domestic hot water boilers and furnaces including dedicated Pellergy boilers and furnaces The PB 1525 is intended for use with Premium Wood Pellets as defined by the Pellet Fuels Inst...

Page 4: ...ed installation professionals ONLY Any unauthorized installation of the PB 1525 system voids the product warranty and may result in loss of property bodily injury to personnel and even death Pellergy...

Page 5: ...warning may result in damage or loss of property bodily injury and even death CAUTION A caution identifies risk of damage to equipment failure to abide by a caution may result in permanent damage to t...

Page 6: ...nded to operate unattended for up to 3 4 weeks with proper maintenance and automatic burn chamber cleanout The PB 1525 system provides an alarm output contact that can integrate to an existing or add...

Page 7: ...ash buildup between cleanings This ash will accumulate within the boiler furnace The host boiler furnace must be easily cleaned on a more regular basis than when firing on oil Additionally the boiler...

Page 8: ...n and apply his her experience with the particular boiler furnace type during the initial evaluation of the system 5 The PB 1525 should be set up to fire an existing boiler or furnace at a maximum of...

Page 9: ...to convert the unit to solid fuel please consult the boiler or furnace manufacturer before installation NOTE When installing the PB 1525 take note of the surrounding area with regard to the regular m...

Page 10: ...urnaces unless specifically allowed by local Code AND the use of an interlock system is used such that only one unit may use the chimney at any given time The PB 1525 should not be used in conjunction...

Page 11: ...er system if the door is opened 4 Fit the custom PB 1525 burner mounting plate to the boiler or furnace For specific fitting details refer to documentation included with the custom mounting plate 5 Af...

Page 12: ...th a Pellergy KPA 100 5 Cast Iron 5 Section boiler Installations will vary however this figure shows a typical installation with the standard 550LBS working hopper The working hopper can be replaced b...

Page 13: ...on Boiler Installation of the Pellet Conveyor When determining the location of the pellet conveyor mounting position the location of both the PB 1525 burner and the pellet hopper must be considered 1...

Page 14: ...be opening Max 30 inches See Figure 2 3 below c The conveyor must be mounted such that the drop tube is a minimum of 6 inches laterally away from the PB 1525 pellet feed tube opening Maximum of 12 inc...

Page 15: ...must be installed at an angle between 40 50 as shown in Figure 2 3 above b The feed conveyor auger tube must not exceed 10 FT in length The feed conveyor may be cut to a desired length provided that f...

Page 16: ...hes of the PB 1525 wood pellet burner Keep all combustible materials a minimum of 24 inches from the PB 1525 wood pellet burner Follow all boiler and furnace manufacturer s required combustible keep o...

Page 17: ...requiring supply air ventilation hoods etc An improperly ventilated room can lead to incomplete combustion lower efficiency and even the production of harmful gasses within the living space WARNING Pr...

Page 18: ...ended for use in every installation due to the potential for high winds and resulting high draft If the system is exposed to temporary draft in excess of 0 10 in H2O a misfire can occur thereby shutti...

Page 19: ...al connection listing is provided below as well as on the door of the terminal panel enclosure Figure 2 5 below shows a detail of the enclosure Four 4 knock outs are supplied on both sides of the encl...

Page 20: ...Auger Motor 7 L1 Air Cleanout Solenoid 8 N Air Cleanout Solenoid 9 Ground Air Cleanout Solenoid 10 N O Contact Alarm Output 11 N O Contact Alarm Output 12 T1 Tstat Dry Contact Input N O V olt age 13...

Page 21: ...RED ORG BLU TERMINAL PANEL ENCLOSURE Figure 2 7 Factory Terminal Connections within the Pellergy Supplied enclosure There are two external electrical connections required to connect the PB 1525 1 Conn...

Page 22: ...urned Connecting the PB 1525 System to a Voltage Source 1 The PB 1525 connects to household line voltage 120V AC 60Hz for operation The voltage source for the PB 1525 must a Be connected to the same p...

Page 23: ...s of the PB 1525 wood pellet burner system will result in improper and potentially dangerous system operation and system damage The Thermostat connections are for Normally Open N O Dry Contacts only A...

Page 24: ...ire Connecting the WHT BLK and WHT YEL leads of the RIB to the aquastat and the BLU and ORG leads of the RIB to the Pellergy PB 1525 thermostat input will result in proper operation Figure 2 8 RIBU1C...

Page 25: ...TOBER 2011 Page 25 of 67 RED BLU BLK YEL BLK RED WHT RED ORG GRN BLK L N G V V V V YEL RED BLK BLK WHT WHT ORG RED WHT BLU WHT BLK GRN TEMP IGNITOR FLAME SENSOR 24VDC POWER SUPPLY BLK BLK BLK WHT BLOW...

Page 26: ...er Interface The display indicates system status and serves as an information panel for the Certified Installer and Operator It contains four rows of alphanumeric characters and displays the following...

Page 27: ...unter is at 0 during idle mode This counter will count down in seconds until the next change of state during operations however in the Idle state the counter will remain at 0 The Blower speed indicato...

Page 28: ...tionality is only available in the Idle State Toward the end of the Feed Start State the system will run the auger to feed the initial start amount of pellets into the burn chamber When this occurs an...

Page 29: ...system will enter into an alarm state indicating a failure to ignite The system can be forced into the Shutting Down State by pressing and holding the Disable button for five seconds Stabilizing The...

Page 30: ...y is the total number of running hours of the system indicated as 13 on the display This display area will automatically cycle every 2 3 seconds between Hours Starts and Resets If the system fails to...

Page 31: ...e and a lost flame error will be displayed The system can be forced into the Shutting Down State by pressing and holding the Disable button for five seconds Shutting Down The Shutting Down state indic...

Page 32: ...s state will cause the system to continue the full shut down sequence including the purge then the system will ignore the thermostat See the section on System Disabled Purging The Purging state indica...

Page 33: ...rge then the system will ignore the thermostat See the section on System Disabled ALARM The Alarm state indicates the system has detected a problem and has shut down Following the detection of an alar...

Page 34: ...indicates the type of alarm in this case the lack of a temperature sensor connected to the system WARNING If the system is found in the ALARM State there has been a problem that requires your attentio...

Page 35: ...adjustments control various operational aspects of the system and ensure both reliable and safe system operation WARNING System operational parameters are to be set by the Pellergy trained Certified I...

Page 36: ...nter this state on the controller perform the following steps 1 Power the unit in Technician Mode 2 As soon as the controller enters the Purging State press and hold the Disable button 3 Once the unit...

Page 37: ...ed On Run Time for the Auger during the Firing State Set as a means to establish the input firing rate of the system 6 Temperature Limit Stack Temperature shutdown set point Set as a means to protect...

Page 38: ...rd functionality This test will run the Combustion Blower Ignitor Auger Feed Motor Not intended for the Certified Installer this test is used to proof the controller boards at the final stages of asse...

Page 39: ...stat or follow the steps below to force the system into the Idle State 1 Power the unit normally or in Technician Mode 2 As soon as the controller enters the Purging State press and hold the Disable b...

Page 40: ...ull of pellets and there is a consistent flow of pellets from the auger 3 IMPORTANT Clean the burn chamber as there may be unburned pellets in the burn chamber 4 Restart the system by pressing and hol...

Page 41: ...roller A good first test time is 33 0 seconds 3 Place a graduated container that will allow you to measure pellets in cups and or ounces under the conveyor drop tube 4 Initiate an initial dump test by...

Page 42: ...ing rate of the burner Failure to do so can result in over under firing of the boiler furnace Place the controller in the Idle State and Technician Mode by following the steps below 1 Power the unit i...

Page 43: ...1 Pound of pellets 8 200 btu of heating value o 1 FT3 of pellets 40 Pounds Therefore if during the six 6 minute test the conveyor feeds a total of 1 15 Pounds of pellets use the following formula to...

Page 44: ...f the system Running the Burner for the First Time During the first burner operation stack gases will be analyzed and the blower value will be adjusted to achieve proper combustion properties Do not i...

Page 45: ...mbustion adjustments to feed rate and fan speed can be made while the burner is running to obtain the proper combustion properties Remember to wait least 2 3 min between making changes to the controll...

Page 46: ...N cycles as set by the Certified Installer To set the number of cycles between cleanout system activation follow the steps below The system must be in Technician Mode 1 Press the Parm button until Cle...

Page 47: ...w the steps below The system must be in Technician Mode 3 Press the Parm button until Temperature Limit is displayed on the controller 4 Use the and buttons to add or subtract degrees F The set number...

Page 48: ...be necessary to remove the clinkers from the bottom of the firebox in the boiler to ensure proper operation This can be done with a simple ash removal shovel inserted through the burn chamber opening...

Page 49: ...roper system operation It is recommended that the PB 1525 owner execute a regular maintenance contract with your certified installation professional for regular cleanout services on the boiler furnace...

Page 50: ...thin the assembly 8 Dump contents of the burner chamber into a properly rated ash can Scrape or brush the chamber as necessary and re assemble the burner IMPORTANT Remember to Enable to system by pres...

Page 51: ...esult of the burner failing to sense the presence of flame within the prescribed time period 1 Burn Chamber clogged or filled with clinkers and ash 2 Out of Pellets 3 Failed Ignitor 4 Failed Flame Sen...

Page 52: ...uggests a flame sensor short as a potential cause 1 Burn filled with clinkers 2 Failed Flame Sensor 3 Foreign light introduced to burn chamber 1 Clean burn chamber and restart system 2 CP install new...

Page 53: ...when the system senses a short in the stack temperature sensor 1 Wire or leads to the temperature sensor damaged 2 Failed temperature sensor 1 Check wore and leads to temperature sensor for mechanica...

Page 54: ...inking 2 Ensure temperature sensor is properly installed in smoke pipe as close t the boiler furnace flue collar connector as possible 3 CP install new temperature sensor No Error Message system inope...

Page 55: ...t Burner System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Page 55 of 67 water 3 Damage to conveyor system connection of the conveyor to the feed motor CP repair of conveyor CP Pellergy Ce...

Page 56: ...r cleanout of the burn chamber as described in this manual is authorized to be performed by Pellergy Certified Installation Professionals only Any alteration performed by a non Pellergy trained indivi...

Page 57: ...cement Burner for steam boilers hot water boilers and hot air furnaces with existing oil burners was tested and found to comply with the intent of test standards UL 391 ETLM 78 1 CAN CSA B 366 1 ASTM...

Page 58: ...Flame sensor Optional Relay Conroller Thermal Safety Switch Fuses Controller Main Control Board Controller Display and User Interface Board Pellet Drop Tubing Flexible Plastic Type Burner chamber Quic...

Page 59: ...____________________________________ Installed for _______________________________________________ Name ___________________________________________________ Address ____________________________________...

Page 60: ...___ CO2 _________________ 10 12 CO2 TARGET Efficiency _________________ Burner Settings Fan High Speed _________________ 1 255 Fan Med Speed _________________ 1 255 Fan Low Speed _________________ 1 2...

Page 61: ...___________________________________ Installation date _________________________________________ Installed for _______________________________________________ Name _____________________________________...

Page 62: ...O________________ ppm 300 ppm TARGET O2 _________________ CO2 _________________ 10 12 CO2 TARGET Efficiency _________________ Burner Settings Fan High Speed _________________ 1 255 Fan Med Speed _____...

Page 63: ...d be made to the dealer Certified Installer from whom this appliance was purchased THIS WARRANTY IS LIMITED TO DEFECTIVE PARTS REPAIR AND OR REPLACEMENT IS AT Pellergy LLC s OPTION AND EXCLUDES ANY IN...

Page 64: ...PB 1525 Wood Pellet Burner System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Page 64 of 67 Installer Note Page System Drawings...

Page 65: ...PB 1525 Wood Pellet Burner System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Page 65 of 67...

Page 66: ...PB 1525 Wood Pellet Burner System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Page 66 of 67...

Page 67: ...12 BOLT GRADE 5 1 4 20 X 2 5 6 400 M 00010 CLAMP 3 PIPE JOINING 23 700 L 00003 SPLIT LOCKWASHER 1 4 7 300 W 00007 ASSEMBLY TUBE 24 300 M 00020 PIN HOOK 8 300 W 00006 SHROUD MOTOR 25 300 M 00012 COUPLE...

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