Chapters
Table of Contents
Summary of Contents for Pellergy PB-1525
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Page 1: Installation & Operation Manual
INSTALLATION & OPERATION 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.mywoodpelletsolution.com... -
Page 2: Table Of Contents
PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 Table of Contents INSTALLATION & OPERATION MANUAL Introduction Chapter ONE: Safety Chapter TWO: Installation Installation of the PB-1525 Wood Pellet Burner System ... -
Page 3: Introduction
The PB-1525 wood pellet burner system is intended for installation with fully approved, regulatory compliant domestic hot water boilers and furnaces including dedicated Pellergy boilers and furnaces. The PB-1525 is intended for use with ¼”... -
Page 4: Chapter One: Safety
Please follow this manual carefully and contact Pellergy or your Certified Installer with any questions. The PB-1525 wood pellet burner system shall be installed by Pellergy trained certified 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. - Page 5 PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 Overview This Safety summary, and this manual, has been prepared to ensure the PB-1525 System is installed, operated and maintained in a safe manner for personnel and to prevent unnecessary damage or loss of property.
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Page 6: Chapter Two: Installation
Pellergy-approved boilers and furnaces. Pellergy engineering staff works closely with our Certified Installers to ensure compatibility between the burner and the heat exchanger. The PB-1525 Wood Pellet Burner System installs through the use of a custom Page 6 of 67... - Page 7 PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 mounting plate to the boiler front that is provided by Pellergy. An initial site survey of the intended host boiler or furnace and environment must be performed. Pellergy must provide the Certified Installer with the appropriate mounting plate for the application.
- Page 8 5. The PB-1525 should be set up to fire an existing boiler or furnace at a maximum of 65% of the rated input firing rate of the unit. This value will account for higher excess air requirements of wood pellet combustion and serve to maintain good efficiency.
- Page 9 NOT 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 maintenance of the burner. The burner requires regular maintenance and ease of access to the burner for this maintenance will be more convenient for the user.
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Page 10: Installation Of The Pb-1525 Wood Pellet Burner System
PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 The PB-1525 Wood Pellet Burner System requires the use of an existing, up to date chimney sized appropriately for the boiler or furnace used. An existing masonry or Class A metal chimney may be used provided that it meets local code. - Page 11 The PB-1525 Wood Pellet Burner System must NOT be operated with the boiler or Furnace door open! If The PB-1525 is mounted to a hinged door, an optional interlock switch is required. This interlock is intended to prevent the burner from operating with the door open.
- Page 12 BOILER) GASKET Figure 2.2: Burner assembled to mounting plate. Figure 2.3a below for a typical layout of a Pellergy System with 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 by compatible bulk pellet bins for direct feed installations.
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Page 13: Installation Of The Pellet Conveyor
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. The conveyor is designed to be hung from a single-point overhead anchor. - Page 14 (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-inches). See Figure 2.3 below ANCHOR...
- Page 15 PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 1525 pellet feed tube without the use of the supplied flexible plastic drop tube assembly. This tube acts as a back-burn safety device and is the only material suitable for use.
- Page 16 PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 SPIRAL AUGER TO HOPPER FLOOR CLEARANCE 1” MIN. Figure 2.4: Conveyor and Auger assembly details showing the auger spiral WARNING! The Pellet hopper and/or pellet storage must not be installed within 24-inches of the PB-1525 wood pellet burner.
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Page 17: Boiler/Furnace Room Ventilation And Maintenance
PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 Boiler/Furnace Room Ventilation and Maintenance 1. The PB-1525 must be supplied with adequate fresh air for combustion. a. The room in which the boiler or furnace is installed should be... -
Page 18: Measuring Chimney Draft
PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 Measuring Chimney Draft The PB-1525 requires a negative draft chimney installation. Draft must be measured with a proper draft gauge. Prior to measuring draft, be sure that the boiler/furnace is air tight and all leak points are sealed. -
Page 19: Electric Installation
(3) on the top for in-field installation of the proper connector for the wire being used. The two (2) outermost connections on the bottom of the panel are used by Pellergy for the factory wired and installed cable/connectors sets. The center knock out may be used for the installation of cables. - Page 20 24V DC - Stack O2 Sensor (OPTION) Stack Temperature Sensor (RED) Stack Temperature Sensor (BLK) Figure 2.6: Terminal Connections for the PB-1525 Wood Pellet Burner System. A schematic detail of the Terminal Panel Enclosure is shown below in Figure 2.7. All wiring connections shown in this detail are factory performed.
- Page 21 1.) Connection to a 120V AC Power Source 2.) Connection to a thermostat (Normally Open Switch with no power) There are two required components of the PB-1525 system that need to be field connected. These are the: 1.) Auger Motor 2.) Stack Temperature Sensor...
- Page 22 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 point as specified for the oil burner by the boiler and furnace manufacturer.
- Page 23 1. The PB-1525 connects to a standard, normally open dry contact thermostat. System firing will be controlled by the demand called for by the thermostat. 2. The thermostat connects to the PB-1525 as indicated in the terminal connection detail above. WARNING!
- Page 24 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 Schematic Detail WARNING! ...
- Page 25 PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 Figure 2.9: PB-1525 Burner Schematic Detail Page 25 of 67...
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Page 26: Chapter Three: System Setup & Operational Overview
PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 Chapter THREE: System Setup & Operational Overview Controller User Interface Description All system setup features are accomplished through the user interface on the controller. Illustrated in Figure 3.0 below, the user interface consists of a backlit alpha numerical display, four buttons and two LEDs. -
Page 27: System Operational Description
PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 System Operational Description The PB-1525 has eight (8) distinct and separate states of operation. These states are detailed in the illustrations and descriptions below. System States Idle The Idle state is “Standby Mode”... - Page 28 Thermostat Disa Indicator Figure 3.2: PB-1525 Burner Controller in the Feed Start State As depicted above, the System State is in “Feed Start”. Two new indicators have been displayed, the “T” indicating that the thermostat is calling for the burner system to fire, and the “I” indicating that the ignitor is on.
- Page 29 PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 Igniting 98°F Starts: 1 Disa Figure 3.3: PB-1525 Burner Controller in the Igniting State As depicted above, the System State is “Igniting”. No new indicators have been displayed; however, we do see that the flame sensor value will change in this state (shown here as a value of 2).
- Page 30 PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 Stabilizing T 74 98°F Hours : 13 Disa Figure 3.4: PB-1525 Burner Controller in the Stabilizing State As depicted above, the System State is “Stabilizing”. The ignitor has shut off (indicated by the absence of the “I”...
- Page 31 PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 Firing T 237 328°F Starts: 489 Disa Figure 3.5: PB-1525 Burner Controller in the Firing State As depicted above, the System State is “Firing”. The unit is now firing at its set firing rate.
- Page 32 185 279°F Starts: 502 Disa Figure 3.6: PB-1525 Burner Controller in the Shutting Down State As depicted above, the System State is “Shutting Down”. The unit is now monitoring the flame sensor to ensure all fuel in the burn chamber is extinguished.
- Page 33 PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 Purging 65°F Resets: 14 Disa Figure 3.7: PB-1525 Burner Controller in the Purging State As depicted above, the System State is “Purging”. The unit is running he combustion blower at high speed and continues to monitor the flame sensor to ensure all fuel in the burn chamber is extinguished.
- Page 34 PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 ALARM 1186 1100°F Temp sensor open Figure 3.8: PB-1525 Burner Controller in the ALARM State As depicted above, the System State is “ALARM”. The unit is running he combustion blower at low speed for a programmed period of time.
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Page 35: System Setup
ALARM System Setup The PB-1525 is intended to be set up in the field by a Pellergy Factory Trained Certified Installer. There are no parameters that can be set up by the homeowner or system operator. In order to set the system parameters, the Certified Installer must place the controller in “Technician... - Page 36 Starts: 129 Parm Test Ena Feed Figure 3.9: PB-1525 Burner Controller in the Idle State, Technician Mode with the unit Disabled The above menu is the starting place for setting up the system. To enter this state on the controller perform the following steps: 1.) Power the unit in Technician Mode...
- Page 37 PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 There are a total of seven (7) operational parameters that may be set by the Certified Installer in Technician Mode. They are: 1.) Fan High Speed: Run Speed of the Combustion Blower. Set after the initial firing of the system in response to flue gas analysis.
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Page 38: Filling The Conveyor
Technician Mode will auto exit after 15-minutes of lack of user input to the controller. Filling the Conveyor The conveyor (auger) must be filled with pellets in order for the PB-1525 system to function properly. Typical scenarios where conveyor filling is required are: 1. - Page 39 PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 received instruction from their Certified Installer. WARNING! The act of filling the conveyor will cause the system to activate and mechanical components to be put in motion. Prior to filling, be sure that all systems are free and clear of obstruction to reduce the risk of entanglement.
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Page 40: Setup Of The Start Feed Value
PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 Place the controller in the Idle State either by powering up the system without a demand for heat (Open Thermostat), or follow the steps below to force the system into the Idle State: 1.) Power the unit normally by connecting the 7-pin connector to the... - Page 41 PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 Place the controller in the Idle State and Technician Mode by following the steps below: 1.) Power the unit in Technician Mode 2.) As soon as the controller enters the Purging State, press and hold the Disable button.
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Page 42: Setup Of The Burner Firing Rate
PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 WARNING! If the burner is set to feed too many pellets on the initial ignition feed (Start Amount) there is a risk of a gas explosion in the boiler. - Page 43 PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 specified test appears and then pressing the “Run” button. The system will simulate the pellet conveyor start and stop cycles that would occur in six minutes of run time during the Firing State. You can monitor the test status by watching the countdown on the display.
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Page 44: Setup Of The Initial Combustion Blower Setting Value
PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 Items such as the conveyor length and angle of installation WILL change the amount of pellets fed in the same period of time. Setup of the Initial Combustion Blower Setting Value The “Fan High Speed”... -
Page 45: Burner Cycles
CO = Less than 300 ppm Efficiency = Maximized using firing rate Burner Cycles The PB-1525 is fully automated and will respond to the heating demand as called for by a thermostat. It is important to reduce the total number of operational cycles by as much as possible to ensure the most efficient operation of the system and to avoid premature failure of system components. -
Page 46: Setting The Cleanout Cycles
Rev 1.0, OCTOBER 2011 Setting the Cleanout Cycles As an option, the PB-1525 can be fitted with an automatic burn chamber cleanout system that will serve to keep the burn chamber cleaner and more clear of clinkers during extended periods of operation. The system utilizes a set of air nozzles affixed to the inside of the burner connected to an air line, compressor and solenoid valve;... -
Page 47: Chapter Four: Maintenance
(burner cleanout) and the other by the certified trained installer (boiler/furnace cleanout). Clinkers are byproducts of combustion that form in the PB-1525 burn chamber. These form as a result of naturally occurring mineral impurities in the wood of the pellets being burned. The burner chamber needs to be cleaned regularly in order to prevent the buildup of clinkers within the system. - Page 48 Pieces of unburned pellets and glowing embers may be present that can start fires. CAUTION! Failure to properly clean the PB-1525 can result in failed operation of the system resulting in property loss or damage due Page 48 of 67...
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Page 49: Cleaning Burner Chamber
In general, oil fired boilers/furnaces require cleaning once per year when fired on oil; when fired using a PB-1525 system cleanout may be required every 3-4 tons of pellets burned, or more frequently depending on your particular boiler. - Page 50 PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 Disable the system by pressing and holding the “Disa” button on the controller for 5-6 seconds; or as soon as the “Ena” display appears. If the burner has just been in operation, wait 10-20 minutes before cleaning to allow the combustion chamber to cool down.
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Page 51: Troubleshooting
PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 Troubleshooting The PB-1525 burner system is fully automated and will provide feedback to the operator if an error occurs. Use the guide below to troubleshoot and remedy any automated shutdown of the system. - Page 52 PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 burn chamber. The Sensor 3. CP* install new error message flame sensor 4. Failed Blower suggests that the 4. CP* install new 5. Improper draft in system has run out...
- Page 53 PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 boiler/furnace firebox. Stack too hot 1. Excessive boiler/ 1. Clean and brush furnace ash down boiler buildup /furnace. Error occurs when preventing 2. CP* verifies firing the stack proper heat rate of system.
- Page 54 PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 kinking. 3. CP* install new temperature sensor No Heat Sensed 1. Wire or leads to 1. Check wire and the temperature leads to sensor damaged temperature Error occurs when sensor for 2.
- Page 55 PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 water connection of the conveyor to 3. Damage to the feed motor. conveyor system CP* repair of conveyor * CP = Pellergy Certified Installer Page 55 of 67...
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Page 56: Burner Servicing
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. -
Page 57: Technical Data
ASTM E-1509, standards for Solid Fuel Fired Central Furnaces. Complete drawings and test data are on file at Guardian and at the manufacturer. Quality Assurance Audits of Pellergy LLC are performed in accordance with the Testing and Listing requirements of the oversight agency. -
Page 58: Available Replacement Parts
PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 Available Replacement Parts Igniter* Blower* Flame sensor* Optional Relay Conroller* Thermal Safety Switch* Fuses (Controller)* Main Control Board* Controller Display and User Interface Board* ... -
Page 59: Warranty And Installation Doc
PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 Warranty and Installation Doc During installation this document must be completed correctly for warranty to be valid. One Copy remains with the system, the other is transmitted to Pellergy. Both sides must be complete. -
Page 60: Burner Measured Values
PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 Burner Measured Values (Customer Copy) Chimney draft (Cold)__________________[in-H Chimney draft (Hot)___________________[in-H Temperature outside house_______________[°F] Values at Firing State Stack gas temperature _______________[°F] CO________________[ppm] <300 ppm TARGET _________________[%]... - Page 61 PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 Warranty and Installation Doc (This copy must be sent to Pellergy LLC within 10-days of installation along with the burner setup data; complete both sides) During installation this document must be completed correctly for warranty to be valid.
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Page 62: Burner Measured Values
PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 Burner Measured Values (This copy must be sent to Pellergy LLC within 10-days of installation along with the burner setup data; complete both sides) Chimney draft (Cold)__________________[in-H Chimney draft (Hot)___________________[in-H Temperature outside house_______________[°F]... - Page 63 NO OTHER WARRANTY, EXPRESSED OR IMPLIED. No employee, agent, dealer, or other person is authorized to give any warranty on behalf of Pellergy LLC. This warranty does not apply if the product has been altered in any way after leaving the factory. Pellergy LLC and its agents assume no liability for “resultant damages of any kind” arising from the use of its products.
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Page 64: Installer Note Page & System Drawings
PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 Installer Note Page & System Drawings Page 64 of 67... - 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 PB-1525 Wood Pellet Burner System: Installation and Operation Manual Rev 1.0, OCTOBER 2011 Drawing 200-A-00003 Reference Part Number Description Reference Part Number Description 300-M-00017 WALL, HOPPER INNER 700-B-00011 SHCS, 10-32 X 5/8" 700-B-00008 BOLT, GRADE 5 1/4-20 X 5/8" 700-L-00004 SPLIT LOCKWASHER, #10 700-W-00001 WASHER, 18-8 SST 1/4"...