Home

INSTALLATION & OPERATION MANUAL

1. N E LO 9 Figure 3 5 1525 Bumer Controller in the Firing State Asdepicted above the System State is Firing The unit is now firing at its set firing rate No new indicators have been displayed If the system fails to maintain a healthy flame during the Firing State the system will trigger the Alarm State 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 forfive seconds Shutting Down The Shutting Down state indicatesthe system has detected the loss of the thermostat input and is entering the shut down mode In the Shutting Down state the unit is running the combustion blower at high speed and monitoring the flame sensor value the system will no longerfeed pellets into the bum chamber Once the system has met the shutting down criteria the system will enterthe Purging State Figure 3 6 below illustrates the controller in the Shutting Down state Page 31 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Shutting Down 1793 185 279 Starts 502 Disa Figure 3 6 PB 1525 Bumer Controller in the Shutting Down State As depicted above the System State is Shutting Down The unit isnow monitoring the flame
2. Overfiring of the boiler fumace is occurring Failed temperature sensor Wire orleadsto the temperature sensor damaged Failed temperature sensor System power connected to the bumer without the temperature sensor connected Wire orleadsto the temperature sensor damaged Failed temperature Sensor boiler fumace firebox Clean and brush down boiler fumace CP verifies firing rate of system CP install new temperature sensor Check wore and leadsto temperature sensor for mechanical damage crushing or kinking CP install new temperature sensor Mate smaller 6 pin sensor connectorto the bumer prior to mating the larger 7 pin power connector Check wore and leadsto temperature sensorfor mechanical damage crushing or Page 53 of 67 No Heat Sensed Emoroccurs when the system senses an absence of heat in the smoke pipe within a prescribed amount of time No Error Message system inoperable Pellets collect in drop tube No pellets feeding into bumer PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OC TOBER 2011 Wire orleadsto the temperature sensor damaged lemperature sensor removed from flue gas stream Failed temperature sensor Lossof orno main powerto system Bum Chamber clogged or filled with clinkers and ash Pellet bin out of pe
3. Flame seen at idle Eroroccursasa result of the bumer sensing flame within the bum chamber while the system is in the Idle State Sensor 4 Failed Blower 5 Improper draft in system Bum filled with clinke rs Failed Flame Sensor Foreign light introduced to bum chamber 1 Bum filled with clinkers 2 Failed Flame Sensor 3 Foreign light introduced to bum chamber CP install new flame sensor CP install new blower CP checking of draft and Cleaning of boiler Clean bum chamberand restart system CP install new flame sensor Ensure bumer cover 5 properly installed do not shine direct amp intense light into the bumercover orboiler fumace firebox 1 Clean bum chamberand restart system 2 CP install new flame sensor 3 Ensure bumer cover is properly installed do not shine direct amp intense light into the bumer coveror Page 52 of 67 Stack too hot Emroroccurs when the stack temperature exceedsthe maximum set point within the system Temp Sensor Shorted Error occurs when the system sensesa short in the stack temperature sensor Temp Sensor Open Emoroccurs when the system senses an absence ofthe temperature sensor connected to the system PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OC TOBER 2011 Excessive boiler fumace ash buildup preventing properheat transfer
4. side of the bumer The following items are provided to Certified Installation Professionals as a part of the Critical Spares Kit Page 58 of 67 PB 1525 Wood Pellet Bumer 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 Installed product PB 1525 Wood Pellet Bumer System Serial No Installation date Installed for Name Address 2 code Phone number Installation Company Name Address 2 code Phone Customer Copy Page 59 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Burner Measured Values Customer Copy Chimney draft Cold in H20 Chimney draft Hot in H20 Temperature outside house F Values at Firing State Stack gastemperature F CO ppm 300 ppm TARGET gt 1 gt 9o 10 12 CO2 TARGET Efficiency 96 Burner Settings Fan High Speed 1 255 Fan Med Speed 1 255 Fan Low Speed 1 255 Start Feed Time seconds Running Feed On seconds Temperature Limit seconds Date of Installation System Serial Number Job Number Name Address Customer Copy Page 60 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Warranty and
5. 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 One Copy remains with the system the other is transmitted to Pellergy Both sides must be complete Installed product PB 1525 Wood Pellet Bumer System Serial No Installation date Installed for Name Address 2 code Phone number Installation Company Name Address 2 code Phone Notes Pellergy Copy Page 61 of 67 PB 1525 Wood Pellet Bumer 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 H20 Chimney draft Hot in H20 Temperature outside house F Values at Firing State Stack gastemperature F CO ppm lt 300 ppm TARGET 96 9o 10 12 CO2 TARGET Efficiency 1 Burner Settings Fan High Speed 1 255 Fan Med Speed 1 255 Fan Low Speed 1 255 Start Feed Time seconds Running Feed On seconds Temperature Limit seconds Date of Installation Job Number Name Address System Serial Number Pellergy Copy Page 62 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 WARRANTY Peller
6. Time forthe Auger during the Firing State Set asa meansto establish the input firing rate of the system 6 Temperature Limit Stack Temperature shutdown set point Setasa meansto protect the specific flue in which the boiler fumace is venting 7 Cleanout Cycles Interval setting forthe Automatic Combustion Chamber Cleanout system Factory Set to 10 may be adjusted based upon pellet quality and operational experience with the system Pressing the Parameter button on the controller will allow the Certified Installer to cycle through the set points Settings are changed using the and buttonsto add or subtract from the displayed set value Settings can be made while the system is running and all settings update the system operational characteristics in real time For example if you are tuning the system for proper combustion gas properties and need to make a blower speed adjustment doing so while the bumeris in the Firing State will adjust the combustion blowerspeed while the system is firing and allow you to see the effectsusing your combustion analysis equipment Operational Tests Page 37 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 There are a total of seven 7 operational parametersthat may be set by the Certified Installer in Technician Mode They are 1 Initial Dump Test of the Start Feed Time setting Thistest is run to establish the comect starting a
7. allow forthis buildup without compromise to the combustion gasflow within the heat exchanger surfaces of the boiler Pellergy engineering must approve of all candidate boilers fumaces priorto conversion WARNING Failure to properly match a PB 1525 system with a host boiler fumace can result property damage injury and even death 2 The system requires a firebox with a Minimum volume of 1FP b Minimum depth of 12 inchesas measured from the bumer face to the back wall of the firebox c A minimum width that can easily accommodate the largest outer diameter of the PB 1525 6 inches 3 The bumer must be installed into the firebox such that a A minimum of 2 inches of clearance from the opening of the bumerto the floor of the fireboxis provided b The centerline of the bumershall be positioned atthe same centerline asthe pre existing oil bumerto ensure proper firing Page 7 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 of the boilerorfumace This will ensure enough volume forthe collection of ash between Cleanings 4 Not all boilersand fumacesare completely compatible with the Pellergy PB 1525 system For example boilers designed for pressurized firebox firing on oil systems are not suitable for use with the pellet bumer even if the above firebox requirements are met In some cases the boiler will need to be rated1 5 2 0 timeslarger in input Btu sin orderto gain requir
8. azo gt gt gt gt 24VDC m POWER SUPPLY gt OOO gt cieli FLAME acoz SENSOR I TEMP x sal m WHT BLK mi GRN BLK Xx eT WEE BULLE RED IGNITOR WHT WHT BLU WHT BLK ORG Figure 2 9 PB 1525 Bumer Schematic Detail Page 25 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Chapter THREE System Setup amp 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 aloha numerical display four buttons and two LEDs The interface is direct mounted on the back of the bumerand accessible at all times eem ing Red LED N Alphanumeric Display Buttons 1 4 fey Ke ke Figure 3 0 PB 1525 Bumer Controller Interfa ce The display indicates system status and servesasan information panel for the Certified Installer and Operator It contains four rows of alphanumeric characters and displa ysthe following information System State Various Thermostat Status O n Off Stack Gas Temperature Degrees F Flame Sensor Value 0 255 Auger Feed Motor Status On Off Hours Run Time Meter in Hours Resets Number of System Resets S
9. by sliding it from within the a ssembly Dump contents of the bumerchamberinto a properly rated ash can Scrape or brush the chamberasnecessary and re assemble the bumer IMPORTANT Rememberto Enable to system by pressing and holding the Ena button on the controller for 5 6 seconds orassoon asthe Disa display appears Failure to re enable the system will leave you without heatasthe system will not fire in the Disabled state WARNING Neverstore ashesand orclinkers inside the building orin a non metallic container rated forthe storage of hot coals Alwaysuse a container specifically rated forthe removal of ash Ashesand clinkers within the bumercan appearto be cool however once exposed to airand broken up during the cleaning processcan be hot enough to start a fire CAUTION Bumercomponents may be very hot Alwayscheckthe temperature of the bum chamber before removing from the system Use glovesorother protective gearto avoid injury Page 50 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Troubleshooting The PB 1525 bumer system is fully automated and will provide feedback to the operator if an emoroccurs Use the guide below to troubleshoot and remedy any automated shutdown of the system If the system hasentered an enor mode it isfora reason DO NOTsimply restart the controller without taking action to remedy the initial cause of the error The table below providesa g
10. production of harmful gasses within the living space WARNING Proper ventilation must be provided forthe PB 1525 wood pellet bumer system 2 The immediate area sumounding the PB 1525 wood pellet bumer system and host boiler fumace must be kept clean and free of combustible and orflammable materials at all times 3 Additionally the loading of pellets into the pellet hopper may result in large amounts of dust if the proper equipment ortechnique is used Care must be taken to remove dust from the boiler fumace room to prevent a dust fire or explosion WARNING Improperhandling of wood pellets can cause dust to be released into the air Proper ventilation must be provided to avoid personal injury and possible dust fire and or explosion Page 17 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Measuring Chimney Draft The PB 1525 requiresa negative draft chimney installation Draft must be measured with a proper draft gauge Priorto measuring draft be sure thatthe boiler fumace isairtight and all leak points are sealed Airleaks can give faulty results and can cause problems when operating the PB 1525 The draft measurement isto be taken in the firebox of the boilerorfumace asan OverFire measurement Draft should be between 0 03 in H20 to 0 10 in H2O If the Draft is more than 0 10 in H20 or likely to exceed 0 10 in H2O a draft regulator barometric da mper is required for us
11. sensorto ensure all fuel in the bum chamber is extinguished The length of time of this state varies with the amount of fuel left in the bum chamberatthe end ofthe firing state as well asthe physical makeup of the pellet bed Disabling the unit in this 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 indicatesthe system has detected the absence of flame the bum chamberand is completing the shut down mode In the Purging state the unit is running the combustion blowerat high speed and monitoring the flame sensor value the system will no longerfeed pellets into the bum chamber The Purging State runsfora settime duration Upon completion of Purging the system will either enterthe Idle State if the thermostat is not calling forheat orthe Feed Start State if the thermostat is Closed Figure 3 7 below illustratesthe controller in the Purging state Page 32 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Purging 348 0 65 Resets 14 Disa End Figure 3 7 PB 1525 Bumer Controller in the Purging State As depicted above the System State is Purging The unit is running he combustion blowerat high speed an
12. there depending on the feedback regarding pellet quality Installation and Setup of the Flue Gas Temperature Sensor The PB 1525 requires the installation of a supplied flue gas sensor in the stack of the boiler fumace This sensor should be installed as close to the boiler fumace flue collar connection as possible without causing damage to the leadsof the sensor The sensor is installed using a 0 25 hole in the smoke pipe and two self tapping sheet metal screws The Pellergy PB 1525 controller will constantly monitorthe stack gas Page 46 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 temperature and display the value on the controller as shown in the figures in Section 3 As a safety feature the Certified Installer has the ability to input a Temperature Limit setting that will cause the system to enterthe Alarm State if the stack gastemperature exceedsthis set value The Certified Installer shall input a temperature value that doesnot exceed the operational temperature rating of the smoke pipe and chimney including liners Some state and local regulations may require a lower value than the operational temperature rating of the equipment To set the stack gastemperature limit follow the steps below The system must be in Technician Mode 3 Pressthe Pam button until Temperature Limit is displayed on the controller 4 Use the and buttonsto add or su
13. there isa consistent flow of pellets from the auger Filling after running the system out of pellets Page 39 of 67 PB 1525 Wood Pellet Bumer 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 forheat Open Thermostat orfollow the stepsbelow to force the system into the Idle State 1 Powerthe unit normally by connecting the 7 pin connectorto the bumer 2 Assoon asthe controller entersthe Purging State press and hold the Disable button 3 Once the unit hasbeen Disabled pressthe End button Once the unit is in the Idle State the controller interface button on the far right will become the Feed control button See Figure 3 1 Above 1 Press and hold the Feed button will run the auger 2 Run the auger past the first few pellets that drop to ensure the entire augerisfull of pellets and there isa consistent flow of pellets from the auger 3 IMPORTANT Clean the bum chamberasthere may be unbumed pellets in the bum chamber 4 Restart the system by pressing and holding the Enable Ena button following the cleanout of the bum chamberand reassembly of the bumer The system will now run normally WARNING Functions describe in the remainder of the chapterare to be performed by a Pellergy trained certified professional ONLY Setup of the Start Feed Value The Start Feed value controlsthe amount of pe
14. 0 The Blowerspeed indicatorisa bargraph that will fill upwardsforLow Medium and High speeds In the Idle state the Blower is Off and the indicator indicates this through a single thin line The Titles Disa and Feed referto the corresponding button functions Pressing the Feed button will run the auger Pressing and holding the Disa button forfive seconds will disable the system and the button will change to Ena See the system state section on Disabled below Feed Start The Feed Start state isthe beginning of the ignition cycle In the Feed Start state the unit is has sensed a call from the thermostat to start the Page 27 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 ignition sequence Figure 3 2 below illustrates the controller in the Feed Start state ey A I Feed Start 74 65 F 1 Ignitor Thermostat starts 1 Indicator Indicator Disa Figure 3 2 PB 1525 Bumer Controller in the Feed Start State As depicted above the System State isin Feed Start Two new indicators have been displayed the T indicating that the thermostat is calling forthe bumer system to fire and the I indicating that the ignitor is on When the thermostat is in the Off mode oropen and when the ignitor is Off these indicators are not pr
15. 25 Bumer Controller in the ALARM State As depicted above the System State is ALARM The unit is running combustion blowerat low speed fora programmed period of time The display indicatesthe type of alarm in this case the lack of a temperature sensor connected to the system WARNING If the system isfound in the ALARM State there hasbeen a problem that requires your attention ALWAYS empty the bum chamber of pellets and combustion byproducts before resetting the system Failure to do so can cause an unsafe condition that Can result in injury bodily harm equipment damage and even death LED Status The Red and Green LEDs indicate bumer status The key below indicates the LED and Bumer status at different states Page 34 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 s rea Idle LED Off LED LED Flashing ae 54 Operating LED Solid Burner Disabled Operating a Burner Disabled Not Operating 2221 ALARM System Setup The PB 1525 is intended to be setup 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 orderto set the system parameters the Certified Installer must place the controllerin Technician Mode to make adjustments These adjustments control various operational aspects of the system and ensure both reliable and sa
16. 5 bumer and select a suitable point forthe overhead anchor The conveyor Page 13 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 must be positioned such that a The overhead anchor point must be able to continuously support a minimum of 100 pounds See Figure 2 3 below b The conveyor must be mounted such that the drop tube isa minimum of 15 inches above the PB 1525 pellet feed tube opening Max 30 inches See Figure 2 3 below c The conveyor must be mounted such that the drop tube isa minimum of 6 inc hes laterally a way from the PB 1525 pellet feed tube opening Maximum of 12 inches See Figure 2 3 below ANCHOR POINT CONVEYOR CHAIN CABLE Figure 2 3 Conveyor mounting details WARNING pellet feed conveyorassembly can weigh asmuch as 100 pounds when in operation and filled with pellets Ensure a suitable overhead anchor point from which to hang the conveyor Do notdirect couple the conveyor drop tube to the PB Page 14 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 NOTE 2 1525 pellet feed tube without the use of the supplied flexible plastic drop tube assembly Thistube actsasa back bum safety device and isthe only material suitable foruse Replacing thistube with any otherthan supplied by Pellergy voidsthe warranty and can result in injury equipment damage and even death Do
17. 8 7 THB CAVO C OM ABO MIOR MAION WHICH 6 TWE PE PROPERTY OF PELUASY c E MAG N COM DENS AND CONTE MAY VO ME DEC LOTES WENOLE THE P MOR wa Pitu CONSENT OF PALLIAT LI 4 5 PER UE ENNER AQOW _ 7 CLAMP IGNITOR 8 LATCH ADJUSTABLE DRAW 9 10 COVER 20k W BURNER OUTER 11 HOSEI BLOWER BRUSHLESS 1 12 2 BLOWOUT ASSEMBLY 1 18 ELECTRONICS ASSEMBLY 20KW 1 4 000003 26 7 COND FEMALE HV T5 MOEA FLUG FEMALE LV T 16 700 00004 1 8 7 ma m ancene e c STATUS RELEASED anu ries map anoa MO C PELLERGY LLC Ld BURNER ASSEMBLY 20KW om nen ae 9 400A 0004 z LI mw 1 P Page 65 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 DETAIL A m SCALE 1 3 MOTOR ASSEMBLY COVER FEED TUBE NOT SHOWN FOR CLARITY RUN CAPACITOR AND HARDWARE TO BE ADDED 400 E 0001 7 400 E 00018 400 M 00017 17 18 4X 19 4X 8 9 4x 10 4X 1 2X 2 18 EA 3 36X 4 18X EA 24 4 9 30 10 23 25 26 4 31 CUT TO LENGTH INSTALL TUBING TO JOIN FEED SYSTEM TO BURNER AND CLAMPS TO BE ADDED AT INSTA LL 400 M 00015 AND 400 M 00016 2 11 CUT TO LENGTH AT INSTALL 12 2X 2 2X EA 3 4X EA 4 2 EA 13 4X 2 10X EA 3 20X EA 4 10X 13 2X 2 2X EA 3 4X EA A 2X 14 15 8 3 16 4 8X FELLERGY LIC
18. Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 received instruction from their Certified Installer WARNING The act of filing the conveyor will cause the system to activate and mechanical componentsto be put in motion Priorto filling be sure that all systems are free and clearof obstruction to reduce the risk of entanglement Filling at Initial system set up and post Certified Installer maintenance NOTE Before loading pellets into the hopperorbin run the auger following the steps below to verify properrotational direction of the auger screw If the augerisrunning opposite the required direction reverse the input lead on the auger motor running capacitorto reverse the motorrotation Referto the motor wiring schematic on the auger motor Place the controller in the Idle State either by powering up the system without a demand forheat Open Thermostat orfollow the stepsbelow to force the system into the Idle State 1 Powerthe unit normally orin Technician Mode 2 Assoon asthe controller enters the Purging State press and hold the Disable button 3 Once the unit hasbeen Disabled pressthe End button Once the unit is in the Idle State the controller interface button on the far right will become the Feed control button See Figure 3 1 Above Pressing and holding this button will run the auger Run the auger past the first few pellets that drop to ensure the entire auger is full of pellets and
19. INSTALLATION amp OPERATION MANUAL Product P N Pellergy PB 1525 Serial Number Wood Pellet Burner System SK PELLERGY REV 1 0 OCTOBER 2011 16 Railroad Street Barre VT 05641 802 659 4866 www pellergy com www mywoodpelletsolution com PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Table of Contents INSTALLATION amp OPERATION MANUAL Introduction Chapter ONE Safety Chapter TWO Installation Installation of the PB 1525 Wood Pellet Burner System Installation of the Pellet Conveyor Boiler Furnace Room Ventilation and Maintenance Measuring Chimney Draft Electric installation Chapter THREE System Setup amp Operational Overview Controller User Interface Description System Operational Description System States System Setup Filling the Conveyor Setup of the Start Feed Value Setup of the Burner Firing Rate Setup of the Initial Combustion Blower Setting Value Running the Burner for the First Time Burner Cycles Setting the Cleanout Cycles Installation and Setup of the Flue Gas Temperature Sensor Chapter FOUR Maintenance General information Cleaning burner chamber Troubleshooting Burner Servicing Technical Data Available Replacement Parts Warranty and Installation Doc Burner Measured Values Burner Settings Burner Measured Values Burner Settings Installer Note Page amp System Drawings Page 2 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation
20. Manual Rev 1 0 OCTOBER 2011 Introduction Congratulations on your purchase of a PB 1525 Wood Pellet Bumer System This manual is provided to give you an overview of the system and to provide important instruction asto the installation operation and maintenance of the system In orderto ensure years of safe trouble free operation please follow the guidelines and instructions set forth in this manual The PB 1525 wood pellet bumer system is intended forinstallation with fully approved regulatory compliant domestic hot waterboilers and fumaces including dedicated Pellergy boilers and fumaces The PB 1525 is intended for use with 2 Premium Wood Pellets as defined by the Pellet Fuels Institute The Bumer System usesan extemal pellet conveyor auger to deliver pellets from Pellergy and third party extemal pellet bins hoppers to bumer Following the installation of your system your Pellergy trained certified installation professional Certified Installer will review with you the operation of your system record important information asto the installed system give you a copy of this manualand askthat you acknowledge receipt of such If at any time you have questions or concerms please contact Pellergy customer service or your Certified Installer Page 3 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Chapter ONE Safety Remember Safety doesnot happen on its own You must follow th
21. PIRAL AUGER TO HOPPER FLOOR CLEARANCE 1 MIN Figure 2 4 Conveyorand Auger assembly details showing the auger spiral WARNING Pellet hopperand or pellet storage must not be installed within 24 inc hes of the PB 1525 wood pellet bumer Keep all combustible materials a minimum of 24 inches from the PB 1525 wood pellet bumer Follow all boilerand fumace manufacturer s required combustible keep out zones 5 If using an altemate pellet storage silo or hopper follow manufacturer installation instructions Do not install orstore any combustible orflammable materials within 24 inc hes of the PB 1525 bumer Page 16 of 67 PB 1525 Wood Pellet Bumer 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 airfor combustion a The room in which the boilerorfumace isinstalled should be supplied with a minimum 4 inch diameter fresh air inlet vented to atmosphere or minimum calculated dia meteras perlocalcode This ventilation must come from outside the building not from an adjoining room orenclosed space b The installation boilerorfumace room must not at any time be undera vacuum Thiscan be caused by otherappliances such as whole house fans other combustion devices requiring supply air ventilation hoods etc An improperly ventilated room can lead to incomplete combustion lower efficiency and even the
22. Page 66 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Reference Part Number 300 M 00017 700 B 00008 700 W 00001 700 N 00005 300 M 00001 400 M 00010 300 W 00007 300 W 00006 700 B 00002 700 W 00002 300 M 00019 300 M 00021 300 M 00022 300 M 00018 700 B 00009 400 M 0001 1 400 E 00016 Description WALL HOPPER INNER BOLT GRADE 5 1 4 20 X 5 8 WASHER 18 8 SST 1 4 FLAT NUT 1 4 20 WITH NYLOK WALL HOPPER OUTER CLAMP 3 PIPE JOINING ASSEMBLY TUBE SHROUD MOTOR SCREW 18 8 SST 8 32 X 3 8 BH WASHER 18 8 SST 48 FLAT TUBE CONVEYOR BRACE HOPPER LEG HOPPER COLLECTOR HOPPER BOLT GRADE 5 1 4 20 X 1 2 EDGING SERRATED PE MOTOR DRIVE Drawing 200 A 00003 Reference Part Number 700 B 0001 1 700 L 00004 700 M 00001 400 M 00008 700 B 00012 700 L 00003 300 M 00020 300 M 00012 700 S 00001 300 M 00013 400 M 00012 400 M 00007 700 B 00008 400 M 00009 Description SHCS 10 32 X 5 8 SPLIT LOCKWASHER 10 CIRCLIP EXTERNAL STANDOFF UNTHREADED BRASS BOLT GRADE 5 1 4 20 X 2 5 SPLIT LOCKW ASHER 1 4 PIN HOOK COUPLER MOTOR SETSCREW CUP POINT 1 4 20 X 5 16 PLATE MOTOR MOUNTING FITTING CONDUIT 3 8 BEARING MOUNTED BALL BOLT GRADE 5 1 4 20 X 5 8 AUGER Page 67 of 67
23. TH PLEASE KEEP THIS MANUAL FOR FUTURE REFERENCE Page 4 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Overview This Safety summary and this manual hasbeen prepared to ensure the PB 1525 System is installed operated and maintained in a safe mannerfor personnel and to prevent unnecessary damage orlossof property Precautions described in this and subsequent chapters should be observed during system installation operation and maintenance Definitions The following definitions of wa mings cautions and notesare provided and shall be applied throughout this document e WARNING A waming identifiesa cleardangerto person s performing that procedure and personnel utilizing the system failure to abide by a waming may result in damage orlossof property bodily injury and even death e CAUTION A caution identifies risk of damage to equipment failure to abide by a caution may result in permanent damage to the system and or auxiliary equipment NOTE A note is used to highlight essential procedures conditions or statements that convey important instructional data to the reader WARNING The system must be installed by a Pellergy Trained Certified Installation Professional ONLY e Neverintroduce a fuel otherthan Premium Wood Pellets into the system There isa high risk of fire and explosion if gasoline diesel fuel kerosene 2 heating oil orany other flammable liquid or ma
24. alue will change in this state shown here asa value of 74 We also see that the Feed motor will come on and off based upon the programmed values indicated here by the F on the display And we see that the combustion blower speed is at the Low setting indicated by the bar graph Shown on this display isthe total numberof running hoursof the system indicated as 13 on the display Thisdisplay area will automatically cycle every 2 3 secondsbetween Hours Starts and Resets If the system failsto maintain a healthy flame during the Stabilization State the system will revert to the Igniting state an attempt to re establish flame The system can be forced into the Shutting Down State by pressing and holding the Disable button for five seconds Firing The Firing state indicates the system has established a healthy flame in the bum chamberand isfiring at the full firing rate set up by the Certified Installer In the Firing state the unit isrunning the combustion blowerat high speed and pellets are being fed into the bum chamber every 15 seconds The system is continuously monitoring the flame sensor forthe presence of proper flame Figure 3 5 below illustrates the controller in the Firing state Page 30 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Firing T 237 328 F Starts 489 Disa
25. ation showing minimum intemal dimensions and clearances CAUTION If the manufacturers data on the boiler orfumace to be fired using the PB 1525 Wood Pellet Bumer System gives specific instruction NOTto convert the unit to solid fuel please consult the boiler orfumace manufacturer before installation NOTE When installing the PB 1525 take note of the surrounding area with regard to the regular maintenance of the bumer The bumer requires regular maintenance and ease of accessto the bumerforthis maintenance will be more convenient forthe user Page 9 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 The PB 1525 Wood Pellet Bumer System requires the use of an existing up to date chimney sized appropriately forthe boilerorfumace used An existing masonry or Class A metal chimney may be used provided that it meets local code When no local code exists follow the requirements of 211 Standard for Chimneys Fireplaces Vents and Solid Fuel Buming Appliances Certain Canadian Codes may require the chimney be fully relined priorto installation WARNING If the boilerand orfumace isnot properly cleaned and maintained chimney temperatures can approach orexceed 1000 F and create unsafe conditionsthat can lead to fire Regularcleaning and maintenance routines must be followed CAUTION e The PB 1525 should not be used in a system installed in a chimney serving multiple boilers or fuma
26. btract degrees The set number isthe temperature the controller will use to enterthe Alarm Sate Chapter FOUR Maintenance General information The PB 1525 requires regular general maintenance for proper operation There are two types of regular maintenance One accomplished by the homeowner bumer cleanout and the otherby the certified trained installer boiler fumace cleanout Clinkers are byproducts of combustion that form in the PB 1525 bum chamber These form asa result of naturally occurring mineral impurities in the wood of the pellets being bumed The bumerchamberneedsto be Cleaned regularly in orderto prevent the buildup of clinkers within the system The amount of cleaning required on a regular basis will vary depending Page 47 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 on the amount of pellets bumed the firing rate of the system the total number of start stop cyclesbetween cleanings the wood pelletsbeing bumed during the season and the operation of the Optional automatic bum chambercleanout unit Initially it isrecommended that the bumer be cleared of clinker buildup every 3 4 daysin orderto begin to predict the amount of buildup experienced in your particularinstallation Typical cleanout periodicity is between 7 10 days during the heating season and 10 14 days during the non heating months when the system may be used to provide domestic hot wateronly With
27. button 5 Upon running the test the pellet conveyor will begin to rotate dropping pellets into the container Wait forthe test period to end at which time the conveyor motor will stop 6 Take a reading from the graduated container 7 If you have less that 2 1 Volume cups increase the start feed time amount If you have more than 2 1 cupsdecrease the start feed time amount Empty the containerand repeat steps 1 6 until you get 2 1 cups 8 Once the setting is correct the value will be stored in nonvolatile memory on the controller NOTE Rememberto empty the measuring cup orcollection device between tests Page 41 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 WARNING If the bumeris set to feed too many pelletson the initial ignition feed Start Amount there isa risk of a gasexplosion in the boiler Pay particular attention to the Start Amount of pellets being fed to the bumer system Setup of the Burner Firing Rate The Running Feed On setting controlsthe fuel feed rate and results in the system sbumer firing rate The value is secondsand corespondsto the number of seconds conveyor will run at intermittent intervals during the Firing State of operation This setting and test must be run foreach bumer installation to accurately set up the firing rate of the bumer Failure to do so can result over under firing of the boiler fumace Place the controlle
28. ces unless specifically allowed by local Code AND the use of an interloc k system is used such that only one unit may use the chimney at any given time e The PB 1525 should not be used in conjunction with a flu damper If a flue damper exists in the existing system as is typical for wood fired boilers and fumaces the damper must be removed prior to the installation of the PB 1525 NOTE e The existing chimney should be cleaned and inspected priorto installation of the PB 1525 Wood Pellet Bumer System Pellergy recommends yearly cleaning of the chimney to remove the buildup of ash and maintain properand safe system functionality Installation of the PB 1525 Wood Pellet Burner System 1 Plan ahead Ensure proper installation operation and maintenance space isavailable before beginning installation Ensure the PB 1525 bumer can be disassembled for proper cleaning in the intended installation space 2 Remove oil bumerand oil bumer mounting plate if applicable 3 Inspect all gaskets and mounting surfaces Replace any gasket material that is damaged orthat is wom ordeteriorated to the Page 10 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 point where a propersealcan not be made WARNING e The PB 1525 Wood Pellet Bumer System must NOTbe operated with the boilerorFumace dooropen e f The PB 1525 is mounted to a hinged door an optional inte rloc k switch is required Thi
29. d continues to monitorthe flame sensor to ensure all fuel in the bum chamber is extinguished If the system senses the presence of flame or intense glowing embers within the bum chamberit will revert back to the Shutting Down State Disabling the unit in this state will cause the system to continue the full purge then the system will ignore the thermostat See the section on System Disabled ALARM The Alarm state indicatesthe system hasdetected a problem and has shut down Following the detection of an alarm condition the unit will run the combustion blowerfora set period of time on the Low Speed setting The display will indicate the type of alarm and may suggest a potential cause forthe condition For example if flame islost during the Firing State the alarm will read Lost flame No Fuel The only way to reset the system and exit the Alarm State isto cycle the power Thiscan be accomplished by removing the larger 7 Pin cable from the bumerunit and plugging it backin When powered backup the alarm will be cleared and the system will run nomally Figure 3 8 below illustrates the controller in the Alarm state Page 33 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 ALARM 1186 0 11009 e Temp Sensor open FTN J o Figure 3 8 PB 15
30. des but is not limited to cleaning adjustment of controls and customer education Labor materials expenses and or equipment needed to comply with law and or regulations set forth by any governmental agencies are not covered This Warranty provides specific legal rights and the consumer may have other rights that vary from state to state In the event of change in ownership the remaining portion of this warranty may be transferred to the new owner by sending the new owner information and a transfer fee of 35 00 US to the Pellergy LLC If the system is sold independently it MUST installed by a Pellergy LLC trained professional The remedies set forth herein are exclusive and the liability of seller with respect to any contract or sale or anything done in connection therewith whether in Contract in tort under any warranty or otherwise shall not except as herein expressly provided exceed the price of the equipment or part of which such liability is based The above represents the complete warranty which is given in connection with the burner units manufactured by Pellergy LLC No other commitments verbal or otherwise shall apply except by a written addendum to this warranty Page 63 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Installer Note Page amp System Drawings Page 64 of 67 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011
31. e The use of a draft regulator barometric damper isrecommended 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 2 a misfire can occurthereby shutting down the system WARNING Improperdraft can lead to potentially hazardous conditions Chimney draft must be within system limitations at all time boilerand chimney must be kept clean to maintain proper draft If draft is less an 0 03 in H20 a forced draft blower ordraft inducer can be installed to create properdraft Install per manufacturer s recommendation and guidelines Be sure that any device used is listed for use with solid fuels Following initial installation of the PB 1525 proper cleanout maintenance in the boiler fumace aswell asthe chimney isa necessity Fly ash clinkers and buildup within the chimney and boiler fumace can cause blockage and improperoperational draft Referto ChapterFour Maintenance for information on cleanout Page 18 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Electric installation General All electrical connections to the PB 1525 wood pellet bumer system are made in the supplied connection panel The panel isfactory wired with two quick connect cable setsthat connect directly to the PB 1525 bumer head All field connectionsare made to the supplied terminal blocks in t
32. e instructions set forth in this manual as well as those given to you by the certified installerand mandated by applicable local state and federal codes Adhering to these guidelines does not ensure accident free operation however not following the instruction guidance and procedures presented herein increases the risk of loss of property bodily injury and even death Please follow this manual carefully and contact Pellergy or your C ertified Installer with any questions The PB 1525 wood pellet bumer system shall be installed by Pellergy trained certified installation professionals ONLY Any unauthorized installation of the PB 1525 system voidsthe product warranty and may result in loss of property bodily injury to personnel and even death Pellerg y systems are sold only through Pellergy trained and authorized personnel If you have purchased this system on the secondary market please contact Pellergy or your local Certified Installer for assistance in installation and important operational instruction A listing of Pellergy trained certified installation professonals is maintained by Pellergy LLC Please contact Pellergy customer service foran up to date listing of professionalsin yourarea FOR YOUR SAFETY PLEASE READ THIS ENTIRE MANUAL PRIOR TO INSTALLING AND OR OPERATING THE PB 1525 WOOD PELLET BURNER SYSTEM FAILURE TO FOLLOW THESE INSTRUCTIONS AND LOCAL CODE MAY RESULT IN DAMAGE ORLOSS OF PROPERTY BODILY INJ URY AND EVEN DEA
33. ed Btu output and handle the heat load The Certified Installer must evaluate the total heat load requirement against the installation requirements detailed herein and apply his her experience with the particular boiler fumace type during the initial evaluation of the system 5 The PB 1525 should be set up to fire an existing boilerorfumace ata 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 Your Certified Insta ller will perform heat load calculations or use other methods to ensure the properamount of heat is being provided to meet your heating needs WARNING Installation of the PB 1525 shall result in no permanent modification to the existing boiler orfumace All existing safety interloc ks and controls must be utilized If the installation of the PB 1525 will require such modification asthe cutting away of insulation gasket material steel orany other part of the existing boiler orfumace Do not attempt to use the 1525 on this system Page 8 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 FIREBOX minimum 1FT BOILER FURNACE PB 1525 BURNER Burner Centerline matches pre existing burner centerline Min Firebox Refractory Insulati efractory Insulation depth 12 Required Min Clearance 2 Figure 2 1 Typical install
34. esent Also notice the Feed button functionality has been removed in this state Thisfunctionality is only available in the Idle State Toward the end of the Feed Start State the system will run the augerto feed the initial start amount of pellets into the bum chamber When thisoccursan F will appearnextto the ignitor indicator indicating that the augerfeed motoris running See Feeding section fordepiction The system can be forced into the Shutting Down State by pressing and holding the Disable button forfive seconds Igniting The Igniting state indicatesthe system is the ignition phase In the Igniting state the unit is monitoring the flame sensorforthe presence of flame thereby signaling ignition of the pellets within the bum chamber The controller will cycle the combustion bloweron and off and the ignitor will remain on forthe duration of this state Figure 3 3 below illustrates the controller in the Igniting state Page 28 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Igniting 242 DL 2 98 F le Starts 1 Disa 5 Figure 3 3 1525 Bumer Controller in the Igniting State Asdepicted 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
35. f the PB 1525 asindicated The Functional Devices RIBUIC is an acceptable input relay for use with the Pellergy PB 1525 wood pellet bumer system The schematic detail of the RIB is Shown below in Figure 2 8 Asan example connection the bumerpowered outputs of an aquastat controller Page 23 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Typically labeled Bl and B2 typically switch 120V AC when there is a call forthe bumerto fire Connecting the WHT BLK and WHT YEL leadsof the RIBto the aquastat and the BLU and ORG leadsofthe RIB to the Pellergy PB 1525 thermostat input will result in proper operation Wht Blk 120Vac Wht Blu 10 30 Vac dc Figure 2 8 RIBUIC Schematic Detail WARNING PB 1525 shall be connected using one powersource only The power source forthe PB 1525 must be provided through the existing boiler fumace safety interlock features Page 24 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 7 PIN CONNECTOR 6 PIN CONNECTOR _ BLOWER gt RED BLK SIS amp SI
36. fe system operation WARNING System operational parameters are to be set by the Pellergy trained Certified Installeronly Technician Mode on the controller is intended forthe exclusive use of Pellergy trained Certified Installers Modification of the system settingsby anyone otherthan a Pellergy trained Certified Installer may cause an unsafe operational conditionsthat can result in injury bodily harm equipment damage and even death Certified Installer Settings There are two menu headingsavailable on the display within Technician Mode that allowsthe Certified Installerto adjust for proper firing of the PB 1525 system and test certain operational settings on the unit These are Page 35 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Parm or Parametersand Test forthe test menu Figure 3 9 below depictsthe controller in the Technician Mode disabled EN N Idle 0 i 0 65 Starts 129 Parm Test Ena Feed P Figure 3 9 PB 1525 Bumer Controller in the Idle State Technician Mode with the unit Disabled The above menu isthe starting place for setting up the system To enter this state on the controller perform the following steps 1 Powerthe unit in Technician Mode 2 Assoon asthe controller enter
37. gy LLC backs its products to be free from defects in material or workmanship under normal use and service for a period of five 5 years with limitations and exclusions noted below from the date of sales invoice to the customer Installation documentation must be provided to Pellergy LLC within 10 days of sales invoice date If defective in material or workmanship during the warranty period Pellergy LLC will at its sole discretion repair or replace the product as described below Warranty Limitations The 5 Year warranty period covers all parts with the exception of those noted below 1 Ignitor 1 Year Warranty or 5 000 Cycles whichever occurs first 2 Electronics 2 Year Warranty The warranty above constitutes the entire warranty with respect to Pellergy LLC products PELLERGY LLC MAKES 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 In addition the manufacturer and its warranty administrator shall be held free and harmless from liability from damage to property related to the operation proper or improper of the equipment THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION OF WARRANTY HEREIN DESCRIBED This warra
38. he connection panel A terminal connection listing is provided below as well ason the doorof 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 enclosure as well asthree 3 on the top for in field installation of the properconnectorforthe wire being used The two 2 outermost connections on the bottom of the panel are used by Pellergy forthe factory wired and installed cable connectorssets The center knock out may be used forthe installation of cables 6 00 TOP VIEW 8 00 SIDE VIEW FRONT VIEW SIDE VIEW BOTTOM VIEW Figure 2 5 Pellergy PB 1525 Terminal Panel Enclosure Exterior Detail Page 19 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Field wiring connections are made at the Terminal Strip located within the Terminal Panel Enclosure Figure 2 6 below details the numbered terminal strip and connection detail All connectionsare to be made to the lower numbered terminal connections P e av AC rp ower 2 Ps Wira s e Pa A Ar Geena Senos o Sua Ar AO oneei Ammo Contact at wo verae T2 Tata Dy Contact oot
39. he system and enabling the bumerby pressing and holding he Ena button on the controller If powering up the system forthe first time you may press End to bypassthe startup purge cycle Page 44 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 and initiate the ignition sequence orFeed Start State 2 Afterbumerhasbeen running in the Firing State for approximately 5 minutes insert the combustion analyzer into the exhaust gases outlet chimney and take readings 3 Adjustthe airsetting by adjusting the Fan High Speed value if more less air if needed Adjust this value by pressing the Parm button until Fan High Speed appearson the display and use the and keysto adjust the value up ordown The maximum setting forthe Fan High Speed is 255 Combustion adjustmentsto feed rate and fan speed can be made while the bumeris running to obtain the proper combustion properties Rememberto wait least 2 3 min between making changesto the controllerto allow the combustion within the bumerto stabilize Bumer settings and tuning should be accomplished to establish these operational values CO 10 1296 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 forby a thermostat It is important to reduce the total number of operational cyclesby as much as possible to ensure
40. lation and Operation Manual Rev 1 0 OCTOBER 2011 THs Technical Data Firing Rate 60 000 120 000 btu hr Fuel Premium Grade Wood Pellets Voltage 120V AC 60 Hz Amps 6A max Hopper Capacity 550 LBS Std Auger Length 10 FT Std Control Input N O Switch Std Weight 55LBS bumer Certifications The Pellergy Pellet Replacement 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 E 15090 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 Tested by Guardian Fire Testing Laboratories Inc ISO IEC 17025 2005 Certificate 1247 Page 57 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Available Replacement Parts e lgniter e Blower e Flame sensor e Optional Relay Conroller e Thermal Safety Switch e Fuses Controller e Main Control Board e Controller Display and User Interface Board e Pellet Drop Tubing Flexible Plastic Type e Bumerchamber e Quick release latches
41. llets Pellets bridging in pellet bin due to improperly stored pellets or exposure to 1 kinking CP install new temperature sensor Check wire and leadsto temperature sensorfor mechanical damage crushing or kinking Ensure temperature sensor is properly installed in smoke pipe ascloset the boiler fumace flue collar connector as possible CP install new temperature sensor Check power source including any safety interlocks on boiler fumace Clean bum chamberand restart system Fill pellet bin 2 Remove pellets from bin and replenish with new pellets inspect conveyor atthe Page 54 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 water connection of the conveyorto the feed motor CP repair of conveyor 3 Damage to conveyor system CP Pellergy Certified Installer Page 55 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Burner Servicing Bumer servicing otherthan regular cleanout of the bum chamberas described in this manual isauthorized to be performed by Pellergy Certified Installation Professionals only Any alteration performed by a non Pellergy trained individual voidsthe warranty Bumer failures caused asthe result of improperly performed service orinstallation by non trained individuals voids the waranty Page 56 of 67 PB 1525 Wood Pellet Bumer System Instal
42. lletsthat are loaded into bum chamber during the ignition cycle This value isthe period of time in secondsthat the conveyor motor will run thusloading pellets into the bumer 2 1 cupsor17 ouncesisthe properstart amount of pellets The angle of the conveyor along with other factors including the consistency of the pellets effects this setting The following describesthe stepsto set this value to achieve the proper Start Amount Page 40 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Place the controller in the Idle State and Technician Mode by following the stepsbelow 1 Powerthe unit in Technician Mode 2 Assoon asthe controller enters the Purging State press and hold the Disable button 3 Once the unit hasbeen Disabled pressthe End button Once the unit isin the Idle State the controller interface button on the far left willbecome the Parm of Parameter control button See Figure 3 9 Above 1 Pressthe Pam button until the Start Feed Time is displayed on the top line of the controller 2 Use the and buttonsto adjust the amount of time displayed on the controller A good first test time is 33 0 seconds 3 Place a graduated container that will allow you to measure pellets in cupsand orounces underthe conveyor drop tube 4 Initiate an initial dump test by pressing the Test button until the specified test appearsand then pressing the Run
43. med or more frequently depending on your particular boiler WARNING Failure to properly and regularly clean the boiler fumace may result in high chimney temperatures or system failure Have the boiler fumace cleaned by a trained professional on a regular basis Cleaning burner chamber The PB 1525 bum chamber requiresthe regular manual removal of clinker and ash buildup Thistask can be easily accomplished by the homeowner in aslittle as one minute with practice Before beginning to clean the bum chamber be sure the system is not running by looking atthe controller displa y and listening to the system Do not interupta bum cycle rather wait till the bum cycle is complete to perform the cleanout Page 49 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Disable the system by pressing and holding the Disa button on the controllerfor 5 6 seconds orassoon asthe Ena display appears If the bumer has just been in operation wait 10 20 minutes before cleaning to allow the combustion chamberto cool down Follow these steps RWN N Remove the two cables from the bumer Loosen the two wing nuts on the top of the bumer Remove the wing nut on the back side of the bumer Remove the green bumercover Release the two quick latcheslocated on each side of the bumer Bend bumerforward slightly rotating aboutthe drop and lift from assembly Remove the bumerchamber
44. mount of pellets within the system 2 Six Minute Test Test of the Running Feed On setting This test simulates a six minute run time of the auger during the Firing State 3 Fan Speed Test Test of the Fan High Med and Low settings Typically used fortroubleshooting only 4 Fan Start Stop Test Test of the combustion blowers ability to start and stop Typically used for troubleshooting only 5 Bum In Test Test of the control board functionality This test will run the Combustion Blower Ignitor Auger Feed Motor Not intended forthe Certified Installer this test is used to proof the controller boardsatthe final stages of assembly and checkout 6 Alarm Test Test of the alarm relay output of the system 7 End Technician Mode Used to exit Technician Mode Also note 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 orderforthe PB 1525 system to function properly Typical scenarios where conveyor filling is required are l Atinitial system set up 2 Aftermaintenance is performed that requires disassembly of the conveyororremoval of the conveyorfrom the pellet hopper 3 In the event that the system is permitted to run out of pellets Scenario land 2 above shall only be performed by a Certified Installer Scenario 3 may be performed by a homeowner operatorthat has Page 38 of 67 PB 1525 Wood Pellet
45. no env DO Sensor ORTON anv DO sta Ge Sensor OFTON ack Tenperatire Sensor a Figure 2 6 Terminal Connections forthe PB 1525 Wood Pellet Bumer 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 The detail is provided for informational and troubleshooting purposes only Page 20 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 7 CONDUCOR 6 CONDUCTOR CABLE CABLE E BLK WHT GRN RED BLU ORG WHT BLK 213456781 91011 12 13 14 15 16 17 TERMINAL PANEL ENCLOSURE Figure 2 7 Factory Terminal Connections within the Pellergy Supplied enclosure There are two extemal electrical connections required to connect the PB 1525 1 Connection to a 120V AC PowerSource 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 21 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Additionally there are three Optional components of the PB 1525 system that can be field connected These are the 1 Air Cleanout Solenoid This isthe automated ai
46. no more than 5 5A during ignition mode Page 22 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 WARNING WARNING Connecting household line voltage to any terminal otherthan those indicated on the terminal connection detail below will cause damage to the PB 1525 wood pellet bumer system and voids the warranty The PB 1525 must be connected to a proper ground connection aSlabeled Connecting the Controller to the Thermostat 1 The PB 1525 connectsto a standard nomally open dry contact thermostat System firing will be controlled by the demand called for by the thermostat 2 The thermostat connectsto the PB 1525 asindicated in the terminal connection detail above WARNING Connecting any low voltage to the Thermostat terminals of the PB 1525 wood pellet bumer system will result in improper and potentially dangerous system operation and system damage The Thermostat connections are for Normally Open N O Dry Contactsonly Applying or DC voltage to the thermostat inputs to the system voids the warranty 3 An optional universal voltage input relay is available for installations where the existing control circuit provides direct 120V AC or 24V AC DC to the bumerforoperation IF required this relay is installed within an exterior control box Connectthe control voltage as indicated on the relay and connect Normally Open N O relay outputsto the thermostat inputs o
47. not install the conveyor drop tube directly overthe PB 1525 pellet feed tube Misalignment is intended and acts asa safety feature The feed conveyor must not exceed 10 FTin length Adding to the length of the feed conveyor will result in bumer malfunction When positioning the pellet hopperand installing the conveyor into the pellet hopper a The conveyor must be installed atan angle between 40 509 asshown in Figure 2 3 above b The feed conveyoraugertube must not exceed 10 FTin length The feed conveyor may be cutto a desired length provided that final length isable to meet all other installation requirements of the conveyor Installthe overhead anchorand hang the conveyorusing an appropriate chain cable oranchorasin Figure 2 3 above Install the conveyor into the pellet hopper ensure there is Clearance between the auger spiral and the bottom of the hopper of atleast 1 If the conveyoraugermakes contact with the bottom of the hopper damage can occur Referto Figure 2 4 below The auger spiral end should ride on the augertube ring created by the cutout on the end of the augertube If the auger spiral is cut too short it may hop out of the augeropening and jam If the auger spiral is cuttoo long it may wearthrough the bottom of the hopperbottom causing damage to the system and jamming the auger system Page 15 of 67 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 S
48. nting plate Figure 2 3a below fora 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 hoppercan be replaced by compatible bulk pellet binsfor direct feed installations Page 12 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Smoke Pips All boiler clearances must be maintained and local codes followed in any installation Per Peller uldelines a min KPA 100 5 Pallargy Wood Pallet SRY ci ce on ade Boller 5 Saction Castiron top and 18 to the rear are to b maintained Pallargy Burner mountad to Boller Door Service Envelope irequir sd for cleanout 24 3 Min L i L li AF 1 ie 1 s Pallet Hopper Location Hopper continues for full 270 510 2 distances from 48 M Figure 2 3a Pellergy wood pellet bumer mounted to a Pellergy s 5 Section ASME Rated Cast Iron Boiler Installation of the Pellet Conveyor When determining the location of the pellet conveyor mounting position the location of both the PB 1525 bumer and the pellet hopper must be considered 1 The conveyoris designed to be hung from a single point overhead anchor Inspect the overhead in the vicinity of the PB 152
49. nty applies only if the system is installed and operated as recommended in the user s manual and installed by a Pellergy LLC trained professional following all applicable requirements local state county or other regulatory governmental and those imposed by Pellergy LLC THESE WARRANTIES WILL NOT APPLY if abuse accident improper installation negligence or use beyond rated capacity causes damage Any claim under this warranty should 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 INCIDENTAL AND CONSEQUENTIAL DAMAGES CONNECTED THEREWITH WARRANTY EXCLUSIONS Failure due but not limited to fire lightning acts of God power failures and or surges rust corrosion and venting problems are not covered Damage and or repairs including but not limited to fuses knobs glass plastic paint and related duct work chimney are not covered Also excluded from this warranty are consumable or normal wear Excluded in this warranty is any coverage of the existing boiler or heating system being converted Additional or unusual utility bills incurred due to any malfunction or defect in equipment and the labor cost of gaining access to or removal of a unit that requires special tools or equipment are not covered Maintenance needed to keep the system in good operating condition is not covered This inclu
50. r in the Idle State and Technician Mode by following the steps below 1 Powerthe unit in Technician Mode 2 Assoon asthe controller enters the Purging State pressand hold the Disable button 3 Once the unit hasbeen Disabled press the End button Once the unit isin the Idle State the controller interface button on the far left will become the Parm of Parameter control button See Figure 3 9 Above 4 Pressthe Parm button until Running Feed On isdisplayed on the top line of the controller 5 Use the and buttonsto adjust the amount of time displayed on the controller A good first test time is 2 1 seconds 6 Place a graduated container that will allow you to measure pellets in cupsand orounces underthe conveyordrop tube 7 Initiate an SixMinute Test by pressing the Test button until the Page 42 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 specified test appearsand then pressing the Run button The system will simulate the pellet conveyor start and stop cyclesthat would occurin six minutes of run time during the Firing State You can monitor the test status by watching the countdown on the display Following the test run you must weigh the amount of pellets in the collection containerusing a scale accurate down to an ounce 9 The amount of pellets measured during this test will determine the firing rate of the bumer Be s
51. r valve that activates the bum chamber cleanout system 2 Alarm Output Connection This set of Normally Open Contacts close upon the activation of a PB 1525 system alarm These contactscan be tied to central alarm systems indicator lights dial out systems and other remote devicesto alert the operator of a system enor 3 Stack O2 Sensor This is an oxygen sensor module that allows the system to automatically adjust fuel air ratios to ensure the best possible complete combustion of the pellet fuel being bumed Connecting the PB 1525 System to a Voltage Source 1 The PB 1525 connectsto household line voltage 120V AC 60Hz for operation The voltage source forthe PB 1525 must a Be connected to the same point asspecified forthe oil bumer by the boiler and fumace manufacturer This is to ensure that all controls cut out switches and safety devices remain active b Be installed such that all devicesused to cut powerto the bumer in the event of high temperature high pressure low water etc remain between the voltage source and the 1525 such that any of these devices will cut powerto the wood pellet bumer system if required WARNING All safety controls required to protect the boiler fumace from overheating overpressure low water and others must be installed between the voltage source and the PB 1525 2 The PB 1525 should be serviced from a dedicated branch circuit breaker rated at not more than 15A The system will draw
52. s interlock is intended to prevent the bumerfrom operating with the dooropen Contact the boilerorfumace manufacturer for details regarding to and availability of the interlock switch The Certified Installer may install an interloc k switch that cuts powerto the bumer system if the doorisopened 4 Fitthe custom PB 1525 bumer mounting plate to the boileror fumace Forspecific fitting details referto documentation included with the custom mounting plate 5 Aftermounting the bumer mounting plate to the boilerorfumace inspect to ensure that the interface between mounting plate and boiler orfumace form an airtight seal 6 Assemble the PB 1525 bumerto the mounting plate 7 Refractory material installed on the boiler door or mounting plate shall be maintained asoriginally installed by the boilerorfumace manufacturerto limit the surface temperature Pellet Auger oft Auger Motor PelletHopper Electronic Controller 550LBS Capacity Pellet Feed Tube oileror Furnace NotIncluded with System Show for Clarity Wood Pellet Burner Figure 2 2a System Overview Page 11 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 WOOD OIL BOILER X MOUNTING PLATE WILL VARY BY BOILER PELLERGY BURNER b MOUNTING PLATE TO BOILER GASKET BURNER TO WILL VARY BY MOUNTING PLATE BOILER GASKET Figure 2 2 Bumer assembled to mou
53. state shown here asa value of 2 Also the State Counter will count down from a preset value If the system failsto ignite within the set time period the 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 forfive seconds Stabilizing The Stabilizing state indicatesthe system hasdetected the presence of flame in the bum chamberand isentering the first phase of the firing mode In the Stabilizing state the unit is monitoring the flame sensorfor the presence of a quality flame within the bum chamberand will adjust the blower speed in response to flame intensity During the Stabilizing mode the system will also feed a small amount of pellets into the bum chamber Figure 3 4 below illustratesthe controller in the Stabilizing state Page 29 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Co o N Z Stabilizing 188 T 74 98 F E d Hours 13 Disa 1 J 1 Figure 3 4 PB 1525 Bumer Controller in the Stabilizing State Asdepicted above the System State is Stabilizing The ignitor has shut off indicated by the absence of the I on the display No new indicators have been displayed however we do see that the flame sensor v
54. sthe Purging State press and hold the Disable button 3 Once the unit hasbeen Disabled pressthe End button The display will now appearasit doesin Figure 3 9 above and the initial system set points ma y be entered Pressing the Parameters or Test button will allow the Certified Installerto scroll through the settings and tests made available within the controller Pressing no button for 5 6 seconds will cause the display to revert back to that shown in Figure 3 9 above Operational Parameters Page 36 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 There are a total of seven 7 operational parametersthat 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 gasanalysis Value must not exc eed 255 2 Fan Med Speed Run Speed of the Combustion Blower Factory Set to a value of 105 and should not be adjusted without consulting Pellergy Value must not exceed 255 3 Fan Low Speed Run Speed of the Combustion Blower Factory Set to a value of 95 and should not be adjusted without consulting Pellergy Value must not exceed 255 4 Sta rt Feed Time Run Time forthe Augerupon startup Set asthe initial setting on the system This value will vary given different lengths of auger installation angles and pellet consistenc y 5 Running Feed On Run
55. tarts Number of Start Stop Cycles Ignitor Status On Off Combustion Blower Status High Med Low Speed or Off Alarm Display Various Button Functions Various The following sections of this manual will disc uss the display during the various states of the controller Page 26 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 System Operational Description The PB 1525 has eight 8 distinct and separate statesof operation These states are detailed in the illustrations and descriptions below System States Idle The Idle state is Standby Mode forthe system In the Idle state the unit is monitoring the thermostat to start the ignition sequence Figure 3 1 below illustratesthe controller in the Idle state oy 0 Me Blower Speed tack Lemp Indicator 65 F Flame Sensor 1 Value Disa Feed Buttons Functions Cycle Meter M 4 aw Figure 3 1 PB 1525 Bumer Controller in the Idle State As depicted above the System State is Idle The stacktemperature reading isat 65 degrees F The Flame Sensor value is 0 The State Counter 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
56. terial is used in the system always avoid the use of these e Do notstore combustible materials within 24 of the PB 1525 bumer CAUTION Items may fallinto an open pellet hopperand cause damage to the auger Keep allobjectsclearof the pellet Page 5 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 hopperopening e Pellets otherthan Premium Wood Pellets may cause system damage Use only Premium Wood Pellets as designated and by the Pellet Fuels Institute NOTE When installed asthe only automatic source of central heat within a home orbusiness check with your existing insurance mortgage provider and local building codesbefore installing the PB 1525 wood pellet bumer system Fully understand any limitations or restrictions that may apply asto the use of a solid fuel fired central heating unit This system provides thermostatically controlled heat that is intended to operate unattended forup to 3 4 weeks with proper maintenance and automatic bum chamber cleanout The PB 1525 system provides an alam output contact that can integrate to an existing oradd on home alarm orautomatic dial out system Chapter TWO Installation WARNING The PB 1525 wood pellet bumer system shall be installed by Pellergy trained certified installation professionals ONLY Any unauthorized installation of the PB 1525 system voidsthe product warranty and may result in damage or loss of property inj
57. the addition of the automatic bum chamber cleanout option these numbers can be adjusted upwardsto give up to 4 weeks of uninterupted bum time If this system is installed and operational it is still recommended to checkthe bum chamberperthe initial schedule above and adjust the cleanout cyclesasrequired In addition when checking the bum chamber at regular intervals it willbe necessary to remove the clinkers from the bottom of the firebox in the boilerto ensure properoperation This can be done with a simple ash removal shovel inserted through the bum chamberopening when the inner bum chamber is removed the boiler fumace doordoesnot need to be opened or removed for this operation Every installation is different and wood pellets various manufacturers can vary widely In the initial weeks of operation with your system keep a log of your cleanouts using the hoursand start stop cycle counter on the controller Begin to leam the cleanout cycle that best suitsthe operation of your system Remember if you change the brand of pellet being used oryourusage pattem you may also need to change yourcleanout routine PELLET QUALITY MATTERS If you bum pellets with a high ash or high impurity content you will ha ve to clean both your bum chamber and boiler fumace more frequently WARNING If using a vacuum to clean the boiler use only one approved forthe removal of wood ash and let the boiler fumace cool down entirely before cleaning Piecesof
58. the most efficient operation of the system and to avoid premature failure of system components On average systems will operate between 10 20 times perday during the heating season Page 45 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Setting the Cleanout Cycles Asan option the PB 1525 can be fitted with an automatic bum chamber Cleanout system that will serve to keep the bum chambercleanerand more clearof clinkers during extended periods of operation The system utilizes a set of air nozzles affixed to the inside of the bumer connected to an airline compressorand solenoid valve all provided by Pellergy The bumer controller will activate the solenoid valve ata set time during the Purge cycle to push the by products of combustion into the ash collection area ofthe boiler The frequency of this cleanout cycle is set within the controller and can be blow down the bum chamber every cycle orevery cyclesas set by the Certified Installer To set the number of cycles between Cleanout system activation follow the stepsbelow The system must be in Technician Mode 1 Press the Pam button until Cleanout Cycles is displayed on the controller 2 Use the and buttonsto add or subtract cycles The set numberisthe numberof cyclesthe controller will wait to perform the cleanout function Pellergy recommends starting with a value of 10 and adjusting from
59. uch asthe conveyor length and angle of installation WILL change the amount of pelletsfed in the same period of time Setup of the Initial Combustion Blower Setting Value The Fan High Speed setting controlsthe combustion blowerspeed and thereby the amount of combustion air provided to the system during the Firing State Please note that the combustion blower sometimes referred to asa fan performs a ramp up before starting in any speed Thisramp lastsa fraction of a second however it can be heard any time the blower starts oradjusts speed from one levelto another Take the stepsbelow to run the bumerforthe first time and adjust the combustion properties of the system Running the Burner for the First Time During the first bumeroperation stack gases will be analyzed and the blower value will be adjusted to achieve proper combustion properties Do not insert the combustion analyzer into the chimney before bumer is the Firing State fora minimum of 5 min Thisisbecause in the beginning of fiing the bumercan produce smoke that can cause the combustion analyzer probe to become dirty and produce enoneous results If the flame looks dark orange and lazy orthere isthe presence of smoke in the flue gasses raise the blowerspeed by following the steps below before inserting the combustion analyzer into the flue gas path The system must be in Technician Mode 1 Sartthe bumer by initiating a call forheat at the thermostat input to t
60. uide to ermors potential cause and remedy Error Message Potential Cause Ignition Failure 1 Bum Chamber clogged or filled with clinkers and Eroroccursasa ash result of the bumer failing to sense the 2 Out of Pellets presence of flame 3 Failed Ignitor within ae 4 Failed Flame prescribe time Sansor period 5 Failed Blower 6 Improper draft in system Too much ortoo little Lost flame no fuel 1 Bum Chamber clogged or filled with clinkers and Eroroccursasa ash result of the bumer failing to maintain a 2 Out of Pellets proper fla me in the 3 Failed Flame Remedy Clean bum chamberand restart system Load pellet bin and fill auger tube completely CP install new ignitor CP install new flame sensor CP install new blower CP checking of draft and cleaning of boiler checking operation of barometric draft regulator on flue pipe Clean bum chamberand restart system Load pellet bin and fill auger tube Page 51 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 bum chamber The emor message suggests that the system hasrun out of fuel Flame sensed short Emoroccursasa result of the bumer failing to sense the extinguishing of flame within the bum chamber within the prescribed amount of time during the shut down cycle The emor message suggests a flame sensor short asa potential cause
61. unbumed 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 lossordamage due Page 48 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 to freezing NOTE Failure to properly maintain the PB 1525 can result in equipment damage The boiler fumace needsto be cleaned on a regularly basis by a trained certified professional During operation of the bumer fly ash is created This ash is carried throughout the boiler fumace through the normal combustion gasflow from the bum chamber through the firebox over the heat exchanger surfacesand out the chimney Fly ash will accumulate on every horizontal surface within the boiler fumace and will also begin to adhere to the heat exchangersurfaces This causesa reduction in system efficiency due to the insulative effect the ash has within the boiler fumace Regular cleanout of the boiler fumace is required to maintain the highest efficiency as well asto maintain proper system operation It isrecommended that the PB 1525 owner execute a regular maintenance contract with your certified installation professional for regular cleanout serviceson the boiler fumace In general oil fired boilers fumaces 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 bu
62. ure to measure appropriately and double checkthe figures 10 The measured amount of pellets in this test cycle will be used to set the firing rate of the bumer Use the valuesbelow to calculate the firing rate and determine next stepsto be taken o 1Pound of pellets 8 200 btu of heating value 1FPof pellets 240 Pounds Therefore if during the six 6 minute test the conveyorfeedsa total of 1 15 Pounds of pellets use the following formula to calculate the input firing rate of the bumer gt 1 15 LB Pellets in six 6 minutes 360 sec 1 15lb X 8 200btu Ib X 10 294 300 btu hr gt Ifthe desired firing ishigher than the calculated amount input a higher Running Feed On time and re test If itis lower input a lower Running Feed On time and re test gt Use the following formula to calculate btu hr LB of Pellets in 6 Minute Test X 8 200 btu Ib X 10 btu hr input firing rate If you know the btu LB value of the specific pellets you are using use that number instead of the 8 200 btu LB average given above WARNING Ifthe bumerisset to feed too many pellets on the power feed cycle there isa risk of a gas explosion in the boiler and or overfiring the boiler Pay particular attention to the amount of pellets being fed to the bumer system Thistest must be run for each installation of the bumer Page 43 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 Items s
63. ury to personnel and even death The PB 1525 Wood Pellet Bumer System may only be used to convert Pellerg y approved boilers and fumaces Pellergy engineering staff works Closely with our Certified Installers to ensure compatibility between the bumerand the heat exchanger The PB 1525 Wood Pellet Bumer System installs through the use of a custom Page 6 of 67 PB 1525 Wood Pellet Bumer System Installation and Operation Manual Rev 1 0 OCTOBER 2011 mounting plate to the boilerfront that is provided by Pellergy An initial site survey of the intended host boiler orf mace and environment must be performed Pellergy must provide the Certified Installer with the appropriate mounting plate forthe application The PB 1525 must be installed to fire the boiler fumace in the same manner asthe original fuel source when converting to wood pellets In orderto accomplish this the following guidelines must be followed 1 The system must only be used in oil and wood fired boilersand fumaces a Not all boilers fumacesare good candidates for use with a Pellergy System The boiler must be closely evaluated by a Certified Installerfor compatibility In addition to meeting local state and regulatory codes the boiler fumace must accommodate ash buildup between cleanings This ash will accumulate within the boiler fumace The host boiler fumace must be easily cleaned on a more regular basisthan when firing on oil Additionally the boiler fumace must

INSTALLATION & OPERATION MANUAL

Contents

Download Pdf Manuals

Related Search

Related Contents

INSTALLATION &amp; OPERATION MANUAL

Contents

Download Pdf Manuals

Related Search

Related Contents

INSTALLATION & OPERATION MANUAL