INSTALLATION & OPERATION MANUAL
Contents
1. INSTALLATION amp OPERATION MANUAL Product P N Pellergy PB 3550 Serial Number NAME TRAINING COPY Wood Pellet Burner System A h PECLERGY REV 6 1 MAY 2010 16 Railroad Street Barre VT 05641 802 659 4866 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 Table of Contents INSTALLATION amp OPERATION MANUAL Introduction Chapter ONE Safety Chapter TWO Installation Installation of the PB 3550 Wood Pellet Burner System Installation of the Pellet Conveyor Boiler Furnace Room Ventilation and Maintenance Measuring Chimney Draft Electric installation General Connecting the Controller to a Voltage Source Connecting the Controller to the Thermostat Chapter THREE Initial System Setup Filling the Conveyor Controller User Interface Description Setup of Start Amount Value Setup of Power Feed Value Setup of Burner Firing Rate Setup of Blower Setting Value Running the Burner for the First Time Burner Cycles Chapter FOUR Maintenance General information Cleaning burner chamber Troubleshooting Burner Servicing General Technical Data Available Replacement Parts Warranty and Installation Doc Burner measured values Warranty and Installation Doc Burner measured values Installer Note Page amp System Drawings O 12 17 18 18 18 19 21 21 23 24 26 26 27 28 28 29 29 31 33 35 35 36 37 39 40 41 42 44 Page 2 of 50 PB 3550 Wood Pellet Bume2. Page 48 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 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 4 1 2X 2 18 EA 3 36X 4 18 EA 24 4 9 30 10 23 25 26 4 31 CUT TO LENGTH AT INSTA LL 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 4 10X 13 2 2 2 EA 3 4X A 2X 14 15 8 3 16 4 8 FELLERGY LIC Page 49 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 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 ED
3. chamberand restart system 1 Fill pellet bin 2 Remove pellets from bin and replenish with new pellets inspect conveyor atthe connection of the conveyorto the feed motor CP repair of conveyor Page 34 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 Burner Servicing General Bumers servicing is authorized by Pellergy Certified Installation Professionals only Any alteration performed by a non Pellergy trained individual voids the warranty Bumer failures caused of uncertified servicesor installations wrong done service or installation voids warranty and Pellergy LLC do not take any responsibility of any damage caused by this Also look local regulation of electric work before chance igniterorany electrical part of the bumer where there 5 chance to cause electric shock Page 35 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 Technical Data Dimension out side of boiler Dimension of combustion chamber 7 0 x 8 mm Average buming rate C a 9596 Maxenergy output 180 000 btu hr Min energy output 100 000 btu hr Voltage 120VAC 60Hz 600W ma 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
4. 2 PowerFeed controlsfuel feed rate and results in bumer firing rate 3 BlowerSetting controls supply air blowerspeed asa percentage 1 100 There are 8 Buttonson the controllerthat allow navigation and input to the controller General input keys 1 Use H buttonsto change values on display Values change in realtime and valuesare stored automatically in the control memory 2 Use up down amowsto navigate and scroll display 3 To run test mode press and hold down left arrow button for 4 seconds 4 To exit test mode press right arrow button once WARNING Functions describe in the remainder of the chapterare to be performed by a Pellergy trained certified professional ONLY Setup of Start Amount Value The Start amount value controlsthe amount of pelletsthat are loaded into bum chamber during the ignition cycle This value is period of time secondsthat the conveyor motor will run thus loading pellets into the bumer 2 1 cupsor17 ouncesisthe proper start amount of pellets Angle of conveyor along with otherfactors affect this setting Following describesthe stepsto set this value to achieve the proper Start Amount Page 24 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 NOTE Scroll to starting amount position using the up and down keys Use the keysto seta time amount of 30 seconds Place a graduated container that will allow you to measure pel
5. CO ppm 300 ppm O2 96 CO 9o 10 1296 CO2 Blower Setting setting 9o 1 100 Start Amount seconds Powerfeed 1 seconds Date of Installation Job Number Name Page 42 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 WARRANTY Pellergy LLC backs its products to be free from defects in material or workmanship under normal use and service for a period of one year 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 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 DESCRI
6. 3550 1 Connection to a 120V AC PowerSource 2 Connection to a thermostat Connecting the Controller to a Voltage Source 1 The PB 3550 connectsto household line voltage 120V AC 60Hz for operation The voltage source forthe PB 3550 must a Be connected to the same point asspecified forthe oil bumer by the boiler and fumace manufacturer This is to insure 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 3550 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 3550 2 The PB 3550 should be serviced from a dedicated branch circuit breaker rated at not more than 15A The system 120V AC Main Fuse 5 rated at 6A CAUTION Do not connect the PLC controller directly to household voltage The controller isa low voltage device that must be supplied powerfrom the AC to DC converter Page 18 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 3 Input Voltage is supplied to the PB 3550 at the bottom of the electronics control box using the entry point labeled and cable strain relief pro
7. date Installed to Name Address 2 code Phone number Installation Company Name Address 2 code Phone Customer Copy Page 39 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 Burner measured values Customer Copy Chimney draft Cold in H20 Chimney draft Hot in H20 Temperature outside house F Values at Power Feed Stack gastemperature F CO ppm lt 300 ppm O2 9o 10 12 CO2 Blower Setting setting 9o 1 100 Start Amount seconds Powerfeed 1 seconds Date of Installation Job Number Name Customer Copy Page 40 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 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 Installed product PB 3550 Wood Pellet Bumer System Production No Installation date Installed to Name Address 2 code Phone number Installation Company Name Address 2 code Phone This copy must be sent to Pellergy LLC within 10 days of installation Page 41 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 Burner measured values Chimney draft Cold in H20 Chimney draft Hot in H20 Temperature outside house F Values at Power Feed Stack gastemperature F
8. 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 3550 The draft measurement isto be taken atthe exhaust gas outlet of the boiler fumace at exhaust pipe connection Draft should be between 0 03 in H20 to 0 10 If the Draft is more than 0 10 in H20 or likely to exceed 0 10 in H2O a draft regulator barometric control unit is recommended for use WARNING mproperdraft can lead to potentially hazardous conditions Chimney draft must be within system limitations at all time The boilerand chimney must be kept clean to maintain proper draft If draft is less an 0 03 in H20 a forced draft blower or draft inducer can be installed to create properdraft Install per manufacturer s recommendation and guidelines Following initial installation of the PB 3550 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 Chapter Four Maintenance for information on cleanout Page 17 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 Electric installation General There are two electrical connections required to connect the PB
9. switch 1 Earth to burner core Figure 2 5 Electrical Schematic Page 20 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 Chapter THREE Initial System Setup Filling the Conveyor The conveyor must be filled with pellets in orderforthe PB 3550 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 conveyor orremoval of the conveyor from the pellet hopper 3 In the event that the system is permitted to run out of pellets Scenario 1 and 2 above should only be performed by a Certified Installer Scenario 3 may be performed by a homeownerthat has received instruction from their C ertified 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 maintenance 1 Scroll to start amount position using the up and down keys Use the and keysto set a time amount of 30 seconds Initiate a start amount test by pressing and holding the left arrow key for 4 seconds After pressing and holding the button on the controllerthe red indicatorlamp underthe electronics control box will illuminate the text TEST will b
10. 1509 standards for Solid Fuel Fired Central Furnaces This application is only for the use of replacing existing oil burning firing units in existing furnaces Thus the Pellergy Pellet Solid Fuel Replacement Burner is eligible for listing and labeling under Guardian s Factory Inspection Program when applied for by the customer Pellergy LLC Complete drawings and test data are on file at Guardian and at the manufacturer Tested by Guardian Fire Testing Laboratories Inc ISO IEC 17025 2005 Certificate 1247 Page 36 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 Available Replacement Parts e lgniter e Blower e Flame sensor e Optional Relay Conroller e Thermal Safety Switch e Fuses Controller e Bumerchamber e Quick release latches side of the bumer The following items are provided to Certified Installation Professionals as a part of the Critical Spares Kit Page 37 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 Page 38 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 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 3550 Wood Pellet Bumer System Production No Installation
11. 1FT PB 3550 BURNER Burner Centerline matches pre existing burner centerline Min Firebox depth 12 Min Clearance 2 Refractory Insulation Required Figure 2 1 Typical installation showing minimum intemal dimensions and clearances CAUTION If the manufacturer sdata on the boiler orfumace to be fired using the PB 3550 Wood Pellet Bumer System gives specific instruction NOTto convert the unit to solid fuel please consult the boiler orfumace manufacturer before installation Page 8 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 NOTE When installing the PB 3550 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 The PB 3550 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 uns
12. 550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 b The conveyor must be mounted such that the drop tube isa minimum of 15 inches above the PB 3550 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 3550 pellet feed tube opening Maximum of 12 inches See Figure 2 3 below ANCHOR POINT ____ CONVEYOR CHAIN Figure 2 3 Conveyor mounting details WARNING pellet feed conveyorassembly can weigh asmuch as 100 pounds when in operation and filled with pellets Insure a suitable overhead anchor point from which to hang the conveyor a Do notdirect couple the conveyor drop tube to the PB 3550 pellet feed tube without the use of the supplied flexible plastic drop tube assembly Thistube actsasa back bum safety device Page 13 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 a Do not install the conveyordrop tube directly overthe PB 3550 pellet feed tube Misalignment is intended and acts asa safety feature NOTE The feed conveyor must not exceed 10 FTin length Adding to the length of the feed conveyor will result in bumer malfunction 2 When positioning the pellet hopperand installing the conveyor into the pellet hopper a The conveyor must be installed at an angle between 40 509 asshown in Figure 2 3 above b T
13. EEP THIS MANUAL FOR FUTURE Page 4 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 Overview This Safety summary and this manual hasbeen prepared to insure the PB 3550 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 e NOTE A note is used to highlight essential procedures conditions or statementsthat convey important instructional data to the reader WARNING e 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 material is use
14. GING 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 1 00003 300 00020 300 00012 700 5 00001 300 00013 400 00012 400 00007 700 B 00008 400 M 00009 Description SHCS 10 32 X 5 8 SPLIT LOCKW ASHER 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 50 of 50
15. LUG 3 PIN SCREW 18 8 SST 4 40 X 1 2 BH PLUG 6 PIN BRACKET ELECTRICAL CONNECTOR TERMINAL BLOCK 6P SCREW 18 8 SST 6 32 X 1 BH COVER TEMP SWITCH BRACKET TEMP SWITCH CABLE SCREW 18 8 SST 6 32 X 1 4 BH SWITCH FAN LIMIT IAS FEED TUBE SCREW 18 8 SST 1 4 20 X 3 8 BH STRAIN RELIEF NYLON 08 20 COVER ELECTRICAL CONNECTOR NUT 18 8 SST 8 32 DEFLECTOR IAS FEED TUBE Page 46 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 7 190 0t Ai C CON Aids IN HORAM HO POP RIHALY DPP CH FUIS Pdr AH DID CO MAY WI EF OSZ OSHO foa Ink es FII IP Ph NEGY 1 STATUS RELE ASED DE AWE Abl YI PELLERGY LLC OPAWEG Faw HIER NACE 5 KO SDC BURNER AGIT PONC O TE OE 1 car l 2 Page 47 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 ITEM NO PART NUMBER DESCRIPTION ECOLOGY 20800 MODIFIED 400 00012 POWER CONTROLLER 400 E 0001 1 CONTROLLER ALPHA 2 400 00013 POWER SUPPLY 400 00005 NYLON 400 0001 5 ISOLATOR STATUS RELEASED Antia neron PELLERGY LLC t ELECTRONICS ASSEMBLY 200 0002
16. PTION OF WARRANTY HEREIN DESCRIBED This warranty 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 go
17. Pellergy System with a Bumham 231 six section boiler Page 11 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 24 gt Smoke Pipe 17 All boiler clearances must be maintained and local codes followed in any installation Per Burnham guidelines a min n n 35 of 6 clearance on sides and top and 18 to the rear are to be maintained 6 Section Burnham MPO Boiler MPO231 TB Pellergy Burner mounted to Boiler Door 20 5 7 10 Max L e I 71 Service Envelope 7 required for cleanout y 24 3 M in s w 1 s Y bI ia Pellet Hopper Location pd continues for full 270 f 6 y distance from 48 d boilerf _ ad J Figure 2 3a PB 3550 bumer mounted to a Bumham 231 Six Section Boiler Installation of the Pellet Conveyor When determining the location of the pellet conveyor mounting position the location of both the PB 3550 bumerand 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 3550 bumer and select a suitable point forthe overhead anchor The conveyor 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 Page 12 of 50 PB 3
18. 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 S pm N Bend bumer forward slightly rotating aboutthe drop and lift from assembly N Remove the bumerchamber by sliding it from within the assembly 8 Dump contents of the bumer chamberinto a properly rated ash can Scrape orbrush the chamberasnecessary and re assemble the bumer WARNING Neverstore ashesand orclinkers inside the building orin a non metallic container Alwaysuse a container specifically rated for the 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 Bumer components may be very hot Alwayscheck the temperature of the bum chamber before removing from the system Use glovesor other protective gearto avoid injury Page 32 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 Troubleshooting The PB 3550 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 NOT simply restart the controller without taking action to remedy the initial cause of the error The table below providesa guide to errors potential cause
19. afe conditionsthat can lead to fire Regular cleaning and maintenance routines must be followed CAUTION e The PB 3550 should not be used in a system installed in a chimney serving multiple boilers orfumacesunless 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 3550 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 3550 NOTE e The existing chimney should be cleaned and inspected priorto installation of the PB 3550 Wood Pellet Bumer System Installation of the PB 3550 Wood Pellet Burner System 1 Plan ahead Insure proper installation operation and maintenance space isavailable before beginning installation Insure the PB 3550 bumercan be disassembled for proper cleaning in the intended installation space 2 Remove oil bumerand oil bumer mounting plate if applicable Page 9 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 3 Inspect all gaskets and mounting surfaces Replace any gasket material that is damaged orthat is wom ordeteriorated to the point where a propersealcan not be made WARNING e The PB 3550 Wood Pellet Bumer System must not be operated with the boilerorFumace dooropen e If The PB 3550 is mounted t
20. ance General information The PB 3550 requires regular general maintenance forproperoperation There are two types of regular maintenance One accomplished by homeowner bumer cleanout and the otherby the certified trained installer boiler fumace cleanout Page 29 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 Clinkers are byproducts of combustion that form in the PB 3550 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 on the amount of pellets bumed the firing rate of the system the total number of start stop cycles between cleanings the wood pellets being bumed and the season Initially it isrecommended that the bumerbe Cleared of clinker buildup every 3 4 daysin order to begin to gauge the amount of buildup experienced in your particular installation 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 water only Every installation is different and wood pellets from various manufacturers can vary widely In the initial weeks of operation with your system keep a log of your cleanouts using the hours and start stop cyc
21. and remedy Error Message Potential Cause Remedy Ignition Error Bum Chamber Clean bum clogged or filled chamberand with clinkers and restart system ash Load pellet bin Fiing Down Error 2 Outof Pellets 3 Failed Ignitor 4 Failed Flame Sensor Failed Blower 6 Improper draft in system Bum Chamber clogged or filled with clinkers and ash 2 Out of Pellets 3 Failed Flame Sensor 4 Failed Blower Improper draft in system and fill auger tube CP install of new ignitor CP install of new flame sensor CP install of new blower CP checking of draft and Cleaning of boiler Clean bum chamberand restart system Load pellet bin and fill auger tube CP install of new flame sensor CP install of new blower Page 33 of 50 No Error Message system inoperable Pellets collect in drop tube No pelletsfeeding into bumer CP Certified Trained Professional PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 Lossof orno main powerto system Bum Chamber clogged or filled with clinkers and ash Pellet bin out of pellets Pellets bridging in pellet bin due to improperly stored pellets or exposure to water Damage to conveyor system CP checking of draft and Cleaning of boiler Check power source including any safety interlocks on boiler fumace Clean bum
22. d in the system always avoid the use of these e Do notstore combustible materials within 24 of the PB 3550 bumer CAUTION e Items may fallinto an open pellet hopperand cause damage to the auger Keep allobjectsclearof the pellet Page 5 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 hopperopening e Pellets otherthan Premium Wood Pellets may cause system damage Use only 44 Premium Wood Pellets as designated and certified 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 3550 wood pellet bumer system Fully understand any limitations or restrictions that apply asto the use of a solid fuel fired central heating unit Chapter TWO Installation WARNING The PB 3550 wood pellet bumer system shall be installed by Pellergy trained certified installation professionals ONLY Any unauthorized installation of the PB 3550 system voidsthe product warranty and may result in damage or loss of property injury to personnel and even death The PB 3550 Wood Pellet Bumer System installs through the use of a custom 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 w
23. e 1 The PB 3550 must be supplied with adequate fresh airfor combustion a The room in which the boilerorfumace isinstalled should be supplied with a minimum 2 inch diameter fresh air inlet vented to atmosphere This ventilation must come from outside the building not from an adjoining room or enclosed space b The installation room must not at any time be undera vacuum which can be caused by otherappliances such as whole house fans other combustion devices requiring supply air and the like An improperly ventilated room can lead to incomplete combustion lower efficiency and even the production of harmful gasses within the living space WARNING Proper ventilation must be provided forthe PB 3550 wood pellet bumer system 2 The immediate area surrounding the PB 3550 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 Care must be taken to remove dust from the boiler fumace room to prevent a dust fire or explosion WARNING Handling of wood pellets can cause dustto be released into the air Proper ventilation must be provided to avoid personal injury and possible dust fire and orexplosion Page 16 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 Measuring Chimney Draft The PB 3550 requiresa negative
24. e displayed on the graphic display and the conveyor will begin to rotate priming the conveyor Wait forthe test period to end at which time the conveyor motor will stop before proceeding The blower will run forthe first 180 seconds of the test period Thisis normal Care should be taken to insure that all systems are free and clearof obstruction with the blower Page 21 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 and blowercooling fan to reduce the risk of entanglement 5 Pressright arrow button once and repeat steps3 and 4 as required to fillthe conveyor with pellets This will be evident as pellets begin to drop regularly from the drop tube 6 Once the conveyoris filled pressthe right arrow button to exit the Test Mode Filling after running the system out of pellets 1 Priorto refiling the conveyor the system must be placed in the OFF mode by depressing the OK button The emor message must be cleared by cycling the system powerOFF Switch the bumerback ON When the bumer system is switched backON the emor will be cleared and the system will be in the OFF mode asindicated on the graphic display Scroll to starting amount position using the up and down keys Initiat a start amount test by pressing and holding the left arrow key for 4 seconds After pressing and holding the button on the controller the red indicatorlamp underthe electronics control box
25. et 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 insure 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 Certified Installer with any questions The PB 3550 wood pellet bumer system shall be installed by Pellergy trained certified installation professionals ONLY Any unauthorized installation of the PB 3550 system voids product warranty and may result in loss of property bodily injury to personnel and even death Pellergy 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 professionals is maintained by Pellergy LLC Please contact Pellergy customer service for an up to date listing of professionalsin yourarea FOR YOUR SAFETY PLEASE READ THIS ENTIRE MANUAL PRIOR TO INSTALLING AND OR OPERATING THE PB 3550 WOOD PELLET BURNER SYSTEM FAILURE TO FOLLOW THESE INSTRUC TIONS AND LOCAL CODE MAY RESULT IN DAMAGE ORLOSS OF PROPERTY BODILY INJ URY AND EVEN DEATH PLEASE K
26. ets 7 900 btu of heating value If you know the btu value ofthe pellets you are using substitute that value of pellets 240 Pounds Therefore if during the six 6 minute test the conveyorfeedsa total of 2 10 Pounds of pellets AND the desired firing rate on the boileris 125 000 btu hr use the following formula s gt 2 10 LB Pellets in six 6 minutes 360 sec 2 10lb X 7 900btu Ib X 10 165 900 btu hr gt The desired firing is 125 000 btu hrtherefore input a lower powerfeed and re test Use the following formula to calculate btu hr LB of Pellets in 6 Minute Test X 7 900 btu Ib X 10 btu hr input firing rate WARNING a Ifthe bumerisset to feed too many pellets on the power feed cycle there isa risk of a gasexplosion in the boiler and orover firing the boiler Pay particular attention to the amount of pellets being fed to the bumer system a This test must be run foreach installation of the bumer Items such asthe conveyor length and angle of installation WILL change the amount of pelletsfed in the same period of time Setup of Blower Setting Value 1 Scrollto blowersetting position using the up and down keys 2 Use the and keysto set a value of 50 Note This value will be tuned real time later in section Run Bumerforthe First Time Page 27 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 Running the Burner for the First Time During the
27. f clearance from the opening of the bumer to the floor of the fireboxis provided b The centerline of the bumer shall be positioned atthe same centerline asthe pre existing oil bumerto insure proper firing of the boilerorfumace This will insure enough volume forthe collection of ash between Cleanings 4 Notall boilersand fumacesare completely compatible with the Pellergy PB 3550 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 times larger in input Btu sin orderto gain required Btu output and handle the heat load The Certified Installer must evaluate the total heatload 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 Page 7 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 WARNING Installation of the PB 3550 shall result in no permanent modification to the existing boiler orfumace All existing safety interlocks and controls must be utilized If the installation of the PB 3550 will require such modification asthe cutting away of insulation gasket material steel or any other part of the existing boiler orfumace Do not attempt to use the PB 3550 on this system FIREBOX minimum
28. first bumeroperation stack gases will be analyzed and the blower value may be adjusted to achieve properbuming Do not insert the combustion analyzer into the chimney before bumer is Heat mode fora minimum of 5 min Thisisbecause in the beginning of the bumercan produce smoke that can cause the combustion analyzer probe to be come dirty and produce erroneous results 1 Push Ok button to run bumer Bumer will cycle through Ignition and Stabilization modes and settling in Heat mode 2 Afterbumer has running on Heat mode for5 minutes insert the combustion analyzer into the exhaust gasesoutlet chimney and take readings 3 Adjustthe blowersetting value more lessair if needed Rememberto wait least 3 5 min between making changesto the controllerto allow the combustion within the bumerto stabilize Burner Cycles The PB 3550 is fully automated and will respond to the heating demand as called forby a thermostat The normal modesof operation are 1 Standby Mode The bumeris shut down the controller is monitoring the thermostat input fora heating demand 2 Ignition Mode The thermostat has called forheat and the controller hasbegun the heating cycle During ignition mode the conveyor loadsthe Start Amount of Pellets into the bum chamber poweris applied to the igniterand the blowercycleson and off The controller monitors the flame sensorforthe presence of flame in the bum chamber Page 28 of 50 PB 3550 Wood Pellet Bumer Sys
29. he PB 3550 owner execute a regular maintenance contract with your certified installation professional for regular cleanout services on the boiler fumace In general oil fired boilers fumaces require cleaning once per yearwhen fired on oil when fired using a PB 3550 system cleanout may be required every 3 4 tonsof pellets bumed 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 3550 bum chamber requiresthe regular manual removal of clinker and ash buildup Thistask can be easily accomplished by the homeowner in as little 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 the system OFF using the switch on the left side of the controller If the bumer has just been in operation wait at least 10 20 minutes before Cleaning to allow the combustion chamberto cool down Follow these steps 1 Remove the two cables from the bumer Page 31 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 Loosen the two wing nuts on the top of the bumer
30. he feed conveyoraugertube must not exceed 10 length The feed conveyor may be cutto a desired length provided that final length isable to meet all other installation requirements of the conveyor 3 Installthe overhead anchorand hang the conveyor using the included conveyor chain asin Figure 2 3 above 4 Install the conveyor into the pellet hopper ensure there is Clearance between the auger spiral and the bottom of the hopper of atleast 1 inch If the conveyorauger makes contact with the bottom of the hopper damage can occur Referto Figure 2 4 below Page 14 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 SPIRAL 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 3550 wood pellet bumer a Keep all combustible materials a minimum of 24 inches from the PB 3550 wood pellet bumer a Follow all boilerand fumace manufacturer srequired combustible keep out zones 5 If using an altemate pellet storage silo or hopper follow manufacturers installation instructions Do not install orstore any combustible orflammable materials within 24 inc hes of the PB 3550 bumer Page 15 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 Boiler Furnace Room Ventilation and Maintenanc
31. ith the appropriate mounting plate forthe application The PB 3550 must be installed to fire the boilerin the same mannerasthe original oil bumer 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 Page 6 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 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 allow forthis buildup without compromise to the combustion gasflow within the heat exchanger surfaces of the boiler WARNING Failure to properly match a PB 3550 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 1FB 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 3550 7 inches 3 The bumer must be installed into the firebox such that a A minimum of 2 inches o
32. le counter on the controller Begin to leam the cleanout cycle that best suits the operation of yoursystem Remember if you change the brand of pellet being used or your usage pattem you may also need to change yourcleanout routine PELLET QUALITY MATTERS If you bum pellets with a high ash orhigh impurity content you will have to clean both your bum chamber and boiler fumace more frequently CAUTION Failure to properly clean the PB 3550 can result in failed operation of the system resulting in property lossordamage due to freezing NOTE Failure to properly maintain the PB 3550 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 Page 30 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 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 is recommended that t
33. lets in cupsand orounces underthe conveyor drop tube Initiate a start amount test by pressing and holding the left arrow key for 4 seconds After pressing and holding the button on the controllerthe red indicatorlamp underthe electronics control box will illuminate the text TEST will be displa yed on the graphic display and the conveyor will begin to rotate dropping pellets into the container Wait forthe test period to end at which time the conveyor motor will stop before proceeding Take a reading from the graduated container If you have lessthat 2 1 cups increase the start amount If you have more than 2 1 cupsdecrease the start amount Pressthe right arrow key once empty the containerand repeat steps 3 6 until you get 2 1 cups Once the setting is correct pressthe right scroll amow button to exit the Tes Mode Rememberto empty the measuring cup orcollection device between tests WARNING If the bumerisset to feed too many pelletson the initial ignition feed Start Amount there isa risk of a gasexplosion in the boiler Page 25 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 Pay particularattention to the Start Amount of pellets being fed to the bumer system Setup of Power Feed Value Power Feed Value controls fuel feed rate and results in bumer firing rate The value is secondsand the number of secondsthe conveyo
34. nd Operation Manual Rev 6 1 MAY 2010 200 00001 26 8 2 9 2 30 31 4X 3 4 23 8 2X 9 2X 33 34 4X 9 4X 18 8 4X 9 4X 15 16 4X 3 4X 12 2X 8 2X EA STATUS RELEASED IA wa na triw aneita metan PELLERGY LLC mI ASSEMBLY SORW BURNER E 17777 200 00001 4 ve Page 45 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 Reference Part Number 300 W 00001 700 N 00004 700 W 00001 300 W 00002 300 M 00005 300 E 00001 300 M 00006 700 B 00002 700 W 00002 300 M 00007 300 M 00002 400 M 00002 400 M 00001 400 E 00002 400 E 00001 700 B 00001 400 M 00003 Drawing 200 A 00001 Description 50KW INNER BURNER WINGNUT 1 4 20 WASHER 18 8 SST 1 4 FLAT 50KW OUTER BURNER NOZZLE IGNITOR IGNITOR BURNER BRACKET NOZZLE SCREW 18 8 SST 8 32 X 3 8 BH WASHER 18 8 SST 8 FLAT BRACKET IGNITOR HOUSING IAS 50 KW BURNER LATCH ADJUSTABLE DRAW STRAIN RELIEF PVDF 27 47 SENSOR FLAME BLOWER 1TDP2 SCREW 18 8 SST 1 4 20 X 1 2 BH STRAIN RELIEF NYLON 2 CONDUCTOR 12 Reference Part Number 300 M 00004 300 W 00004 400 E 00004 700 B 00005 400 E 00005 300 M 00008 400 E 00008 700 B 00007 300 M 00010 300 M 00009 700 B 00004 400 E 00003 300 W 00003 700 B 00006 400 M 00004 300 M 00011 700 N 00002 300 M 00003 Description BRACKET 50 KW OUTER COVER MOUNTING 50KW OUTER COVER P
35. o a hinged door an optional inte rlock switch is required This interlock is intended to prevent the bumer from operating with the dooropen Contact the boilerorfumace manufacturer for details regarding to and availability of the interlock switch 4 Fitthe custom PB 3550 bumer mounting plate to the boileror fumace Forspecific fitting details referto documentation included with the custom mounting plate 5 After mounting the bumer mounting plate to the boiler or fumace inspect to insure that the interface between mounting plate and boiler orfumace form an airtight seal 6 Assemble the PB 3550 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 of 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 10 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 WOOD OIL BOILER X MOUNTING PLATE WILL VARY BY BOILER PB 3550 BURNER b MOUNTING PLATE TO BOILER GASKET BURNER TO WILL VARY BY MOUNTING PLATE BOILER GASKET Figure 2 2 Bumer assembled to mounting plate See Figure 2 3a below fora typical layout of a
36. od operating condition is not covered This includes 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 No other commitments verbal or otherwise shall apply except by a written addendum to this warranty Page 43 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 Installer Note Page amp System Drawings Page 44 of 50 PB 3550 Wood Pellet Bumer System Installation a
37. r System Installation and Operation Manual Rev 6 1 MAY 2010 Introduction Congratulations on your purchase of a PB 3550 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 insure yearsof safe trouble free operation please follow the guidelines and instructions set forth in this manual The PB 3550 wood pellet bumer system is intended forinstallation with fully approved regulatory compliant domestic hot waterboilers and fumaces The PB 3550 is intended for use with 1 Premium Wood Pellets certified by the Pellet Fuels Institute The Bumer System usesan extemal pellet conveyorto transport pellets from both standard Pellergy and third party extemal pellet bins hoppersto bumer Following the installation of your system the 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 manual and 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 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 Chapter ONE Safety Remember Safety doesnot happen on its own You must follow the instructions s
38. r will run continuously during the Heat Mode of operation Use the up ordown arrowsto scroll the display to show Power Feed Then use buttonsto set right value the powerfeed Referto section Set the Bumer Firing Rate for instructions on how to properly set Power Feed value Setup of Burner Firing Rate This test must be run for each burner installation to accurately set up the firing rate of the burner Failure to do so can result in over under firing of the boiler l Begin by setting the powerfeed to a value of 2 5 seconds 2 Place a fairly large containerbeneath the drop pipe to collect the pellets that will drop from the conveyor during the test sequence 3 Pressthe left arrow button and hold for 4 secondsto run test forthe powerfeed The test period runs for six 6 minutes during which time the conveyor feedsin every 20 secondsforthe set time of 2 5 seconds 4 Following the six 6 minute run measure the amount of pellets in the collection container 5 The amount of pellets measured during this test will determine the firing rate of the bumer Be sure to measure appropriately and Page 26 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 double check the figures 6 The measured amount of pellets in this test c ycle 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 lPound ofpell
39. tem Installation and Operation Manual Rev 6 1 MAY 2010 3 Stabilization Mode The flame sensor hasindicated the presence of a flame in the bum chamber The igniter is shut off and the bloweris ramped up to a constant speed Half way through the cycle pellets will be fed into the bum chamberata low rate The flame sensor constantly monitors forthe presence and intensity of flame If the flame beginsto fail pellets will not be fed into the system until the flame intensity recovers 4 Heat Mode Following a preset amount of time the controller placesthe system into High Heat mode Pellets are fed at the Power Feed Rate and the bloweris ramped up to the set blower rate forfull complete combustion Pellets will be fed into the system every 20 second atthe PowerFeed Rate and the blower will remain ata constant speed The flame sensor is constantly monitoring for the presence of a full flame in the bum chamber 5 End Blow Mode The thermostat has ended the demand forheat and the controller beginsthe shut down mode Pellets are no longerfed into the bum chamber however the blowerremainsat a constant speed The flame sensoris monitoring the flame intensity 6 Afterblow Mode The flame sensor hasindicated to the controller that the flame in the bum chamberisout The blowerrampsup to the maximum output level fora preset time of no lessthan 3 minute s The blower isthen shut down and the PB 3550 enters Standby Mode Chapter FOUR Mainten
40. vided Follow connection marksfor Line Neutral and Ground Connections WARNING The PB 3550 must be connected to a proper ground connection aslabeled Connecting the Controller to the Thermostat 1 The PB 3550 connectsto a standard low voltage control normally open dry contact thermostat System firing will be controlled by the demand called forby the thermostat 2 The thermostat connectsto the PB 3550 through the side of the electronics control box using the entry point labeled and cable strain relief provided The Thermostat connects directly to the PLC Controller and to a dedicated labeled connector within the controller located at the 24V fuse output Top Left side of the electronics box 3 An optional 120V AC input relay is available for installations where the existing control circuit provides direct 120V AC to the existing oil bumerforoperation IF required this relay is installed within an exterior control box Input 120V AC control voltage where labeled on the relay and connect the Normally Open N O relay outputs to the thermostat inputs in the electronics control boxasdetailed in 2 above WARNING The PB 3550 shall be connected using one power source only power source forthe PB 3550 must be provided through the existing boiler fumace safety interlock features Page 19 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 Photo sensor Over heating
41. will illuminate the text TEST will be displayed on the graphic display and the conveyor will begin to rotate priming the conveyor Wait forthe test period to end at which time the conveyor motor will before proceeding Press right arrow button once and repeat steps5 and 6 as required to fillthe conveyor with pellets This will be evident Page 22 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 aspellets begin to drop regularly from the drop tube 8 Once the conveyoris filled pressthe right arrow button to exit the Test Mode 9 Powerdown system by tuming the main power switch on left side of the electronics control boxto the off position 10 Clean the bum chamberasthere may be unbumed pellets in the bum chamber 11 Power system on by tuming the main power switch on left side of the electronics control boxto the on position to resume normal operations Controller User Interface Description 5 lt 90902 Que EO Figure 3 1 Image of the controller buttons and display Page 23 of 50 PB 3550 Wood Pellet Bumer System Installation and Operation Manual Rev 6 1 MAY 2010 There are three value headingsavailable on the display menu that allow the Certified Installerto adjust for proper firing of the PM 3550 system 1 Start Amount controls the amount of pellets to be loaded into bum chamber during the ignition cycle
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