Pellergy PB-1525 User manual

INSTALLATION & OPERATION
MANUAL
Product P/N: Pellergy PB-1525
Serial Number : ________________
Wood Pellet Burner System
REV 1.0: OCTOBER 2011
16 Railroad Street
Barre, VT 05641
[phone]
www.pellergy.com www.mywoodpelletsolution.com

PB-1525 Wood Pellet Burner System: Installation and Operation Manual
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Table of Contents
INSTALLATION & OPERATION MANUAL 1
Introduction 3
Chapter ONE: Safety 4
Chapter TWO: Installation 6
Installation of the PB-1525 Wood Pellet Burner System 10
Installation of the Pellet Conveyor 13
Boiler/Furnace Room Ventilation and Maintenance 17
Measuring Chimney Draft 18
Electric installation 19
Chapter THREE: System Setup & Operational Overview 26
Controller User Interface Description 26
System Operational Description 27
System States 27
System Setup 35
Filling the Conveyor 38
Setup of the Start Feed Value 40
Setup of the Burner Firing Rate 42
Setup of the Initial Combustion Blower Setting Value 44
Running the Burner for the First Time 44
Burner Cycles 45
Setting the Cleanout Cycles 46
Installation and Setup of the Flue Gas Temperature Sensor 46
Chapter FOUR: Maintenance 47
General information 47
Cleaning burner chamber 49
Troubleshooting 51
Burner Servicing 56
Technical Data 57
Available Replacement Parts 58
Warranty and Installation Doc 59
Burner Measured Values 60
Burner Settings 60
Burner Measured Values 62
Burner Settings 62
Installer Note Page & System Drawings 64

PB-1525 Wood Pellet Burner System: Installation and Operation Manual
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Introduction
Congratulations on your purchase of a PB-1525 Wood Pellet Burner
System! This manual is provided to give you an overview of the system
and to provide important instruction as to the installation, operation and
maintenance of the system. In order to ensure years of safe, trouble-free
operation, please follow the guidelines and instructions set forth in this
manual.
The PB-1525 wood pellet burner system is intended for installation with fully
approved, regulatory compliant domestic hot water boilers and furnaces
including dedicated Pellergy boilers and furnaces. The PB-1525 is
intended for use with ¼” Premium Wood Pellets as defined by the Pellet
Fuels Institute. The Burner System uses an external pellet conveyor (auger)
to deliver pellets from Pellergy and third-party external pellet bins/hoppers
to burner.
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 as to the installed
system, give you a copy of this manual and ask that you acknowledge
receipt of such. If at any time you have questions or concerns, please
contact Pellergy customer service, or your Certified Installer.

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Chapter ONE: Safety
Remember: Safety does not happen on its own. You must follow the
instructions set forth in this manual as well as those given to you by the
certified installer and 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 Certified Installer with any questions.
The PB-1525 wood pellet burner system shall be installed by Pellergy
trained certified installation professionals ONLY. Any unauthorized
installation of the PB-1525 system voids the product warranty and may
result in loss of property, bodily injury to personnel, and even death.
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 professionals in your area.
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 OR LOSS OF PROPERTY, BODILY INJURY, AND EVEN DEATH.
PLEASE KEEP THIS MANUAL FOR FUTURE REFERENCE

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Overview This Safety summary, and this manual, has been prepared to
ensure the PB-1525 System is installed, operated and maintained
in a safe manner for personnel and to prevent unnecessary
damage or loss of property. Precautions described in this and
subsequent chapters should be observed during system
installation, operation and maintenance.
Definitions The following definitions of warnings, cautions, and notes are
provided and shall be applied throughout this document:
WARNING: A warning identifies a clear danger to
person(s) performing that procedure and personnel
utilizing the system; failure to abide by a warning may
result in damage or loss of property, bodily injury, and
even death.
CAUTION: A caution identifies risk of damage to
equipment; failure to abide by a caution may result in
permanent damage to 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.
Never introduce a fuel other than Premium Wood Pellets
into the system. There is a high risk of fire and explosion if
gasoline, diesel fuel, kerosene, #2 heating oil or any other
flammable liquid or material is used in the system; always
avoid the use of these.
Do not store combustible materials within 24” of the PB-
1525 burner
CAUTION! Items may fall into an open pellet hopper and cause
damage to the auger. Keep all objects clear of the pellet

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hopper opening.
Pellets other than Premium Wood Pellets may cause
system damage. Use only ¼” Premium Wood Pellets as
designated and by the Pellet Fuels Institute.
NOTE When installed as the only automatic source of central heat
within a home or business check with your existing insurance,
mortgage provider, and local building codes before installing
the PB-1525 wood pellet burner system. Fully understand any
limitations or restrictions that may apply as to the use of a solid
fuel fired central heating unit.
This system provides thermostatically controlled heat that is
intended to operate unattended for up to 3-4 weeks with proper
maintenance and automatic burn chamber cleanout.
The PB-1525 system provides an alarm output contact that can
integrate to an existing or add on home alarm or automatic dial
out system.
Chapter TWO: Installation
WARNING! The PB-1525 wood pellet burner system shall be installed by
Pellergy trained certified installation professionals ONLY.
Any unauthorized installation of the PB-1525 system voids the product
warranty and may result in damage or loss of property, injury to personnel,
and even death.
The PB-1525 Wood Pellet Burner System may only be used to convert
Pellergy-approved boilers and furnaces. Pellergy engineering staff works
closely with our Certified Installers to ensure compatibility between the
burner and the heat exchanger.
The PB-1525 Wood Pellet Burner System installs through the use of a custom

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mounting plate to the boiler front that is provided by Pellergy. An initial
site survey of the intended host boiler or furnace and environment must
be performed. Pellergy must provide the Certified Installer with the
appropriate mounting plate for the application.
The PB-1525 must be installed to fire the boiler/furnace in the same
manner as the original fuel source when converting to wood pellets. In
order to accomplish this, the following guidelines must be followed:
1. The system must only be used in oil and wood fired boilers and
furnaces.
a. Not all boilers/furnaces are good candidates for use with a
Pellergy System. The boiler must be closely evaluated by a
Certified Installer for compatibility. In addition to meeting
local, state and regulatory codes, the boiler/furnace must
accommodate ash buildup between cleanings. This ash will
accumulate within the boiler/furnace. The host
boiler/furnace must be easily cleaned on a more regular
basis than when firing on oil. Additionally, the boiler/furnace
must allow for this buildup without compromise to the
combustion gas flow within the heat exchanger surfaces of
the boiler. Pellergy engineering must approve of all
candidate boilers/furnaces prior to conversion.
WARNING! Failure to properly match a PB-1525 system with a host
boiler/furnace can result property damage, injury and even
death.
2. The system requires a firebox with:
a. Minimum volume of 1FT3.
b. Minimum depth of 12 inches as measured from the burner
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 burner must be installed into the firebox such that:
a. A minimum of 2-inches of clearance from the opening of the
burner to the floor of the firebox is provided.
b. The centerline of the burner shall be positioned at the same
centerline as the pre-existing oil burner to ensure proper firing

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of the boiler or furnace.
This will ensure enough volume for the collection of ash between
cleanings.
4. Not all boilers and furnaces are 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 burner 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´s in order to gain required 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/furnace
type during the initial evaluation of the system.
5. The PB-1525 should be set up to fire an existing boiler or furnace at a
maximum of 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
Installer will perform heat load calculations or use other methods to
ensure the proper amount 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 or furnace. All existing safety
interlocks and controls must be utilized. If the installation of the
PB-1525 will require such modification as the cutting away of
insulation, gasket material, steel or any other part of the existing
boiler or furnace: Do not attempt to use the PB-1525 on this
system.

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Figure 2.1: Typical installation showing minimum internal dimensions and
clearances.
CAUTION! If the manufacturer’s data on the boiler or furnace to be fired
using the PB-1525 Wood Pellet Burner System gives specific
instruction NOT to convert the unit to solid fuel, please consult
the boiler or furnace manufacturer before installation.
NOTE When installing the PB-1525, take note of the surrounding area
with regard to the regular maintenance of the burner. The
burner requires regular maintenance and ease of access to the
burner for this maintenance will be more convenient for the user.
Min. Firebox
depth 12” Min. Clearance 2”
BOILER/FURNACE
FIREBOX
(minimum 1FT3)
PB-1525
BURNER
Burner
Centerline
matches pre-
existing burner
centerline
Refractory Insulation
Required

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The PB-1525 Wood Pellet Burner System requires the use of an existing, up
to date chimney sized appropriately for the boiler or furnace used. An
existing masonry or Class A metal chimney may be used provided that it
meets local code. When no local code exists, follow the requirements of
NFPA 211: “Standard for Chimneys, Fireplaces, Vents, and Solid Fuel-
Burning Appliances”. Certain Canadian Codes may require the chimney
be fully relined prior to installation.
WARNING! If the boiler and/or furnace is not properly cleaned and
maintained, chimney temperatures can approach or exceed
1000° F and create unsafe conditions that can lead to fire.
Regular cleaning and maintenance routines must be
followed.
CAUTION! The PB-1525 should not be used in a system installed in a
chimney serving multiple boilers or furnaces unless
specifically allowed by local Code AND the use of an
interlock system is used such that only one unit may use
the chimney at any given time.
The PB-1525 should not be used in conjunction with a flu
damper. If a flue damper exists in the existing system, as is
typical for wood fired boilers and furnaces, the damper
must be removed prior to the installation of the PB-1525.
NOTE The existing chimney should be cleaned and inspected
prior to installation of the PB-1525 Wood Pellet Burner
System.
Pellergy recommends yearly cleaning of the chimney to
remove the buildup of ash and maintain proper and safe
system functionality.
Installation of the PB-1525 Wood Pellet Burner System
1. Plan ahead. Ensure proper installation, operation and
maintenance space is available before beginning installation.
Ensure the PB-1525 burner can be disassembled for proper cleaning
in the intended installation space.
2. Remove oil burner and oil burner mounting plate (if applicable).
3. Inspect all gaskets and mounting surfaces. Replace any gasket
material that is damaged, or that is worn or deteriorated to the

PB-1525 Wood Pellet Burner System: Installation and Operation Manual
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point where a proper seal can not be made.
WARNING! The PB-1525 Wood Pellet Burner System must NOT be
operated with the boiler or Furnace door open!
If The PB-1525 is mounted to a hinged door, an optional
interlock switch is required. This interlock is intended to
prevent the burner from operating with the door open.
Contact the boiler or furnace manufacturer for details
regarding to and availability of the interlock switch. The
Certified Installer may install an interlock switch that cuts
power to the burner system if the door is opened.
4. Fit the custom PB-1525 burner mounting plate to the boiler or
furnace. (For specific fitting details refer to documentation
included with the custom mounting plate)
5. After mounting the burner mounting plate to the boiler or furnace,
inspect to ensure that the interface between mounting plate and
boiler or furnace form an air tight seal.
6. Assemble the PB-1525 burner to the mounting plate.
7. Refractory material installed on the boiler door or mounting plate
shall be maintained as originally installed by the boiler or furnace
manufacturer to limit the surface temperature.
AugerMotor
DropTube PelletFeed Tube
WoodPelletBurner
BoilerorFurnace
(NotIncludedwithSystem,
Show forClarity)
PelletAuger
PelletHopper
(550LBSCapacity)
ElectronicController
Figure 2.2a: System Overview

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Figure 2.2: Burner assembled to mounting plate.
Figure 2.3a below for a typical layout of a Pellergy System with a
Pellergy KPA-100-5 Cast Iron, 5-Section boiler
Installations will vary; however, this figure shows a typical installation
with the standard 550LBS working hopper. The working hopper can be
replaced by compatible bulk pellet bins for direct feed installations.
WOOD/OIL
BOILER
PELLERGY
BURNER
MOUNTING
PLATE
(WILL VARY
BY BOILER)
MOUNTING PLATE
TO BOILER GASKET
(WILL VARY BY
BOILER)
BURNER TO
MOUNTING PLATE
GASKET

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Figure 2.3a: Pellergy wood pellet burner 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 burner and the pellet hopper
must be considered
1. The conveyor is designed to be hung from a single-point overhead
anchor. Inspect the overhead in the vicinity of the PB-1525 burner
and select a suitable point for the overhead anchor. The conveyor

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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 is a
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 is a
minimum of 6-inches laterally away from the PB-1525 pellet feed
tube opening (Maximum of 12-inches). See Figure 2.3 below
Figure 2.3: Conveyor mounting details.
WARNING! The pellet feed conveyor assembly can weigh as much as
100-pounds when in operation and filled with pellets.
Ensure a suitable overhead anchor point from which to
hang the conveyor.
Do not direct-couple the conveyor drop tube to the PB-
ANCHOR
POINT
15-30”
6-12”
CONVEYOR
CHAIN/CABLE
40-50º

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1525 pellet feed tube without the use of the supplied
flexible plastic drop tube assembly. This tube acts as a
back-burn safety device and is the only material suitable
for use. Replacing this tube with any other than supplied
by Pellergy voids the warranty and can result in injury,
equipment damage, and even death.
Do not install the conveyor drop tube directly over the PB-
1525 pellet feed tube. Misalignment is intended and acts
as a safety feature.
NOTE The feed conveyor must not exceed 10 FT in length. Adding to
the length of the feed conveyor will result in burner malfunction.
2. When positioning the pellet hopper and installing the conveyor into
the pellet hopper:
a. The conveyor must be installed at an angle between 40-50º
as shown in Figure 2.3 above.
b. The feed conveyor auger tube must not exceed 10 FT in
length. The feed conveyor may be cut to a desired length
provided that final length is able to meet all other installation
requirements of the conveyor.
3. Install the overhead anchor and hang the conveyor using an
appropriate chain, cable or anchor as in 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 at least 1-inch. If the conveyor auger makes contact with the
bottom of the hopper, damage can occur. Refer to Figure 2.4
below.
The auger spiral end should ride on the auger tube ring created by
the cutout on the end of the auger tube. If the auger spiral is cut
too short it may “hop” out of the auger opening and jam. If the
auger spiral is cut too long it may wear through the bottom of the
hopper bottom causing damage to the system and jamming the
auger system.

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Figure 2.4: Conveyor and Auger assembly details showing the auger
spiral
WARNING! The Pellet hopper and/or pellet storage must not be
installed within 24-inches of the PB-1525 wood pellet
burner.
Keep all combustible materials a minimum of 24-inches
from the PB-1525 wood pellet burner
Follow all boiler and furnace manufacturer’s required
combustible keep out zones.
5. If using an alternate pellet storage silo or hopper, follow
manufacturer’s installation instructions. Do not install or store any
combustible or flammable materials within 24-inches of the PB-1525
burner.
SPIRALAUGER TO
HOPPER FLOOR
CLEARANCE 1”
MIN.

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Boiler/Furnace Room Ventilation and Maintenance
1. The PB-1525 must be supplied with adequate fresh air for
combustion.
a. The room in which the boiler or furnace is installed should be
supplied with a minimum 4-inch diameter fresh air inlet
vented to atmosphere or minimum calculated diameter as
per local code. This ventilation must come from outside the
building, not from an adjoining room or enclosed space.
b. The installation (boiler or furnace) room must, not at any time,
be under a vacuum. This can be caused by other appliances
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 production of harmful gasses within
the living space.
WARNING! Proper ventilation must be provided for the PB-1525 wood pellet
burner system.
2. The immediate area surrounding the PB-1525 wood pellet burner
system and host boiler/furnace must be kept clean and free of
combustible and/or flammable 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 or technique is
used. Care must be taken to remove dust from the boiler/furnace
room to prevent a dust fire or explosion.
WARNING! Improper handling 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.

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Measuring Chimney Draft
The PB-1525 requires a negative draft chimney installation. Draft must be
measured with a proper draft gauge.
Prior to measuring draft, be sure that the boiler/furnace is air tight and all
leak points are sealed. Air leaks can give faulty results and can cause
problems when operating the PB-1525. The draft measurement is to be
taken in the firebox of the boiler or furnace as an “Over Fire”
measurement.
Draft should be between -0.03 in-H2O to -0.10 in-H2O. If the Draft is more
than -0.10 in-H2O, or likely to exceed -0.10 in-H2O a draft regulator
(barometric damper) is required for use.
The use of a draft regulator (barometric damper) is recommended for use
in every installation due to the potential for high winds and resulting high
draft. If the system is exposed to temporary draft in excess of -0.10 in-H2O
a misfire can occur thereby shutting down the system.
WARNING! Improper draft can lead to potentially hazardous
conditions. Chimney draft must be within system
limitations at all time.
The boiler and chimney must be kept clean to maintain
proper draft.
If draft is less an -0.03 in-H2O , a forced draft blower, or draft inducer, can
be installed to create proper draft. 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/furnace as well as the chimney is a necessity. Fly ash, clinkers
and buildup within the chimney and boiler/furnace can cause blockage
and improper operational draft. Refer to Chapter Four: Maintenance, for
information on cleanout.

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Electric installation
General
All electrical connections to the PB-1525 wood pellet burner system are
made in the supplied connection panel. The panel is factory wired with
two quick-connect cable sets that connect directly to the PB-1525 burner
head. All field connections are made to the supplied terminal blocks in
the connection panel. A terminal connection listing is provided below as
well as on the door of the terminal panel enclosure. Figure 2.5 below
shows a detail of the enclosure. Four (4) knock outs are supplied on both
sides of the enclosure as well as three (3) on the top for in-field installation
of the proper connector for the wire being used. The two (2) outermost
connections on the bottom of the panel are used by Pellergy for the
factory wired and installed cable/connectors sets. The center knock out
may be used for the installation of cables.
FRONT VIEW
TOP VIEW
SIDE VIEW SIDE VIEW
BOTTOM VIEW
6.00
4.00
8.00
Figure 2.5: Pellergy PB-1525 Terminal Panel Enclosure Exterior Detail

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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 connections are to be made to the lower,
numbered terminal connections.
Terminal # Connection
1L1 - 120V AC Input Pow er
2N- 120V AC Input Pow er
3Ground - Input Power
4L1 - Auger Motor Output
5N- Auger Motor Output
6Ground - Auger Motor
7L1 - Air Cleanout Solenoid
8N- Air Cleanout Solenoid
9Ground - Air Cleanout Solenoid
10 N.O. Contact - AlarmOutput
11 N.O. Contact - AlarmOutput
12 T1 - Tstat Dry Contact Input (NO Voltage)
13 T2 - Tstat Dry Contact Input (NO Voltage)
14 24V DC- Stack O2 Sensor (OPTION)
15 24V DC - Stack O2 Sensor (OPTION)
16 Stack Temperature Sensor (RED)
17 Stack Temperature Sensor (BLK)
PellergyPB‐1525ConnectionDetail
Figure 2.6: Terminal Connections for the PB-1525 Wood Pellet Burner
System.
A schematic detail of the Terminal Panel Enclosure is shown below in
Figure 2.7. All wiring connections shown in this detail are factory
performed. The detail is provided for informational and troubleshooting
purposes only.