Pellet Burner Systems Engineering Breakdown

Auger
Motor

e
ub
e dt Auger
Fe

Feeder
Chute

Controller
Flame
Sensor
Blower
Double Wall Burn Body Overfed, horizontal,
Chamber
Igniter underfed burner types
 Visual BOM (not our imlementation)

http://www.sunsystem.bg/en/otoplenie/details.php?id=153
Link
 Slow
Technical Design - Beginning Cat 5
Auger
motor
Connector

Auger to
motor
Loading Chute Overheat sensor coupler
Motor
Mount
Plate
PVC Tee
Flame Sensor

Tube in Flex Auger 1

a Tube
Flex auger 2
PVC
Blower Pipe, 3”

Grate
Stop
To auger
hole

Ignitor Tube
Cat 5
Tube with air holes
Peforated steel
Connector Feed Auger

Burner On/off
Auger Speed
Knob

120 AC
Power
Controller Fan Speed
Knob
 Single Cat 5 If 240V, may need transformer

Design Rationale interface to

controller

PVC flange mounts

motor to PVC

Back of combustion
10 more holes chamber is closed except Flame sensor detects
around end of for air holes when pellets are lit upon
tube, ⅙” each startup Blower speed
determines combustion
power together with
auger feed rate

Blower

Grate

Stop grate prevents

pellets from falling
out

Flexible auger does

Slanted grate Air holes in inner tube not get stuck
directs air towards deliver combustion air Hot air blown by Single Cat 5
exit from the bottom blower through the interface to
ignitor lights pellets controllr
Hole in tube allows
2.5”x7” with 120 easier feeding
holes, 0.1”
diameter (about 1”
sq of hole area)
Controller Algorithm Concept
Startup
● User turns power on
● Ignitor turns on
● Fan turns on
● Auger starts feeding
● When flame sensor detects flame, ignitor turns off
○ If a time threshold is reached and ignition does
not occur, machine is shut down
● Once flame is detected, motor speed goes from preset
Flame
Sensor
value to that set by the fan and auger speed knobs
Operation
Ignitor Blower ● Stove power is adjusted by user with fan and auger speed
knobs
● Flame detection continues, and if flame dies, machine is
shut down
○ If flame dies, there is an issue, and issue must be
addressed

Auger Speed
On/off Knob

120 AC
Power
Controller Fan Speed
Knob
Air Delivery Pattern
Secondary air goes
out at end of tubes

6” tube
154 mm=

80% of air goes

inside space
between inner and
outer tube
129 mm= 5”

20% of air goes straight

through, most air goes into
space between 2 tubes

Ignitor holes below

grate

Most of the air is sent

Air goes up through
below the grate holes in bottom

Front View
Side View
Technical Design - Controller Logic and Phases
Phases
● Phase 1 - manual control - for testing, shakedown, etc.
● Phase 2 - automatic control. See reference controller - Ebay $150. Video and manual
are informative.
○ Controller includes both manual and automatic control options
Phase 1 - discrete elements with minimal microcontroller control

● Question - is minimal microconrol allowable, or is the system unstable and goes out
from time to time? Goal would be to make a system that never goes out
unintentionally, which would mean sufficient thermal mass in the burner barrel
● User turns on the igniter. Igniter is on a 30 second timer.
 Technical Design - Controller Full Logic Specification

Startup
● User turns power on. Power engages Arduino
● Ignitor turns on - 20 seconds
● Fan turns on - at same time as ignitor, and stays on
○ Knob on fan sets fan speed. Modular design makes logic as simple as possible
● Auger starts feeding
○ Knob on Arduino controls feed rate
● When flame sensor detects flame, ignitor turns off
○ If a time threshold is reached and ignition does not occur, machine is shut down
● Once flame is detected, motor speed goes from preset value to that set by the fan and auger
speed knobs
Operation
● Stove power is adjusted by user with fan and auger speed knobs
● Flame detection continues, and if flame dies, machine is shut down
○ If flame dies, there is an issue, and issue must be addressed
● Kill - shuts of auger and blower at the same time
Shut-Down
● Auger motor stops
● Blower continues for 5 minutes to burn remaining pellets and cool the device off