Englander 25-PDV Pellet Stove - Top Auger Jams

[Navy Submariner]

I bought my 25-PDV stove at HD 12/11. I have had nothing but problems with the top auger jamming and a whimpy fire in the burn pot. I have called Tech Support several times - they were always very nice to talk to. Finally a couple of weeks ago I talked to Tech Support again and he suggested resetting the controller with a simple procedure that he emailed to me which put the stove into mode "C". Low and behold the stove comes alive and was firing to beat the band. The stove ran for about twelve hours and the upper auger jammed. I cleared the jam by taking the auger out and vaccuming the pellets out of the end of the tube. What I found was the pellets were being compacted or mashed at the end of the tube and not dropping down the opening to the lower auger.

Right now the controller is set as follows: mode "C" 6-4-1. HR - 9 BR -9.

I have read all the stories about deburring the augers and the auger tube - and I get all that. But if the upper auger is feeding the pellets faster than they can be pulled by the lower auger then the timing on the upper auger is not right. Using a stop watch the auger is on for about 3 secs and off for about 3 secs. This timing needs to be tuned a little better and I can't seem to find anyone who knows how to do this.

I have tried mode "C" all the way to 3-3-1 and the timing on the auger is not changing. So what is up? Do I need a new controller or a new stove. I use this stove when I am in my barn doing wood working and it works great until the top auger jams.

Yesterday I cleared a top auger jam. Put a handful of pellets in the hopper and turned the stove on. Within 30 secs the top auger jammed again. Pulled it out and the pellets were mashed at the end of the auger tunnel again.

The pellets I am using are FireSide. I haven't found a pellet longer than about 3/4". The opening for the lower auger is 1.0". I get that. This is a timing issue on the top auger.

Both augers are free and clear - done the grinding and smoothing thing to both.

P.S. If anyone is questioning my mechanical/electrical qualifications I have been a Mechanical Engineer for 35 years and I know this problem can be fixed.

I want the "manual" for the controller so I can tune this stove the way I know it can tuned and running like a Swiss watch.​

 

[slvrblkk]

Have you tried something simple as a different brand of pellet? You said you are using Fireside....Is it Fireside Ultras?

 

[Navy Submariner]

Have you tried something simple as a different brand of pellet? You said you are using Fireside....Is it Fireside Ultras?

Not sure - I am not at home right now.

 

[trudd]

Did you smooth the auger tubes as well? I just got over this exact problem. I personally believe that the auger tubes were a bigger problem than the augers them self. I actually went back and smoothed the tubes a second time. I'm not questioning your ability I'm just saying that I'm not an engineer and definitely did a better job the second time. I even hit areas that I missed the first time. Good Luck.

 

[Navy Submariner]

Did you smooth the auger tubes as well? I just got over this exact problem. I personally believe that the auger tubes were a bigger problem than the augers them self. I actually went back and smoothed the tubes a second time. I'm not questioning your ability I'm just saying that I'm not an engineer and definitely did a better job the second time. I even hit areas that I missed the first time. Good Luck.

No I haven't deburred the auger tubes yet. I checked the best I could to see if there were any pellets bridged in the drop cavity between the augers and didn't find anything - but it is difficult to get something in there to "sweep" the cavity.

I am disappointed the design of the auger casting. The bores for the auger should have been line bored to smooth them out. Also the opening between the augers should have been made a little bigger. Right now it is one inch wide - I would have made it 1.25 inches. But it is what it is. So we are left to do this work. When the stove doesn't jam it works very well. Getting it to run consistently without jamming is the challenge.

 

[trudd]

No I haven't deburred the auger tubes yet. I checked the best I could to see if there were any pellets bridged in the drop cavity between the augers and didn't find anything - but it is difficult to get something in there to "sweep" the cavity. I am disappointed the design of the auger casting. The bores for the auger should have been line bored to smooth them out. Also the opening between the augers should have been made a little bigger. Right now it is one inch wide - I would have made it 1.25 inches. But it is what it is. So we are left to do this work. When the stove doesn't jam it works very well. Getting it to run consistently without jamming is the challenge.

Agreed! Sounds like you've seen this thread: https://www.hearth.com/talk/threads...-little-auger-burs-pimp-my-auger-pics.102423/
I used the same grinding stones and wire wheels with an extension pictured in the thread. I got everything I could. All around the inside of both tubes and the back of the top auger tube. I still got a jam. The second time, I used the circular grinding stone on an extension and inserted it into the top auger tube as far as it would go and then pulled back so I could grind the front section of casting. It was very rough and this is where pellets were jamming for me. They got wedged between the back wall and this front lip of the casting. I did the same thing from the bottom auger tube as well. Also, this time around I attacked the "slide" the pellets ride down when falling from top to bottom tube. I'd say its got about a 45 degree angle to it, I read another thread where a guy said his made a 90 degree angle! Anyway, I smoothed this out, was very rough, using the cone shaped grinding stone. Knock on wood, this was on Jan 27th and I haven't had as much as a hiccup since. Even now while I'm burning dreaded green supreme pellets because the price is right! Keep at it, you'll get it squared away.

 

[imacman]

First, have you observed if there are any really long pellets in the bags?

Second, I guess i understand running on 9-9 to try to heat up a barn, but it's possible that lowering the heat setting a little (7-9) might help.

Are you sure the bottom auger is running at the correct speed? Maybe try swapping the 2 augers. Bottom one gets the most use....give it a "rest" up top?