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Summary of Contents for Keystoker 90,000 BTU
- Page 1 Installation, Operation and Maintenance Manual 90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent 105K BTU Stove Shown © October 2017 REV 2...
- Page 2 As prices of energy continued to escalate, Keystoker continued its research. Over 60 years of research has developed a patented feed-in system, a patented flat grate, and a patented thermal heat exchange, which has produced the highest efficiency possible.
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Page 3: Table Of Contents
90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 Table of Contents Safety Precautions & Definitions General Safety Statements Installation Stove Placement Vent Terminator Location & Direct Vent Arrangement Direct Vent Completion Kit... -
Page 4: Safety
Keystoker shall not be liable for physical injury, damage to property or death caused by a failure to observe the instructions in this manual. -
Page 5: Installation
90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 Installation Stove Placement 1. Safety inspection of a venting system should be performed before and after installing your new stove. Procedures to follow are those recommended by National Fuel Gas Code, ANSI Z223.1 or refer to local codes or ordinances. - Page 6 90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 FIGURE 1b - 6 - © October 2017 REV 2...
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Page 7: Vent Terminator Location & Direct Vent Arrangement
90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 Vent Terminator Location & Direct Vent Arrangement VENT TERMINATOR MAY NOT BE LOCATED A. Less than 1 foot above grade. B. Above or within 3 feet horizontally of oil tank or gas meter. - Page 8 90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 Top Vent Layout Note: Item descriptions on next page Bottom Vent Layout Note: Item descriptions on next page FIGURE 3 - 8 - © October 2017 REV 2...
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Page 9: Direct Vent Completion Kit
90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 Item # Component Item # Component Sealer for All Joints 4” Tee Stove 1 Piece Wall Kit Hanging Baffle Stainless Steel Rain Cap Direct Vent Unit 4”... -
Page 10: Assembly
90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 Assembly 1. Plumb hopper end of stove with level. Hopper end of stove must be vertical. 2. Mount hopper in place and fasten securely. Carefully, reach down into bottom of inside hopper and bend flange of hopper into throat of stoker unit. -
Page 11: Fuel Type
90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 12. Ensure all power for this unit is turned off. Locate thermostat in an area where heat from stove can be freely reached. Mount plastic wall plate of thermostat. -
Page 12: Operation
90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 Operation Startup 1. To start a fire, fill hopper with coal, reach in through fire door and pull coal down to cover entire grate area. Place kindling (charcoal supplied) into a full sheet of newspaper, crumble paper, and dig kindling deep into coal in the center of grate. - Page 13 90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 The stove is equipped with a safety fume switch. If hot coal gases are not vented outdoors, the safety switch will trip out on reset, which will shut off stoker unit. The fire will go out and cannot be restarted until reset button on safety switch cools down.
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Page 14: Diagram 1 - Continuous Heating
90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 Diagram 1 – Continuous Heating Depicts what fire should look like when thermostat calls for heat for extended period: A. Unburned fresh coal supply from coal hopper B. -
Page 15: Diagram 2 - Intermittent Heating
90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 Diagram 2 – Intermittent Heating Depicts what fire size should look like when thermostat has not called for heat for extended periods: A. Unburned fresh coal supply from hopper. -
Page 16: Component Descriptions & Operation
90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 Component Descriptions & Operation Stoker Unit Components 105K BTU Unit Shown FIGURE 5 Item # Component Item # Component Stoker Sub-frame Stoker Grate # 2... - Page 17 90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 PUSHER BAR SUBASSEMBLY: Moves in a reciprocating motion. Activated by cam on gear motor to force coal from hopper onto grate and pushes ashes off grate into ash pan.
- Page 18 90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 NYLON CAM: located on gear motor. To give reciprocating motion to pusher bar shown below. Nylon Cam Gear Motor FIGURE 7 GEAR MOTOR: The drive shaft turns approximately Oil Ports 1RPM.
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Page 19: Timer
90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 TIMER: Unless your stove had been a special order, it will be equipped with our patented flat grate stoker unit and a timer. The timer is shown on the bottom of this page. -
Page 20: Thermostat
90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 THERMOSTAT: Top pointer is to be set at warmth FIGURE 11 desired in home. Bottom pointer is the present temperature in room. When room temperature... -
Page 21: Maintenance
90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 Maintenance Cleaning & Lubrication of Stove Stove pipe and exhaust tubes must be cleaned once during the heating season. On top exhaust stoves, brush exhaust tubes out with a flexible brush. Keep base and interior openings below interior exhaust tubes clear of ash. -
Page 22: Reassembly Of Direct Vent Piping
90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 Reassembly of Direct Vent Piping Top Vent Layout Interior Wall Plate Seal All Joints with High Temperature Silicone Bottom Vent Layout Seal All Joints with High... -
Page 23: Cleaning Stove Glass
90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 Cleaning Stove Glass The following instructions are meant to serve as guidelines for proper cleaning and care of ROBAX glass ceramic windows. To clean glass, first turn down the thermostat to allow the stove to cool. Assemble fire door shield, using metal plate (approximately 16”... -
Page 24: Ash Pan Emptying
90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 Ash Pan Emptying To prevent toxic carbon monoxide gases from entering the home, certain precautions must be taken. 1. Ash pan must be emptied on a regular basis to prevent ashes from overflowing into ash pit area. -
Page 25: Gear Motor Removal & Installation
90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 Gear Motor Removal & Installation Refer to the following Figures 16 & 17 TO REMOVE GEAR MOTOR: 1. Pull power cord pug from 115V outlet. - Page 26 90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 FIGURE 16 Nylon Cam Spring Pin Screw 1/8” x 1-1/4” Long #10-24 x ½” Long Screw #10-32 x ¾” Long Rubber Grommet Gear Motor Screw #10-24 x ½”...
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Page 27: Troubleshooting Guide
90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 Troubleshooting Guide Problem FIRE GOES OUT See page 19 (Timer) and Page 15 Diagram 2 COAL KLINKERING OR FUSING See page 15 Diagram 1 & 2... - Page 28 90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 Troubleshooting Guide – cont’d Problem Fan blades on combustion motor dirty. Brush off. Accumulated fly ash under grate. Remove combustion motor and clean under grate.
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Page 29: Diagrams
90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 Diagrams Wiring - Thermostat Honeywell Limit Control L4064B Intermatic Timer LIMIT C8835 LOAD LOAD LINE Neutral PWR Main PWR Stoker Stoker Unit Combustion Blower... -
Page 30: Wiring - Direct Vent
90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 Diagrams – cont’d Wiring – Thermostat, Direct Vent - 30 - © October 2017 REV 2... -
Page 31: Stove Parts List
90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 Diagrams – cont’d Stove Parts List – 105K, Top Vent Shown Item # Component Stove Pipe, 6” Ash Door Subassembly Fire Door Subassembly Limit Control... -
Page 32: Fire Door & Ash Door Parts Lists
90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 Diagrams – cont’d Fire Door Parts List – 105K, Top Vent Shown Item # Component Ash Door Gasket Glass Glass Clip Lever Handle Subassembly... -
Page 33: Warranty
Stove Model: _______________________________________________________________________ Parts Ordering If not listed above, locate the metal 1 ½” x 3” Keystoker label fastened to stoker unit body, near gear motor. The four or five-digit number will be required to get proper replacement parts from your dealer. -
Page 34: Stove Contents Checklist
90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent Keystoker – Schuylkill Haven, PA 17972 Stove Contents Checklist TT Models Manual Carbon Monoxide Detector Charcoal Thermostat 2-Handles & Bolts Brass Handle / Koker Brass Trim – 90K/105K 2-Ash Tubs...
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