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Summary of Contents for KSM-Stoker Multistoker 375-35
- Page 1 Instructions KSM-Multistoker 375-35 With PCT 300 Producer: -Stoker Make money by installing KSM-Stoker Næssundvej 440, 7960 Karby DK. Tlf. +45 97761072 www.ksm-stoker.dk Email. Mail@ksm-stoker.dk...
- Page 2 KSM-Stoker A/S Næssundvej 440, 7960 Karby DK. Tlf. +45 97761072 Fax. +45 97761372 Mobil. +45 20991072 Www.ksm-stoker.dk Email. Info@ksm-stoker.dk ________________________________________________________________________________________________ EU Declaration of Conformity We the undersigned, PRODUCER: KSM-STOKER A/S ADDRESS: NAESSUNDVEJ 440, CITY: DK-7960 KARBY PHONE: +45 9776 1072...
- Page 3 DK-7960 Karby Tel.: +45 97 76 10 72 Fax: +45 97 97 13 72 Automatic biofuel boiler Product: Manufacturer: KSM-Stoker Type: KSM-Multistoker 375-35 Nominal output: 37 kW Fuel: Wood pellets and grain Deadlines: Date of receipt: 2007.05.15 Date of testing: 2007.05.21 - 2007.05.30...
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Page 4: Table Of Contents
INDEX FOR KSM-Multistoker 375-35 WITH PCT 300. Version 1-2011 1.0 Introduction............................5 2.0 Fuel..............................6 2.1 Wood Pellets ........................... 6 2.2 Grain..............................6 2.3 Alternative Fuels..........................6 2.4 Fire Wood............................6 3.0 Control Panel............................7 4.0 Control Layout and Functioning ...................... - Page 5 6.15 Screw step 0..........................15 6.16 Screw step 1..........................16 6.17 Screw step 2..........................16 6.18 Screw step 3..........................16 6.19 Fan step 0............................ 17 6.20 Fan step 1............................ 17 ...
- Page 6 12.0 Air Nozzles............................. 29 13.0 Automatic Fuel Filling Device, Fire Damper, Transport screw (if mounted) ........ 30 14.0 Moving floor (if mounted) ......................31 15.0 Ash screw (if mounted)........................32 16.0 Automatic Ignition (if mounted)..................... 33 17.0 Boiler Cleaning..........................34 18.0 Precautionary Measures.
- Page 7 21.2.2 Flue gas outlet........................39 21.2.3 Piping........................... 39 21.2.4 Anti-freeze measures......................40 21.2.5. Check the screw direction of rotation ................. 40 21.2.6. Sprinkler, water connection ....................40 21.2.7 Starting Up.......................... 40 22.0 Accessories............................
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Page 8: Introduction
The KSM-Multistoker meets the official prescriptions regarding safety when working with machines and is therefore CE-labelled in accordance to the machinery directive No. 98/37/EC. The KSM-Multistoker 375-35 has been approved of by the Danish Test Station For Small & Medium Bio fuel Boilers. -
Page 9: Fuel
2.0 Fuel. The KSM-Multistoker is constructed to operate on wood pellets, as already mentioned above. At the Danish Test Station For Small & Medium Bio fuel Boilers it was tested and approved of using wood pellets with a water content of about 8%. However, both our customers and we have made the experience that the use of grain will result in a very fine economy. -
Page 10: Control Panel
3.0 Control Panel The following pages describe how to operate the control for a KSM-Stoker. KSM has made great efforts to make a control that is easy to operate and is well arranged. The below picture shows the control panel on which each control button is easily found, references to these buttons will be made on the following pages. -
Page 11: Control Layout And Functioning
4.0 Control Layout and Functioning The starting point for how the control will act in the various situations depends on the actual plant temperature, compared with the chosen running temperature. The KSM oxygen control will automatically adjust the output between full load and 30% load. If the heat consumption drops beneath 30% of full load, the control will make a pause and start up the plant again when heat is required. -
Page 12: Pause
Step 1: When the temperature rises to more than 1°C over set, and up to 5°C over set, the control will switch to step 1. Here, the combustion air fan pulses with a short blow and a long break. Step 0: When the temperature rises to more than 5°C over the set-point, the control will switch to step 0. Here, the combustion air fan runs as at step 1, but the screw running period will be halved in comparison with step 1. -
Page 13: The Control Panel Buttons And Their Functions
5.0 The Control Panel Buttons and Their Functions STEP 3 STEP 3 O2 10% O2 10% TEMP 65C TEMP 65C PRG 1 PRG 1 STOP START STOP START MENU OPSTART MENU OPSTART SNEGL SNEGL KSM has made great efforts to build a well-designed control that is as easy as possible to operate. In the following, the characteristics of each single button will be described. -
Page 14: Operation
6.0 Operation. 6.1 Main Screen. Shows the actually wanted data during operation. STEP 1 OXY: 10% * The actual output step TEMP: 70°C PRG 1 * Oxygen content in fluegas * Boiler forward temperature * Used programme 6.2 Changing the settings. In this section, we describe the various parameters that may be changed, as well as their influence.. -
Page 15: Boiler Temperature
▼ ▲” Select the required programme using the ” ” and ” keys, you may choose between Woodpellets PRG 1 Woodchips PRG 2 Other PRG 3. After the selection is made, enter the ”MENU”key and the choice has been saved. ▼... -
Page 16: Man/Auto
Press ”MENU” WOOD TEMP WOOD TEMP MAN/AUT ADJUST 080°C Use the arrow keys to select the wood temperature, selection between 80 to 99°C. After selection of the wanted temperature, press ”MENU”, and your choice has been saved. ▼ Press ” ”... -
Page 17: Ashscrew
▼ Press ” ” to proceed to the next parameter you wish to change – or press the ”START-UP” and the “MENU” keys at the same time to finish. 6.10 Ashscrew. The ashscrew of a KSM boiler is monitored and controlled by Motor 3, in relation to the stoker screw. By operating in a percentage relationship with the stoker screw, the ashscrew will automatically run more when the stoker is in Step 3, than when the stoker is in Step 1. -
Page 18: Transport Screw On
Use the arrow keys to select the scraper bottom pause period, selection from 0 to 255sec. After selection of the wanted period, press ”MENU”, and your choice has been saved. ▼ Press ” ” to proceed to the next parameter you wish to change – or press the ”START-UP” and the “MENU”... -
Page 19: Screw Step 1
Press ”MENU” SCREW STEP SCREW STEP 3 *KSM-STOKER ADJUST 1.60 SEC Use the arrow keys to select the stokerscrew running period, select from 0.3 to 52sec. After selection of the wanted period, press ”MENU”, and your choice has been saved. -
Page 20: Fan Step 0
6.19 Fan step 0. The fan speed decides the output, and in step 0 you want a very small output as this is just before the plant switches into the pause mode. The speed is adjusted by the fan receiving pulsating signals, these can be clearly heard in the low steps. -
Page 21: Oxygen % Step 0
Press ”MENU” FAN STEP FAN STEP OXY STEP ADJUST Use the arrow keys to select the fan speed, you may choose between values from 001 to 080. After selection of the wanted fan speed, press ”MENU”, and your choice has been saved. ▼... -
Page 22: Oxygen % Step 3
Use the arrow keys to select the oxygen percentage, select a value between 5 and 21 %. After selection of the wanted oxygen % press ”MENU”, and your choice has been saved. ▼ Press ” ” to proceed to the next parameter you wish to change – or press the ”START-UP” and the “MENU”... -
Page 23: Startup Fan
Press ”MENU” OXY. DIFFERENCE OXY. DIFFERENCE STARTUP FAN ADJUST 03 % Use the arrow keys to select the oxygen % during the start-up period, select a value between 0 and 5 %. After selection of the wanted oxygen % press ”MENU”, and your choice has been saved. ▼... -
Page 24: Pause Fan Period
Press ”MENU” PAUSE FAN PAUSE FAN PAUSE FAN TIME ADJUST Use the arrow keys to select the fan speed during pause feeding, select a value between 001 and 080. After selection of the wanted fan speed press ”MENU”, and your choice has been saved. ▼... -
Page 25: Start Portion
6.34 Start portion. When the boiler has been in the pause mode and is about to start up again, we add an adequate portion of fuel (”START FUEL”) to enable the starting-up and facilitate for the oxygen % to quickly drop below the “START-UP OXYGEN LIMIT”... -
Page 26: Boilertemp Start
▼ Press ” ” to proceed to the next parameter you wish to change – or press the ”START-UP” and the “MENU” keys at the same time to finish. 6.37 Boilertemp start. It is possible to adjust the number of degrees dropping below set temp before the boiler starts up again Tryk ”MENU”... -
Page 27: Electric Ignition
6.40 Electric ignition. Automatic Ignition can be Off or work in 3 ways, all functions are set by value between 0 and 3. 0 = No Automatic Ignition 1 = The Ignition, is activated only when the button “OPSTART” is pressed (then generally break operation) 2 = Normal Automatic Ignition for standard units, with Tank or Automatic boilers 3 = Automatic Ignition for Automatic units, the stoker screw will be empty before stopping... -
Page 28: Main Switch
7.0 Main Switch The stoker is provided with a main switch mounted on the boiler side. The main switch should be locked when working on the plant. 8.0 Starting Up The Stoker. This is the simplest way to start up the stoker: The stoker is ignited by pressing turning the main switch to position 1. -
Page 29: Final Adjustments
9.0 Final Adjustments. A KSM Oxygen Control monitors the screw feeding time in all its steps so as to ensure the best possible combustion. However, in order to obtain the optimum performance, a number of settings made at the factory should be checked and, if necessary, adjusted. Seeing that the control itself can only to a certain extent adjust the volume of fuel fed by the stoker screw, it is necessary to set a basic adjustment for each fuel type to be used with the specific heating plant. -
Page 30: Closing Down The Plant
Example 2. The pause times lie very much higher than 25 sec, and the oxygen is very low. Conclusion: The screw feeds too much fuel into the burner, and the adjustment will therefore increase the pause (P2) and thus reduce the fuel volume. By reducing the screw running time, the control will reduce the pause so that we get closer to the ideal time of 25 sec. -
Page 31: Heating With Firewood
11.0 Heating with Firewood. The KSM Oxygen Control PCT300 is a further development, focussing on a better combustion of firewood. As long as there is firewood in the boiler, the stoker will be on stand-by and only feed a little pellets every minute in order to prevent the ember from creeping backwards through the screw tube. -
Page 32: Buffer Tank
11.4 Buffer Tank. The new software is most efficiently used when mounting a buffer tank of 50 litres per kW boiler performance. This will allow for filling up the boiler completely with firewood without risking that the plant runs too hot. After that the wood has burnt, the stoker will remain in pause for a long time seeing that the temperature of both heating system and tank have to fall before the stoker continues. -
Page 33: Automatic Fuel Filling Device, Fire Damper, Transport Screw (If Mounted)
13.0 Automatic Fuel Filling Device, Fire Damper, Transport screw (if mounted) The stoker may be fitted with a fuel filling device which will automatically handle the filling with fuel from an external fuel stock. Such equipment appears from the below sketch. Inlet from external screw Damper motor Sensor... -
Page 34: Moving Floor (If Mounted)
14.0 Moving floor (if mounted) By biomass fuels forming clinker in connection with their combustion, it is a great advantage to fit the burner with a scraper bottom. The scraper bottom constantly scrapes the generated clinker out of the boiler bottom and you need not clean the burner head every day, as it should normally be done when combusting with grain and similar fuels. -
Page 35: Ash Screw (If Mounted)
15.0 Ash screw (if mounted). By biomass fuels forming a lot of ashes in connection with their combustion, it is a great advantage to fit the burner with an automatic ash screw, perhaps in combination with the scraper bottom. The ash screw is mounted as shown below. Ash-bin Mode of operation. -
Page 36: Automatic Ignition (If Mounted)
16.0 Automatic Ignition (if mounted). In connection with the use of wood pellets, it is possible to equip stoker with automatic ignition. The automatic ignition is controlled by several parameters. STARTUP OXY LIMIT: Oxygen limit at which management, detect fire as gone out. If oxygen value is higher than STARTUP OXY LIMIT starts, by using spark fan, after the following principle. -
Page 37: Boiler Cleaning
17.0 Boiler Cleaning. Along with the development of the KSM-Multistoker, it has become easier to clear away the ashes that are simply removed through the bottom boiler door using the appertaining ash shovel, or you may use the ash pan in the boiler bottom. Clean your boiler once a week to remove ashes that have settled at the boiler bottom. -
Page 38: Precautionary Measures
18.2 Personal Protection. The KSM-Stoker is fitted with a safety switch on the silo lid; this switch will cut off the electric power to the stoker if the lid is opened. This is to protect you against any damage while handling screw or stirring device. -
Page 39: Maintenance
19.0 Maintenance. The KSM-Stoker is constructed in a way so as to minimize the maintenance as much as possible; however there are a few things that call for your attention. 19.1 Gear. From the factory, the strong gear has been filled with lubricant and this needs no topping up. However, pay attention if oil spots appear on the floor that might originate from the gear. -
Page 40: Interruptions Of The Operation
20.0 Interruptions Of The Operation 20.1 Unburned fuel in the ashes. 1. False air, causing the oxygen meter to give incorrect measures. Check for open dampers or leaks around doors. 2. More air is required for the combustion, set a higher oxygen % 3. -
Page 41: Bothering Smoke
20.8 Bothering smoke. In case of bothering smoke in the tank, or if smoke comes from the inspection door when opened, this means that the boiler needs cleaning. 20.9 Condensed water in flue gas outlet. If condensed water occurs from the flue gas ducts, these should be insulated as this will otherwise lead to corrosion and reduce the life of both boiler and flue gas ducts. -
Page 42: Mounting Instructions
Place the boiler on a stable and plane surface. 21.2.2 Flue gas outlet. As a KSM-stoker runs with a very moderate flue gas temperature, this involves the following measures. Flue tubes diameter Ø 187 are manufactured from 2mm sheets, if elbows occur on flue gas outlets it is necessary to use elbows with cleaning flap. -
Page 43: Anti-Freeze Measures
Now the stoker is ready to be started up. For more instructions as to starting up and final adjustment, see the relevant sections. 22.0 Accessories. The supply of a KSM-Multistoker 375-35 consists of the following items: Stoker, complete with control and sprinkler equipment Cleaning equipment Instruction manual. -
Page 44: Technical Data
23.0 Technical Data. Nominal output: 36,69 kWs Output: Minimum output: 9,94 kWs Provided firing with wood pellets with a diameter of 8mm and a water content of approx. 8%. At nominal output: 8,13 kgs/h Consumption: At nominal output: 92,4% Efficiency degree: At minimum output: 92,1% Between 78°... -
Page 45: Piping Diagramme
24.0 Piping Diagramme. Titel Drawing No. 3-Way Mixer valve RD 010 Cooling coil RD 012 Safety valve, backfire RD 013 All appertaining drawings appear from the following pages. - 42 -... -
Page 49: Power Diagram
25.0 Power Diagram. Titel Drawing No. Internal connections ED 0110 Wiring diagram ED 0148 Terminal list ED 0148 All appertaining drawings appear from the following pages. - 43 -... - Page 54 KSM-Stoker A/S Næssundvej 440, 7960 Karby DK. Tlf. +45 97761072 Fax. +45 97761372 Mobil. +45 20991072 Www.ksm-stoker.dk Email. Info@ksm-stoker.dk Eldiagram Wiring diagram Schaltplan ED 148 Kabel Beskrivelse Description Beschreibung Komponent Tilslutning Forsyning Power supply Versorgung Forsyning Power supply Versorgung Forsyning...
- Page 55 Supplement B Standard settings...
- Page 57 Supplement B2 for plants with automatic ignition...
- Page 59 Supplement B3 for plants with 1-6 m³ silo...
- Page 61 Supplement C - 44 -...
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- Page 65 Supplement D Dimensions Titel Drawing Nr. KSM-Multistoker 375-35 M 00375000 KSM-Multistoker 375-35 Auto M 00375100 KSM-Multistoker 375-35 F-Auto M 00375200 KSM-Multistoker 375-35 FX M 00375300 More dimension drawings can be downloaded at: https://www.dropbox.com/sh/4q2fp5a2tpjedoy/AACTo6xIHdEHbFGURiVXg7l8a/Dimension%20drawings/PDF?dl=0 - 48 -...
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