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Summary of Contents for KSM-Stoker KSM-Multistoker 775-75 PCT 400
- Page 1 Instructions KSM-Multistoker 775-75 With PCT 400 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 1/ 10-2010 .
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Page 2: Table Of Contents
INDEX FOR KSM-Multistoker Tuxedo with PCT 400 Steering system. 1.0 Introduction ............................5 2.0 Fuel..............................6 2.1 Wood Pellets ........................... 6 2.2 Grain..............................6 2.3 Alternative Fuels..........................6 3.0 Control Panel............................7 3.1 Pushbuttons. - Page 3 4.2.6.1 Ignition delay s. .......................... 1 5 4.2.6.2 Fuel delay. ............................ 1 6 4.2.6.3 No ignition. ............................. 1 6 4.2.6.4 Manual. ............................ 1 6 4.2.6.5 Automatic. ............................ 1 6 4.2.6.6 Auto W. empty .......................... 1 6 4.3 Pause............................. 17 4.3.1 Stoker screw........................... 17 4.3.1.1 Pause fuel seconds. ........................ 1 7 4.3.1.2 Pause in minutes. ........................... 1 7 4.3.1.3 Empty‐run in minutes. ...
- Page 4 4.5.3.13 Pause w. maximum output in seconds. .................. 2 3 4.5.4 Fan............................24 4.5.5 Smoke pipe cleaner........................ 24 4.5.5.1 Run time in seconds. ........................ 2 4 4.5.5.2 Pause in hours. .......................... 2 4 4.5.6 Smoke fan..........................24 4.5.6.1 Smoke fan startup. ......................... 2 5 4.5.6.2 Smoke fan 100, 60, 40, 30 and 20. .................... 2 5 4.5.7 Hydraulic moving floor......................25 ...
- Page 5 16.7 Combustion Air Fan........................39 16.8 Smoke fan ........................... 39 16.9 Mouldings........................... 39 17.0 Service plan............................. 40 18.0 Breakdown ............................41 18.1 Unburned fuel in the ashes......................41 18.2 The boiler becomes sooty......................41 ...
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Page 6: Introduction
The burning chambers of the KSM-Multistoker Tuxedo are built in stones which can resist enormous temperatures which the KSM-stoker is producing while it is operating. The enormous burning temperatures which can reach about 1200°C in a KSM-Boiler contribute to burn the smoke gas completely and grant a high-end output degree. -
Page 7: Fuel
2.0 Fuel. The KSM-Multistoker Tuxedo 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 8: Control Panel
3.0 Control Panel The new PCT400 control from KSM-Stoker A/S is helps making it easy to use your new boiler. The control is equipped with a huge colour-monitor measuring 5,7" The control is as standard equipment with its own little Web-server which gives the perfect opportunity to fully monitor and operate with every kind of hardware which has access to the internet. -
Page 9: Pushbuttons
3.1 Pushbuttons. The panel is equipped with three pushbuttons which changes indications depending on where you are in the program. When the boiler is in the normal run screen the designations are as follows: ↑ ↓ “ ” “ ” “MENU”... -
Page 10: Menu Structure
4.0 Menu structure The menu in our software PCT400 is designed in the same way as we know it from example Windows. The menu is divided in manageable folders which are listed below. “Run”, “Startup”, “Pause”, “Program”, “Accessories”, “Boiler”, “Test” and “Service”. In every folder is parameter which can be adjusted or multiple subfolders in which there is parameters which can be adjusted. -
Page 11: Run
4.1 Run. The run chapter contains all parameters which is significance for the different functions in “Run”. 4.1.1 Set temperature. In this chapter you can find all parameters concerned the set temperature while operating. 4.1.1.1 Set temperature °C Setting of the boiler’s flow temperature Please select: Menu / Run / Set temp / Set temp °C The desired set temperature can be set minimum 70°C and maximum 95 °C... -
Page 12: Minimum Output
4.1.1.5 Minimum output % The lowest output which is desired the boiler to operate with. The ideal setting depends on the fuel and the boiler’s installation. However as starting point we recommend to Please select 1 % because the controller will modulate the boiler’s output from 1 % to 100 %. Please select: Menu / Run / Set temp / Min output % It can be set from 1 % but no maximum... -
Page 13: Minimum Fuel
4.1.2.4 Minimum fuel s. It is also possible to adjust the stoker screw’s minimum fuel conveying. Please select: Menu / Run / Stoker screw / Min. Fuel s. Normally the value is set to 0,1 s. and only in special occasions another setting is selected. 4.1.3 O2. -
Page 14: Start Up
4.2 Start up. In connection with the startup of the boiler or transition from pause to run, there are more parameters which can be adapted or adjusted as pleased. 4.2.1 Stoker screw. In connection with the startup it is important that the volume of fuel is fitting and that is what the next parameter is for. -
Page 15: Go To Startup O2
4.2.2 O2. To make sure that the controller knows if the fire is ignited or/if the ignition should be activated, there is some limit values for the O2 in the smoke gas which has to be set. 4.2.2.1 Go to startup O2 % If the O2 is over the indicated value, the controller will go in startup mode and activate the automatic ignition if such is mounted, If not the fan will start pulsing to ignite the fire. -
Page 16: Boiler Cleaning Temperature
4.2.3.3 Boiler cleaning temperature °C If the smoke gas is getting to high, then is it time to clean the boiler and the efficiency of the boiler will also be less when there is too much heating led out of the chimney. Please select: Menu / Startup / O2 / Boiler clean temp. -
Page 17: Fuel Delay
4.2.6.2 Fuel delay. When the ignition is activated then the stoker screw is stopped in x minutes because we do not want to remove the fuel. We are trying heat. Please select: Menu / Startup / Ignition / Fuel delay Normally two minutes is appropriate. -
Page 18: Pause
4.3 Pause. When the boiler has reached the desired temperature above the boiler’s set temperature, as it is indicated in chapter 4.1.1.2 the boiler switches to pause mode if there is not chosen automatic ignition. 4.3.1 Stoker screw. In connection with pause mode, we should run the screw of two reasons: To transport enough fuel to keep the glows alive To secure that the glows cannot penetrate the screw pipe 4.3.1.1 Pause fuel seconds. -
Page 19: Fan
4.3.2 Fan. Every time there is transported fuel in pause mode the fan is also started to ensure that the fire does not go out. 4.3.2.1 Output. How fast the fan shall blow depends on the fuel. Usually it should not be more than 15 % output. Please select: Menu / Pause / Fan / Output 4.3.2.2 Fan on time. -
Page 20: Accessories
4.5 Accessories. In this chapter all parameters related to the single accessory has to be adjusted. 4.5.1 Transport screw. The transport screw is the screw which provides the fuel from the extern stock. The controller is prepared to run with up to four transport screws. 4.5.1.1 Run as stoker screw. -
Page 21: Delayed Stop In Seconds
4.5.1.5 Delayed stop in seconds. To make sure that the stoker screw does not stop just because the fuel sensor is activated because of a piece of woodchip, it is possible to delay the transport screw from stopping. Please select: Menu / Accessories / Transport screw / delayed stop s. -
Page 22: Moving Floor Run Time
4.5.3.2 Moving floor run time s. The scrap is mounted underneath the moving floor with the purpose to clean for dust etc which has fallen through the fire grates. Please select: Menu / Accessories / Moving floor / Moving floor run time s. The time has to be adjusted so that the moving floor can run a round forward and backward. -
Page 23: Fire Grate 1 Run Time In Seconds
Please notice: The parameters for the fire grates are not used for the XL boilers which mean chapter 4.5.3.5 including 4.5.3.13. 4.5.3.5 Fire grate 1 run time in seconds. The fire grates are transporting the fuel to the burning chamber. If the fire grates do not run enough, there is a risk that the fuel will accumulate in the back which results that the top stones can be pushed up and crack. -
Page 24: Pause W. Minimum Output In Seconds
4.5.3.9 Pause w. minimum output in seconds. Ii is set as fire grate to 30 seconds. Please select: Menu / Accessories / Fire grate 2 / Pause w. min. Output s. And insert 30 seconds. 4.5.3.10 Pause w. max output in seconds. Please select: Menu / Accessories / Fire grate 2 / Pause w. -
Page 25: Fan
4.5.4 Fan. The XXL boilers are mounted with 4 – 5 fans depending on the size of the boiler. The output of the fans is controlled by the demand of output. The speed of the fans by the different outputs can be adjusted. However, as basis the values underneath are used. -
Page 26: Smoke Fan Startup
4.5.6.1 Smoke fan startup. To ensure that no smoke comes out in connection with the startup, it is possible to decide for how long the smoke fan shall start before the fans on the boiler. Please select: Menu / Accessories / Smoke fan / Smoke fan startup 10 seconds is appropriate startup time for the smoke fan. -
Page 27: Boiler
When you wish to stop just press “Select” again and you can see an “OFF” after the function and it stops. 4.8 Service. The options in this menu is recommended not to adjust without closely instructions from KSM-Stoker A/S. Please select: Menu / Service... -
Page 28: Starting Up The Stoker
5.0 Starting up the stoker. When you start the stoker the easiest way is as follows: The stoker is turned on when you turn the yellow main switch on “1”. An appropriate volume of fuel is added into the burning head is you press “SCREW START”. The stoker is turned off because it is best to lighten up when the fan is not running. -
Page 29: Final Adjustments
6.0 Final Adjustments. A KSM oxygen controller is regulating the operating time of the screw in all different outputs to ensure the best consumption as possible. However, to make it optimal functional there are some basis settings to check and adjust as required. This should only be adjusted by a KSM trained engineer. -
Page 30: Air Nozzles
8.0 Air Nozzles. The nozzles distributing the air in the combustion chamber are mounted in the rear plate and maintained by fireproof joint filler. This kind of mounting allows for easy exchange, if necessary. The bottom nozzles must be placed so that the air is blown across the fuel in an angle of about 45 degrees. The holes in the top nozzle just have to point forward in an oblique direction. -
Page 31: Automatic Fuel Filling Device, Fire Damper / Transport Screw
9.0 Automatic Fuel Filling Device, Fire Damper / transport screw. KSM-Multistoker Tuxedo automatic and F-automatic are mounted with an automatic filling device which automatically is filling fuel from an extern stock. Such device is shown on the picture below. Servicecover, if fuel should accumolate the cover will be pressed up against the mounted doorcontact and the transport system will be stopped. -
Page 32: Moving Floor (If Mounted)
10.0 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 33: Ash Screw
11.0 Ash screw. The multi-stoker is mounted with an automatic ash screw in the boiler and a lifting screw to lift up the ash in a suitable ash container. It is important that the transition from the lifting screw and the ash container is closed tight for that there is two reasons: 1. - Page 34 Ascheniemer Asche It is also possible to let the horizontal ash screw out the wall. The lifting screw can be mounted like on this picture with the ash bin. - 33 -...
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Page 35: Automatic Ignition (If Mounted)
12.0 Automatic Ignition (if mounted). In connection with using pellets it is possible to mount the stoker with an automatic ignition. When using automatic ignition there are multiple parameters which controls this function. Those parameters are all described in chapter 4.2 in the chapters concerned following: •... -
Page 36: Boiler Cleaning
13.0 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 37: Hydraulic Feeding System (Hydraulic Moving Floor) (If Mounted)
14.0 Hydraulic feeding system (Hydraulic moving floor) (if mounted). The hydraulic moving floor is the most preferred fuel feeding system for larger installations where it is woodchips which is desired as fuel. The installation can be made in many ways e.g. shown on the picture underneath where the fuel stock is at same level as the boiler room. -
Page 38: Precautionary Measures
15.2 Personal Protection. The KSM-Stoker Tuxedo 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
16.0 Maintenance. The KSM-Stoker Tuxedo 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. 16.1 Oxygen sensor. The oxygen sensor is mounted in the top of the smoke box back the boiler. The oxygen measurements are vital to ensure a good combustion which is why the correct measure is important. -
Page 40: Combustion Air Fan
16.7 Combustion Air Fan. If the stoker is placed in dusty surroundings, the combustion air fan should be dismounted for cleaning before the start of a new heating season. Dust will gather on the fan blades and this will reduce the efficiency of the combustion air fan. For easy removal use a fan pistol connected to a compressor. -
Page 41: Service Plan
17.0 Service plan. Every day 1. Visually watch if everything runs as desired either by go to the boiler room or by watching the boiler on the web control. 2. As required empty the ash bin. 3. Control the fuel stock. Every week 1. -
Page 42: Breakdown
18.0 Breakdown 18.1 Unburned fuel in the ashes. 1. False air, causing the O2 meter to give incorrect measures. Check for open dampers or leaks around doors. 2. More air is required for the combustion, set a higher O2 % 3. -
Page 43: Backfire
18.6 Backfire. If you have been very unlucky and the thermal valve has been triggered, it is necessary to clear out the screw for moist pellets before re-starting the plant. The easiest way is to dismount the 4 bolts holding the gear motor, and then twist it loose. Ask an assistant to press the Start button while you hold on to the motor, and the motor will then quietly unscrew from the screw tube, it may now be cleaned and finally gear-motor and screw can be re-mounted. -
Page 44: Alarm List
19.0 Alarm list. Alarm text Cause Solution Startup timeout. Expiration of the startup time. Check if there is fuel in the burninghead. Restart the plant. Overheat. Overheating thermostat has been Check the boiler’s set released because of to high set temperature. -
Page 45: Mounting Instructions
Place the boiler on a stable and plane surface. 20.2.2 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 46: Piping
20.2.3 Piping. Forward and return is possible in both sides of the boiler. However, check that the not used input is stuffed. The expansion is connected to the forward supply; no tabs are permitted on this piping. The safety pipe for the expansion tank must have a pipe dimension of minimum ¾”. A shunt bypass must be established between forward and return on the boiler, this is to ensure that you will always get min. -
Page 47: Sprinkler, Water Connection
20.2.6. Sprinkler, water connection The stoker sprinkler valve is mounted at the factory, and the appertaining pressure tank is to be mounted in a suitable place near the stoker. Connect the pressure tank directly to your water supply, then mount a pipe from the pressure tank and onto the sprinkler valve sitting at the right side of the screw tube. -
Page 48: Piping Diagram
22.0 Piping Diagram. Title Drawing No. Shunt RD 010 Cooling coil RD 012 Sprinkler system RD 013 All appertaining drawings appear from the following pages. - 47 -... -
Page 49: Power Diagram
23.0 Power Diagram. Title Drawing No. Automatic 11-95 kw ED 0415 Standard 11-95 kw ED 0416 Automatic 125 kw ED 0417 Standard 125 kw ED 0418 All appertaining drawings appear from the following pages. - 48 -... -
Page 50: Dimension Drawings
24.0 Dimension drawings Titel Drawing Nr. All dimension drawings can be downloaded at: https://www.dropbox.com/sh/4q2fp5a2tpjedoy/AACTo6xIHdEHbFGURiVXg7l8a/Dimension%20drawings/PDF?dl=0 - 49 -...
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morning, i require the emission certificate for this boiler. KSM multistoker 775-75. can you help please as OFGEM require it following us moving the boiler to our new location