Keystoker KAA-4 Instructions Manual
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Keystoker KAA-4 Instructions Manual

Hot water boilers
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Schuylkill Haven, PA.
"SAVE THESE INSTRUCTIONS"
HOT WATER BOILERS
Safety, Installation and Operating
Instructions enclosed.
Please read and understand these following instructions. If
instructions are not followed; a fire may result causing
property damage, personal injury, or even death.
Installations must be performed by a qualified installer.
Follow All local building and zoning codes.
SAVE THESE INSTRUCTIONS
Instruction Must be with the owner of the boiler
Keystone Manufacturing Company
60 Keystoker Lane
Schuylkill Haven, PA 17972
(570) 385-3873
info@keystoker.com
© July 2019 Rev 02

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  • Page 1 Installations must be performed by a qualified installer. Follow All local building and zoning codes. SAVE THESE INSTRUCTIONS Instruction Must be with the owner of the boiler Keystone Manufacturing Company 60 Keystoker Lane Schuylkill Haven, PA 17972 (570) 385-3873 info@keystoker.com © July 2019 Rev 02...
  • Page 2 As prices of energy continued to escalate, Keystoker continued its research. Over 70 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.

  • Page 3: Table Of Contents

    Keystoker – Schuylkill Haven, PA 17972 Hot Water Boilers Table of Contents Company Introduction SAFETY UL Label Precautions & Definitions General Safety Statement Safety Hot Water Specification Chart Installation Boiler Placement Set Up Boiler Supply & Return Piping Boiler Fill & Domestic Water Piping 12-13 Installation &...
  • Page 4 MH60075 SOLID FUEL-FIRED BOILER ASSEMBLY Keystone Manufacturing Company 60 Keystoker Lane Schuylkill Haven, PA 17972 Phone 570-385-3873 Models: KAA-4, KFL-6, KA-6, KB-8, KC-10, KD-12, KE-15, KF-18, KG-22 Serial Number Date manufactured stamped on data plate attached to boiler BURN ONLY ANTHRACITE COAL POWER SUPPLY- 120V, 60 Hz, use not less than 14 AWG wire and not less than 15A breaker.
  • Page 5 Keystoker – Schuylkill Haven, PA 17972 Hot Water Boilers The appliance, flue pipe and chimney must be in good condition. These instructions also apply to a draft inducer. Refer to owner’s manual. Do not alter this equipment in any way.

  • Page 6: 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 7: Safety

    Keystoker – Schuylkill Haven, PA 17972 Hot Water Boilers Safety Only fill hopper to the maximum fill line, Do not fill with wet coal.  Coal should not overflow top of the hopper.  Do not store fuel within the recommended installation clearance for proper ash removal and refueling the boiler.
  • Page 8 Keystoker – Schuylkill Haven, PA 17972 Hot Water Boilers  Maximum flue draft shall not exceed -.06 inches of water column. Exceeding maximum draft will result in an out of control burn.  Make sure boiler room is large enough for adequate combustion air. If the room is too small, an outside air vent must be used.
  • Page 9 Keystoker – Schuylkill Haven, PA 17972 Hot Water Boilers  Boiler must be installed on a noncombustible surface (concrete, fireproof floor pad, ect).  Prolonged Power outages, during a prolonged period of time without power steps should be taken to ensure that the boiler does not freeze. Circulating the water to prevent freezing or draining the system before freezing.
  • Page 10 Keystoker – Schuylkill Haven, PA 17972 Hot Water Boilers Hot Water Boiler Specification Charts BTU / Hour (Nearest Stoker Data Hopper Model Relief Valve Thousand) Capacity MAX PSI (Lbs.) # of Grates Gross Model (3” x 14”) KAA-4 3” X 12”...

  • Page 11: Installation

    Installation Boiler Placement 1. Boilers must be installed on a noncombustible floor. Keystoker boilers are available with fire door on the right or left side. When you stand at the stoker end of the boiler and look directly over top of boiler toward stack end, you may choose to have a fire door on the right or left side of boiler.

  • Page 12: Set Up Boiler

    Keystoker – Schuylkill Haven, PA 17972 Hot Water Boilers Setup of Boiler 1. Place boiler in desired position. 2. Place steel shims or bricks under each corner of boiler to allow an air space, to prevent moisture from accumulating and rusting base of boiler. The brick should stick out 2”...

  • Page 13: Installation & Piping Of Accessories

    Keystoker – Schuylkill Haven, PA 17972 Hot Water Boilers 3. Solder a piece of pipe onto the ½” adaptor to extend the pipe outside of the jacket. NOTE: Before proceeding with connections for piping of boiler fill and domestic water, INSTALL stack end of insulated steel jacket NOW.

  • Page 14: Control Installation & Electrical Wiring

    Keystoker – Schuylkill Haven, PA 17972 Hot Water Boilers opening. Bend flange down to fit inside throat of stoker – be sure mechanism is free to operate. Control Installation & Electrical Wiring 1. Install triple aqua stat onto its well being careful not to pinch the wire for connection.

  • Page 15: Operation

    Keystoker – Schuylkill Haven, PA 17972 Hot Water Boilers 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 16: Diagram 1 -Continuous Operation

    Keystoker – Schuylkill Haven, PA 17972 Hot Water Boilers Diagram 1 – Continuous Operation Depicts what fire should look like when the boiler calls for heat for extended period: A. Unburned fresh coal supply from coal hopper B. Burning Coals C.

  • Page 17: Diagram 2 - Intermittent Operation

    Keystoker – Schuylkill Haven, PA 17972 Hot Water Boilers Diagram 2 – Intermittent Operation Depicts what fire size should look like when the boiler has not called for heat for extended periods: A. Unburned fresh coal supply from hopper. B. Burning coal (about 1-1 ½” to 2”) (little to no flames).
  • Page 18 Keystoker – Schuylkill Haven, PA 17972 Hot Water Boilers Initial Main Combustion Air Setting The initial main combustion air setting is open about 1/2'’ may have to be adjusted with draft gauge. Refer to Figure 2. Combustion Air Setting FIGURE 2 Combustion Blower Operation &...

  • Page 19: Component Description & Operation

    Keystoker – Schuylkill Haven, PA 17972 Hot Water Boilers 6. During winter operation, hot coals should never be pushed off end of grate. This would indicate that the coal feed needs to be reduced (CCW) or if during winter operation; fire bed is too small, turn red the nut (CW) to increase.
  • Page 20 Keystoker – Schuylkill Haven, PA 17972 Hot Water Boilers Boiler Unit Components – cont’d FIGURE 4 © July 2019 Rev 02 - 19 -...
  • Page 21 Keystoker – Schuylkill Haven, PA 17972 Hot Water Boilers CONTROLS- Electrical controls insure proper operation of stoker unit and circulator. These controls consist of the following: THERMOSTAT- Adjustable for desired room temperature. Set this to where the house is made comfortable.
  • Page 22 Keystoker – Schuylkill Haven, PA 17972 Hot Water Boilers of lost motion on driving rod. Turn nut CCW for less coal feed. Turn nut CW for more coal feed. AIR ADJUSTMENT – Located under scroll on stoker unit. This is to be adjusted for proper combustion by means of loosening locking screws and setting air shutter in proper position.

  • Page 23: Setting Draft

    Keystoker – Schuylkill Haven, PA 17972 Hot Water Boilers Setting Draft Set draft through fire door on side of boiler. Here is a picture demonstrating placement of draft gauge or manometer. Refer to Page 11 for draft settings. FIGURE 6 ©...

  • Page 24: Setting Timer

    Keystoker – Schuylkill Haven, PA 17972 Hot Water Boilers Setting Timer To set timer you must first turn power to the boiler off, remove cover labeled timer. Timer is solid state and can be adjusted by moving switches on or off according to the switch value.

  • Page 25: Cleaning & Lubrication Of Boiler

    Keystoker – Schuylkill Haven, PA 17972 Hot Water Boilers end of the discharge pipe. After a few minutes dripping should stop. If dripping does not stop relief valve will need to be replaced by a qualified plumber. Cleaning & Lubrication of Boiler Boiler exhaust pipe (stack pipe) must be cleaned at least once per year.

  • Page 26: Troubleshooting Guide

    Keystoker – Schuylkill Haven, PA 17972 Hot Water Boilers Troubleshooting Guide Problem Cause Main circuit breaker tripped Reset Main fuse blown Replace STOKER DOESN’T Fuse on stoker blown Press reset button on motor Lo Water level (steam) Fill boiler to proper water level...

  • Page 27: Diagrams

    Keystoker – Schuylkill Haven, PA 17972 Hot Water Boilers Diagrams Wiring Diagram - Boiler © July 2019 Rev 02 - 26 -...

  • Page 28: Wiring Diagram-Boiler: Coal Oil Option

    Keystoker – Schuylkill Haven, PA 17972 Hot Water Boilers Wiring Diagram –Boiler: Oil & Coal Option Attention: Firing this boiler with any fuel will void the UL listing. Boilers are tested for Anthracite coal ONLY © July 2019 Rev 02...

  • Page 29: Iso Plumbing Diagram Single Boiler

    Keystoker – Schuylkill Haven, PA 17972 Hot Water Boilers ISO Plumbing Diagram 1 - Boiler © July 2019 Rev 02 - 28 -...

  • Page 30: Iso Plumbing Diagram 2-Boilers

    Keystoker – Schuylkill Haven, PA 17972 Hot Water Boilers ISO Plumbing Diagram 2 – Dual Boilers © July 2019 Rev 02 - 29 -...
  • Page 31 Keystoker – Schuylkill Haven, PA 17972 Hot Water Boilers Typical Zone Valve Wiring Diagram - Boiler SINGLE CIRCULATOR — Multiple Zone Valves including Indirect, No Zone Control Panel ZONE/ INDIRECT SWITCH POSITION NOTE: When using zone valves for both heat and indirect, the calls must be separated in order to prioritize indirect calls. This can be accomplished by using a general purpose relay as shown above.

  • Page 32: Boiler Major Components

    Keystoker – Schuylkill Haven, PA 17972 Hot Water Boilers Boiler Major Components Expansion Tank Circulator Pump Relief Valve Flow Check Bypass Boiler Gauge Loop Controls Domestic hot water Hopper coil Fire door Stack Outlet Exhaust Ash Door Boiler Drain Brick and shims...

  • Page 33: Parts Ordering

    Boiler 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: Check List

    Keystoker – Schuylkill Haven, PA 17972 Hot Water Boilers Boiler Contents Checklist Thermostat Relief Valve Pressure / Temperature Gauge 4006H with Well 4006H with Well 4006B with Well Fire Door Draft Regulator Control with Well Instructions Warranty Card (2) 3/8” Stoker Bolts (2) 3/8”...

  • Page 35: Notes

    Keystoker – Schuylkill Haven, PA 17972 Hot Water Boilers Notes © July 2019 Rev 02 - 34 -...

This manual is also suitable for:

Kfl-6Ka-6Kb-8Kc-10Kd-12Ke-15 ... Show all

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