Keystoker problems please help!

Keystoker problems please help!

PostBy: Brentski On: Wed Jan 22, 2014 6:27 pm

Hello everyone, I am the proud owner of a Keystoker KA-6 that was installed 10/1/12. I must say that the stove has been a joy to own and operate but I have developed a couple of problems lately. :shock: problem # 1. Major burnt ash buildup on the burning grate that won't push off into ash pan and fresh unburnt coal spills over the sides of the grate! :mad: I see more of this when it is cold out and the boiler is calling for heat. I called keystoker and they said to make an air adjustment, I tried this without success. The burnt coal that does go into the ash pan looks like bricks, almost sticking or welded together burnt coal.

My info:

2012 keystoker ka6
Burning rice coal
2 pins every 15 min
Barometric damper set @ .02
180 degree high and 160 degree low @ 20 difference
Air adjustment set @ Factory setting
8 turns out on red stoker screw ( I know factory is 12)
I live in Syracuse NY and it's stinking cold

Thanks,
Brent
Brentski
 
Stoker Coal Boiler: Keystoker KA-6

Re: Keystoker problems please help!

PostBy: Brentski On: Wed Jan 22, 2014 6:33 pm

Problem # 2. My gear box is leaking gear oil. Is this common? how to fix?
Brentski
 
Stoker Coal Boiler: Keystoker KA-6

Re: Keystoker problems please help!

PostBy: whistlenut On: Wed Jan 22, 2014 7:21 pm

It sounds like the lack of ash being pushed off the grate may be related to the gearbox. There is nothing else besides the linkage, pusher bar and the gear box. Is it possible that the coupling from the motor shaft is worn out and slipping to some degree? I'd get back on the horn with Don in the AM and explain more about the issue. Try to play with it tonight. I'm thinking that if the blower is working fine, perhaps the drive coupling is slipping due to wear. You know it is something stupid, and that is where I would look first. I do know the gearbox could fail, but you NEED to get parts on the road if you need them, so play detective tonight and call Don at 07:00 tomorrow. I was thinking you could see if ash had fused to the grates, but that is very unlikely. Not much else to look at except the gearbox and the drive to it. If you are handy, you could remove the motor and check things out directly. Yes, shut down the power first, but make it a quick exam because this is not a night to be without heat. A guy told me today it was sooooo cold that he actually saw a Democrat with his hands in his own pockets~~~THAT IS COLD!
whistlenut
 
Stoker Coal Boiler: AA130's,260's, AHS130&260's,EFM900,GJ&VanWert
Hand Fed Coal Boiler: Franks Boiler,Itasca415,NYer130,Van Wert
Hot Air Coal Stoker Furnace: Yellow Flame
Hot Air Coal Stoker Stove: Alaska-4,Keystoker-2,
Hand Fed Coal Stove: Alaska,Gibraltor,Keystone,Vc Vigilant 2
Hand Fed Coal Furnace: Van Wert, NYer's, Ford,Jensen.
Coal Size/Type: Rice,Buck,Pea,Nut&Stove
Other Heating: Oil HWBB

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Re: Keystoker problems please help!

PostBy: Rigar On: Wed Jan 22, 2014 7:25 pm

are u burning rice??
..it sounds like cake like clinkers...
..the oil 'dripping' is common
Rigar
 
Hot Air Coal Stoker Furnace: Keystoker A 150
Coal Size/Type: anthracite rice
Stove/Furnace Make: Keystoker
Stove/Furnace Model: A 150 warm air furnace

Re: Keystoker problems please help!

PostBy: Rigar On: Wed Jan 22, 2014 7:32 pm

Rigar wrote:are u burning rice??
..it sounds like cake like clinkers...
..the oil 'dripping' is common

..
..cont.:
...you may need to adjust air and /or feed rate..
i tried mixig buck in with the rice when the stoker ran hard...and that eliminated clinkers
Rigar
 
Hot Air Coal Stoker Furnace: Keystoker A 150
Coal Size/Type: anthracite rice
Stove/Furnace Make: Keystoker
Stove/Furnace Model: A 150 warm air furnace

Re: Keystoker problems please help!

PostBy: Rob R. On: Wed Jan 22, 2014 7:51 pm

When you start getting the feed & air that high, some coal will produce large clinkers. I think it is preferable to run the stoker at a lower output and eliminate the clinkers, than to run it hard and have it get plugged. Try reducing the feed rate to 12 turns from max and adjust the air so that the fire stops just before the last set of air holes on the grates (you do this after the stoker has been running for 30+ minutes with no other adjustments). If it runs good with those settings, you can try bumping it a up a turn or two and tweak the air if necessary.

As for the leaking oil, did you remove the screw in the vent on the gearbox?
Rob R.
 
Stoker Coal Boiler: EFM DF520
Hand Fed Coal Stove: Hitzer 50-93
Coal Size/Type: Lehigh Rice
Other Heating: Dad's 1953 EFM Highboy

Re: Keystoker problems please help!

PostBy: blrman07 On: Wed Jan 22, 2014 8:15 pm

Your describing what I call clinker cakes. They are ash that has fused together on the grate due to high heat. I had them really bad to the point they would stay together and extend all the way off the end of the grate and hit the glass in the top door on my previous stoker. Not being able to go any further they stopped and the coal and ash just backed up on the grate. I would get raw coal piling up and spilling over the side walls of the grates.

I mixed in some buck with the rice and it slowed it down. when I switched to white ash coal it stopped completely. Your pretty much only going to see it when your running it hard and using a red ash type of coal.

Rev. Larry
New Beginning Church
Ashland Pa
blrman07
 
Hand Fed Coal Boiler: Bucket a Day
Hand Fed Coal Stove: Vigilant Casting 2310
Baseburners & Antiques: rebuilding a 1906 March Brownback Double Heater, using a UMCO 1920's Pot Belly stove in the church
Coal Size/Type: Pea/Nut/Wood in the VC and anything that will fit in the Bucket a Day. It's not fussy.

Re: Keystoker problems please help!

PostBy: Pacowy On: Wed Jan 22, 2014 8:41 pm

blrman07 wrote: Your pretty much only going to see it when your running it hard and using a red ash type of coal.


x2. I had that issue in an Alaska 140, with big "muffin" clinkers clogging the burn plate and plowing fresh coal over the sides. Cutting back the air seemed to be key to reducing the clinkering. As Rob noted, the feed would need to be adjusted to produce a proper ash band for the new air setting.

Mike
Pacowy
 
Stoker Coal Boiler: H.B. Smith 350 Mills boiler/EFM 85R stoker
Coal Size/Type: Buckwheat/anthracite

Re: Keystoker problems please help!

PostBy: Rob R. On: Wed Jan 22, 2014 8:43 pm

Yep...mixing in some buck might also help get you through the cold spell.
Rob R.
 
Stoker Coal Boiler: EFM DF520
Hand Fed Coal Stove: Hitzer 50-93
Coal Size/Type: Lehigh Rice
Other Heating: Dad's 1953 EFM Highboy

Re: Keystoker problems please help!

PostBy: tikigeorge On: Wed Jan 22, 2014 9:13 pm

Do you have the new flat bed or the older tapered bed? I have the tapered bed so I hope this helps.

I have a KA 6. And the gear box leak oil after the second year. The leak was on the covers on the sides. I got new gaskets, cleaned the surfaces and use a marine grade gasket adhesive, only because I had it, and it is ok now. As for the coal issue if the shaft isn't slipping it may be bad coal.
Have you cleaned under the grate. Remove the small blower and look inside.
tikigeorge
 
Stoker Coal Boiler: Keystoker KA-6
Stove/Furnace Make: Keystoker
Stove/Furnace Model: KA-6

Re: Keystoker problems please help!

PostBy: Dirty Steve On: Thu Jan 23, 2014 11:41 am

Brentski,

I have a KA- 6. Forth season. No leak in gear box. Make sure you keep the oil and oil level to manufacturers spec's. Have you tried other coal- different supplier? Where do you get your coal? Who is your installer if not yourself? Where did you get the boiler from? I got mine from Dennis Coal but installed myself with knowledgeable local help. My coal is rice out of Stoyell in Moravia- hot but lot of ash this year. Source is usually Jeddo mine but I think he said this summer (when I filled my bulk) it was Blaashak. Burns good and hot with less unburnt coal but 3-4 ash tubs a week for my set up. If you have lots of tiny particles/fines in the coal- check under the grates through the stoker side as said previously here. Check the plates on the ramp to make sure something is not fused to it like a chunk of metal. Is it pushing real hard in the recent cold weather? That can make it cake up a little more also. Check your air intake and manometer readings. You do have a manometer-right?

Steve
Dirty Steve
 
Stoker Coal Boiler: Keystoker KA-6
Coal Size/Type: Rice
Other Heating: Oil- Off line
Stove/Furnace Make: Keystoker
Stove/Furnace Model: KA-6

Re: Keystoker problems please help!

PostBy: Brentski On: Thu Jan 23, 2014 8:17 pm

Dirty Steve wrote:Brentski,

I have a KA- 6. Forth season. No leak in gear box. Make sure you keep the oil and oil level to manufacturers spec's. Have you tried other coal- different supplier? Where do you get your coal? Who is your installer if not yourself? Where did you get the boiler from? I got mine from Dennis Coal but installed myself with knowledgeable local help. My coal is rice out of Stoyell in Moravia- hot but lot of ash this year. Source is usually Jeddo mine but I think he said this summer (when I filled my bulk) it was Blaashak. Burns good and hot with less unburnt coal but 3-4 ash tubs a week for my set up. If you have lots of tiny particles/fines in the coal- check under the grates through the stoker side as said previously here. Check the plates on the ramp to make sure something is not fused to it like a chunk of metal. Is it pushing real hard in the recent cold weather? That can make it cake up a little more also. Check your air intake and manometer readings. You do have a manometer-right?

Steve


Steve,
I also get my coal from roger @ stoyell . He just brought six tons of rice three weeks ago. The dam coal is burning so hot it's sticking to the burn plate! I took the secondary blower off and blew out some crap but nothing major! I took the air adjustment down to lowest setting and have a draft of 0.02 , set the red nut to 10 turns in. What do you run your red adjustment nut at?
Brentski
 
Stoker Coal Boiler: Keystoker KA-6

Re: Keystoker problems please help!

PostBy: Brentski On: Thu Jan 23, 2014 8:19 pm

Rob R. wrote:Yep...mixing in some buck might also help get you through the cold spell.


I think you might have a good idea here, I'll have to try it... Thanks.
Brentski
 
Stoker Coal Boiler: Keystoker KA-6

Re: Keystoker problems please help!

PostBy: dlite On: Thu Jan 23, 2014 8:51 pm

Had the same problem with coal over flowing on the edges just 3 weeks ago. You have something caught on the grate which is causing the coal to back up. I took a small hand hoe and scrapped the whole grate hard, sides and all (yes, you will have to restart your fire). Now it works fine, no adjust or changes needed.

Had a leak in my gearbox first year, 2011. Leak was small and very hard to find. Ended up blowing flour on the entire unit to find it was around the shaft. Under warranty so I exchanged with a new one at my dealer.

Hope this helps, Dave
dlite
 
Stoker Coal Boiler: Keystoker KA-6

Re: Keystoker problems please help!

PostBy: Brentski On: Thu Jan 23, 2014 10:13 pm

dlite wrote:Had the same problem with coal over flowing on the edges just 3 weeks ago. You have something caught on the grate which is causing the coal to back up. I took a small hand hoe and scrapped the whole grate hard, sides and all (yes, you will have to restart your fire). Now it works fine, no adjust or changes needed.

Had a leak in my gearbox first year, 2011. Leak was small and very hard to find. Ended up blowing flour on the entire unit to find it was around the shaft. Under warranty so I exchanged with a new one at my dealer.

Hope this helps, Dave



I will shut her down and clean off the grate tomorrow and hopefully I will find something. Will let you know. Thanks
Brentski
 
Stoker Coal Boiler: Keystoker KA-6

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