Keystoker KA6 Burn Plate

I just removed the burn plates from my Keystoker KA6 for the first time and noticed that there was refractory clay packed into the top of the plates where the seams are? I was wondering why this was placed there and whether this was done by the factory or the installer? It looks like there was an attempt to limit air from blowing up through the top of the plates near the coal bin feed. I was debating if I actually need to replace this before I start up again? I was hoping maybe some Keystoker people on this forum might know something about this. Any insight would be greatly appreciated. Thanks

WGC

Yes, its there for a reason to stop the air flow around the grates, and make it go thru the holes.
You may get improper burning if not sealed properly.

there are numerous topics on this of re-sealing the grates.

Thanks for the info WNY. I will definitely re-seal this before I start up again.

Don't overlook scraping/grinding the grates to make the reassembly clean and well aligned. It is not about smearing a wad or two of furnace cement, it is about proper alignment and fit to make sure you are not allowing the air to escape through the grates, or adjacent areas. Take the time to get it right.....please.

Thanks for the info. Much appreciated. I noticed that the burn plates didn't go back in all that easy. Did anyone here have good luck with a particular brand of furnace cement?

Have you called Keystoker?

Didn't call Keystoker yet. I think the problem is that the plates need to be cleaned a little better. I'm still shut down for the summer so no hurry. My installer performed the PM last year but never returned my phone call this year. Looks like I'm on my own now.

I have been noticing quite a bit of unburned coal so I was thinking about thinning out the coal bed on the burn plate. Looks to be about 2.5 inches or so thick. Has anyone had any luck trying to adjust this? The unburned coal problem always existed since it was installed back in Jan 2012. Just looks a bit worse recently. Of course the draft was not optimal either but that's besides the point. I'm thinking that a thinner coal bed on the burn plate would allow a more efficient burn.

did you run a small drill bit thru the holes also?

you will always have a certain amount of unburnt coal depending on how's it burning, feed rate, etc...sometimes the coal rides along the sides and never gets burnt. variety of reasons. but there are some threads on unburnt coal, sometimes it just happens.

Sounds like you are on your way to maintaining and tweeking your boiler. you will find a lot of info on here. We've all been thru it before.

If you do not get the upper portion of the grates sealed like they were from new you will end up creating a hopper fire because air will be blowing through that coal at the top of the grates. Been there, done that! Pay close attention to where the cement was when you removed the grates and reseal those same areas with new after you clean all the old stuff off.

WindGapCoal wrote:Didn't call Keystoker yet. I think the problem is that the plates need to be cleaned a little better. I'm still shut down for the summer so no hurry. My installer performed the PM last year but never returned my phone call this year. Looks like I'm on my own now.

I have been noticing quite a bit of unburned coal so I was thinking about thinning out the coal bed on the burn plate. Looks to be about 2.5 inches or so thick. Has anyone had any luck trying to adjust this? The unburned coal problem always existed since it was installed back in Jan 2012. Just looks a bit worse recently. Of course the draft was not optimal either but that's besides the point. I'm thinking that a thinner coal bed on the burn plate would allow a more efficient burn.

If you want I can stop in and check unit and coal ash out for you. I go thru Windgap everyday if that's your location. Best way to let me now is pm me, I'll get email alert.

Looks like I got my work cut out for me before start up time. Unfortunately I disposed all of the ash with the weekly garbage so there is no ash left from the burn season. I read that the ash is loaded with Arsenic so I decided not to dump it on the property. The ash looked about 20-30% unburned so I know something is not set right. I'm just glad that the trash collector is taking this stuff since the bags are about at the 40 lb weight limit for pickup. Anyway, drilling out the plate holes seems like a really good idea to start with. Also, placing the flashlight on the plates and looking through the blower duct is a good tip. You guys have some very good ideas and I appreciate all of the suggestions. WGC

Don't drill holes bigger!!! Only use small bit to clean holes.... where are u getting coal from... most likely that might be the only issue

I will definitely be careful NOT to drill the holes bigger. I imagine there is a fine balance between getting enough air for a good burn and not choking the air flow with ash falling through the holes. This is the first year I took the burn plates off to clean and I definitely had some ash piled under the burn plates. My installer is no longer performing PM's on residential systems anymore so I figured I'd give it a try. He probably never cleaned below the burn plates by the looks of the amount of stuff under there. Anyway, as far as the ash goes, it definitely looked like there was unburned coal because if I would brake the black pieces in half, they looked shinny like anthracite. Any shale in the ash mix wouldn't look shinny. My local supplier (Aerni and Hitzel) is getting Blashack coal from somewhere. At least it's lower in fly ash. I burned Jeddo coal last year and it seemed I had way too much fly ash. I am a relative beginner to the ways of the Keystoker so I definitely appreciate everyone's words of wisdom.