KA4 project (pic heavy)

KA4 project (pic heavy)

PostBy: Qtown1835 On: Tue Dec 06, 2016 7:32 pm

**sorry pics are rotated, loaded from phone**

I picked up a project boiler the day. After reading all of these posts here I do believe I got boiler envy so I decided to get my feet wet. 8-)

Does anyone with a newer keystone have a picture of the secondary air setup? I am curious to see how that fits into the existing assembly.

Few pics of the project. Needs some attention but over all in decent shape for the price.
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After some rudimentary cleaning.
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Couple areas needing attention. Are the thankless coil studs and 1 of the stoker grates is cracked looks like air ports were clogged and overfired the cast. I will be replacing the studs this weekend at some point so i can pressure test the vessel.
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Qtown1835
 
Stoker Coal Boiler: Keystoker '81 KA4 (online 1/16/17)
Hand Fed Coal Stove: Harman MKIII
Coal Size/Type: Nut & Rice Lehigh
Other Heating: EFM SPK600

Visit Leisure Line

Re: KA4 project (pic heavy)

PostBy: StokerDon On: Tue Dec 06, 2016 7:58 pm

Looks like the one that I was thinking about getting last weekend. If it is, that was a good deal!

By secondary air, do you mean the little blower they ad onto the back of the bigger stokers? If so, that is only to help if you are experiencing out-fires. It constantly blows air through the coal bed. This uses up the coal on the grate quicker and blows some of the heat out the chimney. I put one on my Yellow Flame a couple years ago.
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I got the kit from Keystoker. I think it was for a K-6.

Fix up those DHW studs and let's see a pressure test!

-DOn
StokerDon
 
Stoker Coal Boiler: BairMatic BMC-500 with Van Wert VA400 Stoker, Gentleman Janitor GJ-671/EFM S-15 stoker, Van Wert VA-600
Hand Fed Coal Furnace: Harman SF3500
Coal Size/Type: Rice and Chestnut
Other Heating: Noth'in but COAL! Well, Maybe a little tiny bit of wood

Re: KA4 project (pic heavy)

PostBy: Qtown1835 On: Tue Dec 06, 2016 8:05 pm

Thanks Don. Only reason I inquired is because I reached out to keystoker about the boiler and Brian recommended putting secondary air on and also mentioned replacing the coil tunnel so it sits 2.5" from the boiler jacket. Not sure what he meant by that. I don't recon I need the secondary air having that same feeling you mentioned, just burn the coal faster and heat the outside.
Qtown1835
 
Stoker Coal Boiler: Keystoker '81 KA4 (online 1/16/17)
Hand Fed Coal Stove: Harman MKIII
Coal Size/Type: Nut & Rice Lehigh
Other Heating: EFM SPK600

Re: KA4 project (pic heavy)

PostBy: lzaharis On: Tue Dec 06, 2016 8:45 pm

I have a KAA-4-1 with the single squirrel cage blower purchased and brought home in October and I am very happy with it and I have no need for the secondary blower as my Intermatic 30 minute timer is set to run with 8 pins at Zero minutes and 9 pins at Fifteen minutes. I have 9 threads on the stokers pusher plate. The KAA-4-1 runs very well at these temperatures with no overshoots or high temperatures approaching a boiler blowoff.

My boiler temps are 120 low 150 high with a fifteen degree differential. I am burning rice coal in my boiler. I Am Very Happy with the controls and the boiler now that the Hydrostat controls have been replaced.

I will caution you to avoid digital controls for it as the factory supplied controls and I would not trust the chinese gauges supplied by them as they malfunctioned on me twice and I have replaced them with Honeywell mechanical controls specifically the Honeywell L8124L1011 horizontal triple aquastat and completely separate B+G Bulldog RB-122-E Low Water Cut Off wired as the primary control before the triple Aquastat to shut the boiler down in the event of a low water condition. The Second Hydrostat 3250 Plus turned off the LWCO function as I was testing the boiler on oil when I replaced the second unit and that killed the idea of using a third Hydrostat 3250 plus for me as well as an integral LWCO function in a triple aquastat.

I have a New Marsh instruments "MArshalltown Triple Gauge to watch over the temperatures and boiler pressure too.

I had the boiler rewired as Keystoker would not supply me with Honeywell replacement unit for the keystoker KAA-4-1 and I am glad I had it rewired as it is much safer to run now with the Honeywell controls "IN MY OPINION".
Last edited by lzaharis on Tue Dec 06, 2016 8:54 pm, edited 1 time in total.
lzaharis
 
Stoker Coal Boiler: Keystoker KAA-4-1 dual fuel boiler
Coal Size/Type: rice
Other Heating: kerosene for dual fuel Keystoker

Re: KA4 project (pic heavy)

PostBy: StokerDon On: Tue Dec 06, 2016 8:52 pm

YUP! unless you are having problems, I would leave the continuous blower out of it.

The "coil tunnel" Brian was talking about is an extended flange to mount the DHW coil. It sticks out from the jacket making it easy to check for leaks. This is worth doing if you have the time to take it to a welder. DHW coil leaks are the number one cause of premature boiler death. A side benefit is there are no more broken coil studs to deal with, just nuts and bolts.

-Don
StokerDon
 
Stoker Coal Boiler: BairMatic BMC-500 with Van Wert VA400 Stoker, Gentleman Janitor GJ-671/EFM S-15 stoker, Van Wert VA-600
Hand Fed Coal Furnace: Harman SF3500
Coal Size/Type: Rice and Chestnut
Other Heating: Noth'in but COAL! Well, Maybe a little tiny bit of wood

Re: KA4 project (pic heavy)

PostBy: Rob R. On: Tue Dec 06, 2016 9:13 pm

Nice boiler. Don't fret over the cracked stoker grates, get a new set and be done with it. The extended coil mount is a nice upgrade, but yours could easily be repaired with just studs.

I would forget about the secondary blower unless you later discover that you have problems with outfires. There is a nice post on here somewhere about how to install it.
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: KA4 project (pic heavy)

PostBy: McGiever On: Tue Dec 06, 2016 11:23 pm

McGiever
 
Stoker Coal Boiler: AXEMAN-ANDERSON 130 "1959"
Coal Size/Type: PEA / ANTHRACITE
Other Heating: Ground Source Heat Pump
Stove/Furnace Make: Hydro Heat /Mega Tek

Re: KA4 project (pic heavy)

PostBy: McGiever On: Tue Dec 06, 2016 11:29 pm

StokerDon wrote:YUP! unless you are having problems, I would leave the continuous blower out of it.

The "coil tunnel" Brian was talking about is an extended flange to mount the DHW coil. It sticks out from the jacket making it easy to check for leaks. This is worth doing if you have the time to take it to a welder. DHW coil leaks are the number one cause of premature boiler death. A side benefit is there are no more broken coil studs to deal with, just nuts and bolts.

-Don


There it is:

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McGiever
 
Stoker Coal Boiler: AXEMAN-ANDERSON 130 "1959"
Coal Size/Type: PEA / ANTHRACITE
Other Heating: Ground Source Heat Pump
Stove/Furnace Make: Hydro Heat /Mega Tek

Visit Leisure Line

Re: KA4 project (pic heavy)

PostBy: CoalisCoolxWarm On: Wed Dec 07, 2016 12:35 am

My KA6 continuous fan is the smaller black one piggy-backed off the end of the stoker grate.

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I use buckwheat and my "idle fan" runs continuously.

I just posted all my wiring with pics in this thread for another member: http://nepacrossroads.com/about43001.html

Here's the flange on the DHW coil

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Hope these help! :cheers:
CoalisCoolxWarm
 
Stoker Coal Boiler: Keystoker KA-6
Hand Fed Coal Furnace: old Sears rebuilt, bituminous- offline as of winter 2014
Coal Size/Type: Anthracite Buckwheat
Other Heating: Oil Boiler

Re: KA4 project (pic heavy)

PostBy: Qtown1835 On: Wed Dec 07, 2016 10:50 am

Thanks for the info guys. After looking at the DHW flange, i think i will pass. Installing new stainless studs will be an easy fix and should last another 30+ years without hassle. I will hold judgement on the secondary air until i know i can operate effectively with the stoker fan on timer. The stoker came with all of the original install honeywell controls and US made pressure/temp gauge which is cool. I do plan on replacing the timer with a new macromatic timer though as the old mercoid timer does not have the flexibility available as with the macromatic.
Qtown1835
 
Stoker Coal Boiler: Keystoker '81 KA4 (online 1/16/17)
Hand Fed Coal Stove: Harman MKIII
Coal Size/Type: Nut & Rice Lehigh
Other Heating: EFM SPK600

Re: KA4 project (pic heavy)

PostBy: lzaharis On: Wed Dec 07, 2016 11:41 am

If you use and purchase rice coal and invest in a new Intermatic 30 minute timer and spare timer motor coal and set it at 8 pins at 15 minutes and 9 pins at 30 minutes you will not need the secondary fan to complicate things and you will use less coal.
lzaharis
 
Stoker Coal Boiler: Keystoker KAA-4-1 dual fuel boiler
Coal Size/Type: rice
Other Heating: kerosene for dual fuel Keystoker

Re: KA4 project (pic heavy)

PostBy: McGiever On: Wed Dec 07, 2016 1:53 pm

`
Last edited by McGiever on Wed Dec 07, 2016 1:54 pm, edited 1 time in total.
McGiever
 
Stoker Coal Boiler: AXEMAN-ANDERSON 130 "1959"
Coal Size/Type: PEA / ANTHRACITE
Other Heating: Ground Source Heat Pump
Stove/Furnace Make: Hydro Heat /Mega Tek

Re: KA4 project (pic heavy)

PostBy: McGiever On: Wed Dec 07, 2016 1:54 pm

Hello Leon,

You do realize this is Not the same as your AA size stoker boiler, but instead is an older A size stoker boiler little brother to a KA6...no nylon plastic componets were ever used in any A size stokers...day and nite different. ;)

lzaharis wrote:I have a KAA-4-1 with the single squirrel cage blower purchased and brought home in October and I am very happy with it and I have no need for the secondary blower as my Intermatic 30 minute timer is set to run with 8 pins at Zero minutes and 9 pins at Fifteen minutes. I have 9 threads on the stokers pusher plate. The KAA-4-1 runs very well at these temperatures with no overshoots or high temperatures approaching a boiler blowoff.

My boiler temps are 120 low 150 high with a fifteen degree differential. I am burning rice coal in my boiler. I Am Very Happy with the controls and the boiler now that the Hydrostat controls have been replaced.

I will caution you to avoid digital controls for it as the factory supplied controls and I would not trust the chinese gauges supplied by them as they malfunctioned on me twice and I have replaced them with Honeywell mechanical controls specifically the Honeywell L8124L1011 horizontal triple aquastat and completely separate B+G Bulldog RB-122-E Low Water Cut Off wired as the primary control before the triple Aquastat to shut the boiler down in the event of a low water condition. The Second Hydrostat 3250 Plus turned off the LWCO function as I was testing the boiler on oil when I replaced the second unit and that killed the idea of using a third Hydrostat 3250 plus for me as well as an integral LWCO function in a triple aquastat.

I have a New Marsh instruments "MArshalltown Triple Gauge to watch over the temperatures and boiler pressure too.

I had the boiler rewired as Keystoker would not supply me with Honeywell replacement unit for the keystoker KAA-4-1 and I am glad I had it rewired as it is much safer to run now with the Honeywell controls "IN MY OPINION".
McGiever
 
Stoker Coal Boiler: AXEMAN-ANDERSON 130 "1959"
Coal Size/Type: PEA / ANTHRACITE
Other Heating: Ground Source Heat Pump
Stove/Furnace Make: Hydro Heat /Mega Tek

Re: KA4 project (pic heavy)

PostBy: lzaharis On: Wed Dec 07, 2016 6:20 pm

Hello Mcgiever,

Whoopsie, :oops:
Seeing the AA model stoker in the brochure made
me think it had the same unit.
lzaharis
 
Stoker Coal Boiler: Keystoker KAA-4-1 dual fuel boiler
Coal Size/Type: rice
Other Heating: kerosene for dual fuel Keystoker

Re: KA4 project (pic heavy)

PostBy: Qtown1835 On: Wed Dec 07, 2016 8:49 pm

Thanks for all the feedback. I'm going to pick up some 3/8x16 SS tap bolts tomorrow to replace the studs. Not sure if I should just do all of them or the ones that are thinned out. I will be using brass nuts.

Anyone have a good place to buy the coil gasket?

As for the pressure test for the vessel I was thinking 40-45psi should be adequate. Since operating pressure will be 12-15psi and blow-off operates at 30psi. That would give me 1.5x safety range.
Qtown1835
 
Stoker Coal Boiler: Keystoker '81 KA4 (online 1/16/17)
Hand Fed Coal Stove: Harman MKIII
Coal Size/Type: Nut & Rice Lehigh
Other Heating: EFM SPK600

Visit Leisure Line