Looking for help with a new kaa-4-1 boiler install

Re: Looking for help with a new kaa-4-1 boiler install

PostBy: StokerDon On: Sat Dec 17, 2016 7:37 pm

Thanks for the tour Rodmo!

That is some serious look'in insulation on your pipes, nice.

Two minor points of criticism; The bypass should go into the opposite return port, or a crossover pipe. The air scoop needs 18 pipe diameters of strait pipe in front of it to work at its best. Not a big deal, it will still work the way it is.

What kind of coal are you using that comes with all those big rocks?

-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

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Re: Looking for help with a new kaa-4-1 boiler install

PostBy: rodmo1 On: Sat Dec 17, 2016 10:53 pm

Thanks Don! I wanted to put more straight pipe in front of the scoop but just couldn't do it in any way that wouldn't look like a spiderweb. It seems to do the job well as the radiators haven't seemed to pick up any air. I added the insulation a few winters ago because the original was largely in tatters and it was a struggle to get the house comfortable. Cost a good bit of money for what it is but probably worth it. The coal I'm burning is whatever TSC sells in our area. I am going to buy several tons loose in the next week or so.
rodmo1
 
Stoker Coal Boiler: kaa-4-1
Other Heating: oil and outdoor wood boiler

Re: Looking for help with a new kaa-4-1 boiler install

PostBy: CoalisCoolxWarm On: Sat Dec 17, 2016 11:18 pm

Nice video!

I can't tell from the video how much slope you have in your horizontal flue pipe?

I did have to chuckle when you said how much cement you used for the thimble. It seems always a challenge to fit pipe to thimble to chimney ;)
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: Looking for help with a new kaa-4-1 boiler install

PostBy: rodmo1 On: Tue Apr 25, 2017 5:10 pm

Thought I would give an end of season review on my kaa-4-1 while it is cold and raining outside. I am EXTREMELY happy with the boiler. It has saved me a lot of my heating cost had I burned oil this season. It probably saved my marriage had I been using my outdoor wood boiler this season as I was travelling extensively for work all winter. I didn't keep close tallies of my coal consumption as I would pick it up here and there in my truck and sometimes would grab a few bags at tractor supply if I was picking up feed. If I had to guess I would say close to 4 tons but I am heating a large old farmhouse to 70 degrees as well as my DHW so that is pretty good. It was an extremely warm winter here so it will be interesting to see if we ever get back to normal winters for a change. I let it go out 2 weeks ago when we had a few days near 80...unfortunately today it is barely 50 and raining so I have the wood stove burning at the moment. I had to set my hi limit to 200 due to 190 causing too many dump cycles. With the volume of water in my gravity fed system I should have probably gone with the KA6 since on warmer days it pushes out the heat and then sucks in all the cold water out of my 2" loop causing extreme temperature fluctuations within the boiler....190-90. The added gallons of the KA6 would have likely made a good difference in buffering this out. BTU wise it is very capable of heating my house. It works great when the temps get into the 20's and below. Keystoker seems to have made a quality product although I would have made a few design changes that I listed in previous posts. The only complaint I have (and it may be due to my mixing valve) is that I can not get enough DHW out of the system. I had to modify my plumbing so that the DHW coil feeds into my electric hot water tank. This doesn't bother me too much as it likely consumes little energy but I am surprised that this is a problem. Farming season is well underway but I hope to get the boiler and stovepipe cleaned up and ready for next season one of these rainy days. I am surprised how much fly ash is created by coal heat and am very happy I put a clean out at the bottom of the stovepipe entrance into the boiler. That makes it very easy to avoid clogged flue. My brother bought a new house this winter similar to mine and is unhappy with his oil consumption so I keep trying to talk him into switching to coal. Quite a few nice refurbished units on Craigslist...Hopefully he bites on one. Until then he is making a lot of repairs that the energy audit recommended for him.
rodmo1
 
Stoker Coal Boiler: kaa-4-1
Other Heating: oil and outdoor wood boiler

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