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Keystoker Econo 90, Installation, Operation And Maintenance Manual

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Keystoker Econo 90 Installation, Operation And Maintenance Manual Download Page 3

Keystoker – Schuylkill Haven, PA 17972                         

Koker, Koker Lite & Econo 90 Stoker Coal Stoves 

© June 2019 REV 4 

 

- 3 -

 

Table of Contents 

 

Safety 

4 

Precautions & Definitions 

4 

General Safety Statements 

4 

 

 

Installation 

5 

 

Stove Placement 

5 

 

Assembly 

6 

Fuel Type 

6 

 

 

Operation 

7 

 

Start-up 

7 

 

Check Draft 

7 

 

Diagram 1 - Continuous Heating 

8 

Diagram 2 – Intermittent Heating 

9 

 

Component Descriptions & Operation   

10 

 

Stoker Unit Components 

10 

Timer 

13 

 

Thermostat 

14 

 

Fan Limit Switch 

14 

 

 

Maintenance 

15 

Cleaning & Lubrication of Stove 

15 

Cleaning Stove Glass 

(not available with all models)

 

15 

Ash Pan Emptying 

16 

 

Gear Motor Removal & Installation 

17 

 

 

Troubleshooting Guide 

19 

 

 

Diagrams 

21 

 

Wiring – Honeywell Relay & Airotronics Timer 

21 

 

Wiring – Direct Vent, Honeywell Relay & Airotronics Timer 

22 

 

Wiring – Taco Relay & Airotronics Timer 

23 

 

Wiring – Direct Vent, Taco Relay & Airotronics Timer 

24 

 

Stove Parts List 

25 

Fire Door & Ash Door Parts Lists 

26 

Ductwork Configurations – Recommended 

27 

Ductwork Configurations – Not Recommended 

29 

 

Warranty 

30 

 

Stove Information 

30 

 

Parts Ordering 

30 

 

 

Stove Contents Checklist 

31 

 

 

Summary of Contents for Econo 90

Page 1: ...June 2019 REV 4 Installation Operation and Maintenance Manual Koker Koker Lite Econo 90 Stoker Coal Stoves Koker Stove Shown...

Page 2: ...thout frequent maintenance They then saw the need to make a hot water boiler specifically designed to burn coal and built them in multiple sizes to meet our customers needs As prices of energy continu...

Page 3: ...4 Fan Limit Switch 14 Maintenance 15 Cleaning Lubrication of Stove 15 Cleaning Stove Glass not available with all models 15 Ash Pan Emptying 16 Gear Motor Removal Installation 17 Troubleshooting Guide...

Page 4: ...al injury Caution Operating procedure practice etc which if not followed could result in damage or destruction of unit Fire Operating procedure practice etc which if not followed could result in sever...

Page 5: ...stove Maintain 16 clearance on sides of stove to combustibles Zero clearance on rear and 16 clearance on front of stove Clearance from corners of stove is 8 See label on stove Refer to Figure 1 FIGURE...

Page 6: ...re to snap thermostat securely onto wall plate 5 Install stove pipe from stove to chimney and secure with screws On top vent models place the non crimped end of pipe of barometric damper down onto the...

Page 7: ...not need to be changed If it becomes necessary to adjust coal feed the white nut on stoker unit may be turned CLOCKWISE for MORE coal feed and COUNTER CLOCK WISE for LESS coal feed NEVER USE A WRENCH...

Page 8: ...n 1 or 2 full turns Wait at least 1 hour before making any more adjustments When thermostat is calling for heat the gear motor will be in continuous run but if the fire bed remains small increase the...

Page 9: ...019 REV 4 9 Diagram 2 Intermittent Heating Depicts what fire size should look like when thermostat has not called for heat for extended periods A Unburned fresh coal supply from hopper B Burning coal...

Page 10: ...101 Stoker Grate 2 2 Side Rail Left 111 Stoker Grate 4 3 Side Rail Right 12 Screw 20UNC x 2 00 Long 4 Washer 5 16 13 Square Nut 5 Nut 5 16 14 Pusher Bar Subassembly 61 Combustion Blower 15 Top Plate S...

Page 11: ...viceable Item Component Item Component 1 Movable Plate 2 7 Insulation Strip 2 Movable Plate 1 8 Stoker Bar 3 Screw 10 24 x Long 9 Threaded Rod 4 Screw 6 32 x 1 00 Long 10 Cap Nut 5 Nylon Screw 10 24 x...

Page 12: ...ll allow coal to fall in front of pusher bar for preparation of next inward stroke The gear motor will only run when activated by a call for heat from thermostat or when timer turns it on AIR INTAKE A...

Page 13: ...ff 4 2 45 seconds on 6 4 3 1 10 minutes off 4 2 Older boiler and Warm Air Furnace idle time without secondary blower Examples 1 min on 6 5 4 3 10 minutes off 4 2 1 min 15 sec on 7 4 2 1 10 minutes off...

Page 14: ...aches this setting normally set around 160 degrees but is adjustable 3 LOW POINTER turns convection blower off when internal air temperature falls to this setting normally set around 120 degrees but i...

Page 15: ...ly at the end of heating season Completely remove all coal from hopper Remove and clean stove pipe Check chimney and base of chimney for obstructions or blockage Clean under grate Cleaning Stove Glass...

Page 16: ...conditions or high demand on stove running periods the stove and stove pipe may need more frequent cleaning Clean as often as necessary CAUTION ASH PAN IS HOT Always Use Gloves to Remove Ash Pan 1 Bef...

Page 17: ...me out with gear motor 6 While pusher bar is out of its chute clean chute area and remove any obstructions Check nylon screws on pusher bar 4 on each side for wear or breakage Replace if necessary 7 S...

Page 18: ...Keystoker Schuylkill Haven PA 17972 Koker Koker Lite Econo 90 Stoker Coal Stoves June 2019 REV 4 18 Fan Screw for Cage FIGURE 11 Screw 10 24 x Long Bottom of Stoker Unit Gear Motor Support Brackets...

Page 19: ...ld run steady If gear motor is running steady but fire is small increase coal feed See pages 8 9 11 If gear motor is not running steady check for loose wire in Thermostat or in Relay Check for broken...

Page 20: ...8 center punch See Page 10 Figure 2 TO CLEAN UNDER OR REPLACE GRATE See Page 15 Cleaning Lubrication Page 10 Figure 2 NYLON CAM MELTS Under normal operating conditions nylon cam will not melt Melting...

Page 21: ...Keystoker Schuylkill Haven PA 17972 Koker Koker Lite Econo 90 Stoker Coal Stoves June 2019 REV 4 21 Diagrams Wiring Thermostat Honeywell Relay Airotronics Timer...

Page 22: ...Keystoker Schuylkill Haven PA 17972 Koker Koker Lite Econo 90 Stoker Coal Stoves June 2019 REV 4 22 Diagrams cont d Wiring Thermostat Direct Vent Honeywell Relay Airotronics Timer...

Page 23: ...Keystoker Schuylkill Haven PA 17972 Koker Koker Lite Econo 90 Stoker Coal Stoves June 2019 REV 4 23 Diagrams cont d Wiring Thermostat Taco Relay Airotronics Timer...

Page 24: ...Keystoker Schuylkill Haven PA 17972 Koker Koker Lite Econo 90 Stoker Coal Stoves June 2019 REV 4 24 Diagrams cont d Wiring Thermostat Direct Vent Taco Relay Airotronics Timer...

Page 25: ...or Subassembly 3 Fire Door Subassembly 4 Limit Control 5 Thermostat Relay 6 Junction Box 7 Room Blower 8 Stoker Subframe 9 Combustion Blower 10 Stoker Subassembly 11 Stoker Fan 12 Hopper 13 Timer 14 B...

Page 26: ...cont d Fire Door Parts List Koker Top Vent Shown Item Component 1 Fire Door 2 Gasket 3 Hinge Pin 4 Hex Nut 5 Lever Handle 6 Glass Gasket1 7 Glass1 8 Glass Clip1 9 Machine Screw 10 Door Latch 1 Optiona...

Page 27: ...Keystoker Schuylkill Haven PA 17972 Koker Koker Lite Econo 90 Stoker Coal Stoves June 2019 REV 4 27 Diagrams cont d Ductwork Recommended Configurations...

Page 28: ...Keystoker Schuylkill Haven PA 17972 Koker Koker Lite Econo 90 Stoker Coal Stoves June 2019 REV 4 28 Diagrams cont d Ductwork Recommended Configurations cont d...

Page 29: ...Keystoker Schuylkill Haven PA 17972 Koker Koker Lite Econo 90 Stoker Coal Stoves June 2019 REV 4 29 Diagrams cont d Ductwork Not Recommended Configurations...

Page 30: ...efective part is returned to the company and found to be a defect within warranty period the consumer s credit card will be credited back the cost of part Keystone Manufacturing Company assumes no res...

Page 31: ...Lite Econo 90 Stoker Coal Stoves June 2019 REV 4 31 Stove Contents Checklist Packed By __________________________________________________________ Manual Carbon Monoxide Detector Charcoal Draft Regula...

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