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KSM-Stoker KSM-Multistoker XXL, User Manual, Page: 9 / 92

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KSM-Stoker KSM-Multistoker XXL User Manual Download Page 9

 

- 9 - 

23.1 Unburned fuel in the ashes. ......................................................................................................... 83

 

23.2 The boiler becomes sooty. .......................................................................................................... 83

 

23.3 Black display. .............................................................................................................................. 83

 

23.4 Combustion air fan does not run during plant run. ..................................................................... 83

 

23.5 The screw does not run ............................................................................................................... 83

 

23.6 Backfire. ...................................................................................................................................... 84

 

23.7 Clinker. ........................................................................................................................................ 84

 

23.8   Bothering smoke. ...................................................................................................................... 84

 

23.9 Condensed water in flue gas outlet. ............................................................................................ 84

 

24.0 Alarm list......................................................................................................................................... 85

 

25.0 Installation instructions. .................................................................................................................. 86

 

25.1 The boiler room ........................................................................................................................... 86

 

25.2 Stoker .......................................................................................................................................... 86

 

25.2.1 Placing .................................................................................................................................. 86

 

25.2.2 Flue gas outlet. ..................................................................................................................... 86

 

25.2.3 Piping. .................................................................................................................................. 87

 

25.2.4 Anti-freeze measures............................................................................................................ 87

 

25.2.5. Check the screw direction of rotation ................................................................................. 87

 

25.2.6. Sprinkler, water connection ................................................................................................ 88

 

25.2.7 Starting Up. .......................................................................................................................... 88

 

26.0 Accessories...................................................................................................................................... 88

 

27.0 Piping Diagram. .............................................................................................................................. 89

 

28.0 Power Diagram. .............................................................................................................................. 90

 

29.0 Dimension drawings ....................................................................................................................... 91

 

30.0 Formula WEB Setup. ...................................................................................................................... 92

 

 
 

 

Summary of Contents for KSM-Multistoker XXL

Page 1: ...1 User manual KSM Multistoker XXL With PCT400 O2 Controller Dealer Save money Install a KSM Stoker...

Page 2: ...ksm stoker dk hereby declare that KSM Multistoker _____ _____ series No ___________ CE nr 2006 97 56 EEC 016 has been manufactured in conformity with the prescriptions of the EU Machinery Directive d...

Page 3: ...Software instructions 19 7 1 Logs 19 7 2 Run 19 7 2 1 Boiler temp 19 7 2 1 1 Set temperature C 19 7 2 1 2 Go pause temp C 19 7 2 1 3 Back to run mode C 19 7 2 1 4 Max output 19 7 2 1 5 Min output 20...

Page 4: ...Pause 24 7 4 1 Stoker screw 24 7 4 1 1 Pause fuel s 24 7 4 1 2 Pause in minutes 24 7 4 1 3 Empty run in minutes 24 7 4 2 Fan 24 7 4 2 1 Output 24 7 4 2 2 Fan on time 25 7 4 3 Oxy go to pause 25 7 5 Fu...

Page 5: ...6 Boiler cleaner 29 7 6 6 1 Run time in seconds 29 7 6 6 2 Pause in hours 29 7 6 7 Flue fan 29 7 6 7 1 Flue fan prestart s 30 7 6 7 2 Flue fan stop delay m 30 7 6 7 3 Flue fan 100 60 40 30 20 and 0 30...

Page 6: ...7 7 4 Boiler shunt SP 34 7 7 5 Heat circuit 34 7 7 6 Show pump info 34 7 7 7 Buffer tank 34 7 7 7 1 Buffer temp top C 34 7 7 7 2 Buffer temp bottom C 34 7 7 7 3 Shunt close time m 34 7 7 8 Cascade 34...

Page 7: ...Sensor 48 13 2 1 O2 Sensor Calibration 49 13 3 Air Nozzles 49 13 4 Chamot stone 50 13 4 1 Guideline for chamotstone in the burning chamber 51 13 4 2 Chamotstone Maintenance 51 13 5 Combustion fans 52...

Page 8: ...4 Maximum Heat Thermostat 74 16 5 Water pressure switch 74 17 0 WEB interface 75 18 0 Log file 77 19 0 SMS warning system 78 20 0 Precautionary Measures 79 20 1 Fire Protection thermal 79 20 2 Persona...

Page 9: ...ndensed water in flue gas outlet 84 24 0 Alarm list 85 25 0 Installation instructions 86 25 1 The boiler room 86 25 2 Stoker 86 25 2 1 Placing 86 25 2 2 Flue gas outlet 86 25 2 3 Piping 87 25 2 4 Anti...

Page 10: ...ad that have hydraulic moving fire grate this is a big advance when burning biomasses that have a high content of clinker or ash KSM Multistoker XXL is fitted with 2 ash augers one in the boiler botto...

Page 11: ...ot of different quality but KSM only guarantee the output on the boiler when using Wood Chip in the correct quality The tested output are guaranteed when using Wood Chip According to the standard in O...

Page 12: ...he spare parts For exchanged wear parts the guarantee period is 6 months from the date of delivery For all other exchanged parts the guarantee period is 1 year from the date of delivery Comments 1 Dec...

Page 13: ...ective Additives NAME UNIT RANGE Phosphate P2O5 g m3 5 30 Polysilicate SiO2 g m3 20 60 Alkaline Polyamide g m3 10 50 Sulphite SO3 g m3 10 30 Other suitable protective additives may be utilised provide...

Page 14: ...colour monitor and have its own Web server which gives the perfect opportunity to fully monitor and operate the boiler when it is connected to the internet with every kind of hardware which has acces...

Page 15: ...w Smoke fan Fan 1 and 2 Damper motor Damper switch Fuel sensor Stoker screw Functions which cannot be illustrated on the picture are placed in info boxes at the bottom of the picture The green LEDs ar...

Page 16: ...er the whole system will shut down MENU With this button the menu is activated and here it is possible for you to make your desired adjustments If you have had an alarm it will write BACK above the me...

Page 17: ...on 6 If the boiler is without automatic ignition you have to use some flammable liquid but NEVER petrol to put on the fire 7 When the fire is burning well you have to activate the stoker auger again b...

Page 18: ...full filled 9 The empty run time have to be run out 10 The O2 level have to be higher than the limit The empty run timer is only used if you run the boiler with the ignition type Auto w empty In all o...

Page 19: ...apter you can find all parameters concerned the boiler temperature while operating 7 2 1 1 Set temperature C Menu Run Boiler temp Set temp C 75 C The working temperature of the boiler To keep the corr...

Page 20: ...is set to 0 the stoker screw is controlled by the O2 measurements but if you set in a value the stoker screw will be locked and run that time when it goes To use the function the controller can t be...

Page 21: ...kerscrew When the boiler startup it is important that the volume of fuel is correct and for that the next parameter have to be adjusted correct 7 3 1 1 1 Start fuel Menu Startup Stokerscrew 1 Start fu...

Page 22: ...ller are in start up mode this parameter control when the controller recognize that there are fire in the burn head again How it works depend on do the boiler have Automatic ignition or not With no ig...

Page 23: ...is above the value in chapter 7 3 2 1 when the ignition delay s has expired the controller switch to ignition or start up if no ignition are installed 7 3 6 2 Fuel delay Menu Start up Ignition Fuel de...

Page 24: ...ew Pause fuel s 2 sek Is the value for how long the screw shall run every time the pause feeding is activated An appropriate time to run the stoker screw is the same as maximum time for the stoker scr...

Page 25: ...r different type of fuel Then the client can adjust each program to the fuel they are using and in the future it is then easier to change fuel Program 1 Pellets Program 2 Woodchip Program 3 Sawdust Pr...

Page 26: ...min the transport auger will not start before 1 min after the fuel sensor indicate that fuel is needed 7 6 1 5 Stop delay s Menu Accessories Transport auger Stop delay s 2 sek To make sure that the t...

Page 27: ...1 255 7 6 1 10 2 Fuel div Menu Accessories Transport auger Fuel div 10 Weight decimals 1 1 255 kg 10 0 1 25 5 kg and 100 0 01 2 55 kg 7 6 1 10 3 Fuel s Menu Accessories Transport auger Fuel s 0 sek T...

Page 28: ...1 to 3 The firegrates move the fuel forward in the burning chamber and also the ash to the ash auger Firegrate number 1 3 is only used on boilers type XXL how many grates depend off the boiler size If...

Page 29: ...t is the same process for the adjustment for all the used fans 7 6 6 Boiler cleaner Menu Accessories Boiler cleaner These parameters control how often and how much the heat exchanger shall be cleaned...

Page 30: ...has to be set at 100 to adjust the flue fan go to the menu shown below Menu Accessories Flue fan Flue fan 100 and insert 100 Menu Accessories Flue fan Flue fan 60 and insert 100 Menu Accessories Flue...

Page 31: ...sories Cyclon bagfilter Filter ash on s 15 sek This parameter controls the running time for ash auger at the Bagfilter 7 6 9 7 Filter ash pause m Menu Accessories Cyclon bagfilter Filter ash pause m 1...

Page 32: ...e dosage Menu Accessories Lime dosage 5 Especially when using grain and grain waste as fuel it is an advantage to add lime The value which is inserted is the calcium dispenser s run time in of the run...

Page 33: ...play to be equal the value on the sensor 7 7 Heating system Menu Heating system In the following chapters you will find the parameter that control the components in the heating system Circulation pump...

Page 34: ...this function 7 7 7 1 Buffer temp top C Menu Heating system Buffer tank Buffer temp top C 50 C When the buffer tank top temperature comes below this value the boiler will start up again and reheat the...

Page 35: ...30 Since we don t want the Master to send start or stop command as soon as the load change we have this delay time So even if the load is higher or lower than the limit the Master will wait the time...

Page 36: ...that are placed next in the chain 7 7 8 9 IP 3 Menu Heating system Cascade IP 3 Ip adresse 3 on the boiler that are placed next in the chain 7 7 8 10 IP 4 Menu Heating system Cascade IP 4 Ip adresse 4...

Page 37: ...Minute Menu Date Hour Menu Date Weekday Menu Date Date Menu Date Month Menu Date Year Menu Date Activate time After adjusting the clock it have to be activated please note if the boiler have been out...

Page 38: ...efan Fluefan alarm Check Fan and inverter Transport SW Service lid is open Remove the blocking fuel Module comm alarm Cable or module Check module Alarm hydraulic pump Electrical motor at the hydrauli...

Page 39: ...The P3 give us the following information P is an expression that the module is missing a phase 3 is the number on the phase which is missing The alarms in the black boxes can only be removed when the...

Page 40: ...set temperature stop and wait until the temperature have dropped in the system and the boiler will start up again It is the most common way to run our boiler for pellets in the range 12 125kW and the...

Page 41: ...lue the controller goes into run mode If not it goes to step 15 9 5 Ignition alarm A Ignition timeout 10 If the O2 don t drops before the end of the timer Ignition timeout 11 A alarm will come up on t...

Page 42: ...he speed on a pump according to the measured and the wanted temperature The pump is regulated with 0 10V 3 PID regulator to control a 3 way valve according to the measured and the wanted temperature T...

Page 43: ...utput When the 3 way valve is closed the circulation pump will stop If the boiler has ignition installed the boiler will start to shut down at the same time as the 3 way valve start to close Start the...

Page 44: ...iler after the specified running hours as Master There is no limit for how many boilers the Cascade software can control and other brand of Biomass Oil or Gas boilers can be controlled as well If the...

Page 45: ...the same way as start the load on the master have to be below the limit in more than the delay time before a slave will be stopped 12 1 4 Delay start stop Menu Heating system Cascade Delay m 30 Since...

Page 46: ...for the WEB Communication The numbers that have to be set in the menu shown below is the numbers on the next boiler in the chain Menu Heating system Cascade Port Menu Heating system Cascade IP 1 Menu...

Page 47: ...mmands 12 4 Log info In the loggen all the command the masteren send to the slave will be written 16 02 18 16 15 26 Sent to slave 192 168 210 90 90 CMD 6 value 0 16 02 18 16 15 32 Sent to slave 192 16...

Page 48: ...oving fire grate On the picture above all the main parts on the boiler are shown with description in the next chapters a detailed description will follow 13 2 O2 Sensor The XXL boiler have O2 controll...

Page 49: ...to calibrate Main Menu uk Service o Calibrate O2 Just press shortly at the menu and it is calibrated If the reading is still wrong a new O2 sensor is needed By replacing a O2 sensor the new one must...

Page 50: ...he burner and closed when they are pulled out The direction ogf the handel indicate the direction of the air flow KSM recommend that the nozzles are cleaned minimum once a year 13 4 Chamot stone The b...

Page 51: ...d with chamot stone 13 4 1 Guideline for chamotstone in the burning chamber Fuel Water content Roof Side stone Wood chip 30 50 100 100 with extra insulation behind Wood chip 20 40 100 100 Wood chip 15...

Page 52: ...boiler size The secondary fan supplies all the air nozzle in the side off the burning chamber The picture below show how the fan are placed on 300 400 and 500XXL the bigger boiler have more zone below...

Page 53: ...Variable Speed Drive placed The picture below is from a KSM 500XXL boiler Above each inverter is placed an automatic fuse The inverter are controlled from a PCT425 board with 0 10V 13 5 1 Fan Mainten...

Page 54: ...an the hose take it off the pressure transmitter and blow backwards into the boiler NEVER blow into the transmitter it will brake it It is possibly to adjust the under pressure in the boiler with para...

Page 55: ...elf Since the XXL boiler always need to be installed with a multi cyclone the flue fan are mostly placed on the side of that one There can be 2 reasons to clean the flue fan 1 The Flue fan are vibrati...

Page 56: ...te has to run more than the next and the last grate where the fuel almost is burned before it arrives has to run at least It is important that the grates are adjusted correct If the grates are running...

Page 57: ...ture below you can see all the parts concerned the ash screw and scraping system Ash auger Ash exit Moving floor Service door When you make service inspection you have to ensure that when the scrape i...

Page 58: ...the moving floor running perfect When demounting the grates you start with the upper one first which are in the back of the boiler You do not need any kind of special tools to demount the grates they...

Page 59: ...e and bearings you can to take of covers around the boiler The bearings on the fire grate shaft must be greased once a year as minimum At the same time as greasing the bearings the hydraulic hoses and...

Page 60: ...omatic adjust the oil flow according to how many cylinders are activated so they always go with the same speed The hydraulic unit are placed on the back of the boiler Standby pressure 50 55Bar Valve t...

Page 61: ...come up if it get to hot Oil level In the case of too low level of oil in the tank this alarm will be activated and it is not possibly to run the system before oil have been refilled Oil temperatur In...

Page 62: ...ep the correct under pressure in the boiler Adjustments of the ash auger are done as described in chapter 7 6 2 It is important that the bottom ash screw is filled covered with ash If not the is a ris...

Page 63: ...e pipes there are mounted spirals which have two functions They clean the heat exchanger pipe when they rotate and because off those spiral the speed of the hot smoke gasses will be slower that reduce...

Page 64: ...run for about 2 3 sec before you stop it 4 The door can be opened When you are done cleaning and the spirals are mounted again it is important that the clutches on the spirals are vertical and that th...

Page 65: ...stopped The level of the fuel can from this point be checked The fuel sensor have a ermitter and a receiver when the signal between them is interrupted the fuel transport system will stop Maintenance...

Page 66: ...Transport SW will be released If the Transport SW is off for more than 4 sek The transport auger will stop and a yellow alarm box will pop up on the display If SMS warning system is connected the cli...

Page 67: ...per miss 5 10 to full open the flame damper switch will be activated and change to green If you don t get the SW signal in 3 minutes an alarm will popup saying Damper Timeout There can be 3 reason for...

Page 68: ...e is a small delay from auger 1 is started until auger 2 is started and so on And the same when they stop the reason is to prevent the fuel blocking op between the augers Step 5 Fuel sensor When the f...

Page 69: ...s transport delayed stop s 5 The transport has stopped 6 the fire damper closes 7 Transport alert expiration of time in menu accessories transport transport timeout 12 10 22 10 19 05 Fuel from 5 to 6...

Page 70: ...the transport auger will be started 2 If the fuel sensor over the bottom fuel auger give the signal empty The lamp on the screen for the sensor will change to green 3 Hydraulic unit start and the lam...

Page 71: ...sting screw On the sensor you can find a little adjusting screw if it is turned right the switch distance become longer and if it is turned left the distance become shorter To make a correct adjusting...

Page 72: ...120 og 150 Bar and can be read on the pressure gauge on the hydraulic block Adjustment of the switching pressure should be performed only by qualified service personnel the switch pressure should be c...

Page 73: ...ature this alarm will be activated and it is not possibly to run the system before oil are cooled down Hydraulic timeout If the fuel storage is empty it makes no sense to keep on running the hydraulic...

Page 74: ...off the electric power to the stoker if the lid is opened This is to protect you against any damage while handling screw or stirring device 16 3 Electric Protection Fuses The KSM Stoker control is fu...

Page 75: ...have to press the menu button to get access to the menu as you know it from the boiler If you press the Log button a new page will popup with all the logging date please see more in next chapter If t...

Page 76: ...ed password 7 Enter the Port no that is setup in the router 90 When everything is entered please restart the controller and it is ready to use To check if the LAN connection is running correct the wat...

Page 77: ...3 9 10 0 60 0 34 2 15 05 25 21 39 38 75 0 75 6 45 1 100 0 12 4 13 0 3 8 10 0 55 0 33 5 15 05 25 21 39 41 Trans from 0 to 1 15 05 25 21 39 42 Trans from 1 to 2 15 05 25 21 39 48 75 0 75 6 45 0 101 0 12...

Page 78: ...ing to long 016 Fuel storage nearly empty Fuel needed 018 O2 sensor broken New O2 probe needed 020 Transport timeout Transport system have been running to long 022 023 Fluefan alarm Check Fan and inve...

Page 79: ...otect you against any damage while working with the auger 20 3 Electric Protection Fuses The KSM Stoker control is installed with overload protection on each motor which is triggered if the screw moto...

Page 80: ...roken If the nozzles are not absolutely in order the result will be a poor combustion The nozzles shall be remounted with some heat proof gun gum as described in section 12 21 4 Screw Tube As occasion...

Page 81: ...ere can be 2 reasons to clean the flue fan 1 The Flue fan are vibrating 2 It have to run at high speed to keep the under pressure in the boiler On the side of the housing you can find a cleaning door...

Page 82: ...Blow the tube to the vaccum measurer for dust dirt 6 Check if the moving floor is running as desired use the test function 7 Grease the bearing in the bottom for the lifting screw Major overhaul once...

Page 83: ...9 23 3 Black display 1 No power supply Check fuses in the fuse box 2 Electric Protection Fuses for the transport screw is stopped Press the black button to restart 3 Maximum heat thermostat disconnect...

Page 84: ...the screw cannot push it out In that case clean the screw tube in all corners to get rid of any caked clinker in order to make the screw run freely again A too ample formation of clinker by grain comb...

Page 85: ...the switch pressure Smoke fan The frequency transformer is in alarm The frequency transformer is restarted by pushing the red button By multiple alarm please call for assistance Beside the alarms list...

Page 86: ...and 0 5 m behind the stoker screw 25 2 Stoker 25 2 1 Placing Place the boiler on a stable and plane surface 25 2 2 Flue gas outlet As a KSM stoker runs with a very moderate flue gas temperature this i...

Page 87: ...nd in their entire lengths against the formation of ice To the necessary extent expansion tanks and water filled safety pipes must be kept warm by means of circulating water from the plant preferably...

Page 88: ...mm pipe The pressure tank is provided with a non return valve to ensure that there is always water in the sprinkler even in case of a failure in the water supply The water supply connection must be ca...

Page 89: ...89 27 0 Piping Diagram Title Drawing No KSM Multistoker XXL RD 014 All appertaining drawings appear from the following pages...

Page 90: ...90 28 0 Power Diagram Title Drawing No Power diagram for 300 400 500 XXL boilers ED 0460 Power diagram for 750 1000 XXL boilers ED 0450 All appertaining drawings appear from the following pages...

Page 91: ...91 29 0 Dimension drawings Titel Drawing Nr All dimension drawings can be downloaded at https www dropbox com sh 4q2fp5a2tpjedoy AACTo6xIHdEHbFGURiVXg7l8a Dimension 20drawings PDF dl 0...

Page 92: ...to remote connection Go to setup IP 8 Go to Menu Service Konfig IP 9 Enter the stoker s given IP address 10 Enter Sub mask address 11 Enter Gateway address 12 Enter DNS address 13 In slut put in 0 in...

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