KA4 Project (Pic Heavy)

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Qtown1835
Member
Posts: 705
Joined: Sat. Nov. 08, 2014 11:47 am
Location: Quakertown, PA
Stoker Coal Boiler: Keystoker '81 KA4 (online 1/16/17)
Coal Size/Type: WAS Lehigh Rice (TBD)
Other Heating: EFM SPK600

Post by Qtown1835 » Tue. Dec. 06, 2016 6:32 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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StokerDon
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Posts: 7486
Joined: Mon. Nov. 11, 2013 11:17 am
Location: PA, Southern York County!
Stoker Coal Boiler: Gentleman Janitor GJ-5, Van Wert VA-600, Axeman Anderson130 X3.
Hand Fed Coal Furnace: Harman SF3500 reduced down to 3 grates connected to its own plenum
Coal Size/Type: Rice, Chestnut and whatever will fit through the door on the Harman
Other Heating: Noth'in but COAL! Well, Maybe a little tiny bit of wood

Post by StokerDon » Tue. Dec. 06, 2016 6:58 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

 
Qtown1835
Member
Posts: 705
Joined: Sat. Nov. 08, 2014 11:47 am
Location: Quakertown, PA
Stoker Coal Boiler: Keystoker '81 KA4 (online 1/16/17)
Coal Size/Type: WAS Lehigh Rice (TBD)
Other Heating: EFM SPK600

Post by Qtown1835 » Tue. Dec. 06, 2016 7:05 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.

 
lzaharis
Member
Posts: 2366
Joined: Sun. Mar. 25, 2007 8:41 pm
Location: Ithaca, New York
Stoker Coal Boiler: Keystoker KAA-4-1 dual fuel boiler
Hand Fed Coal Boiler: former switzer CWW100-sold
Coal Size/Type: rice
Other Heating: kerosene for dual fuel Keystoker/unused

Post by lzaharis » Tue. Dec. 06, 2016 7:45 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 7:54 pm, edited 1 time in total.

 
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StokerDon
Site Moderator
Posts: 7486
Joined: Mon. Nov. 11, 2013 11:17 am
Location: PA, Southern York County!
Stoker Coal Boiler: Gentleman Janitor GJ-5, Van Wert VA-600, Axeman Anderson130 X3.
Hand Fed Coal Furnace: Harman SF3500 reduced down to 3 grates connected to its own plenum
Coal Size/Type: Rice, Chestnut and whatever will fit through the door on the Harman
Other Heating: Noth'in but COAL! Well, Maybe a little tiny bit of wood

Post by StokerDon » Tue. Dec. 06, 2016 7:52 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

 
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Rob R.
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Stoker Coal Boiler: EFM 520
Hand Fed Coal Stove: Chubby Jr

Post by Rob R. » Tue. Dec. 06, 2016 8:13 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.

 
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McGiever
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Posts: 10130
Joined: Sun. May. 02, 2010 11:26 pm
Location: Junction of PA-OH-WV
Stoker Coal Boiler: AXEMAN-ANDERSON 130 "1959"
Hand Fed Coal Boiler: BUCKET A DAY water heater
Hand Fed Coal Stove: Warm Morning 414A
Coal Size/Type: PEA,NUT,STOVE /ANTHRACITE
Other Heating: Ground Source Heat Pump and some Solar

Post by McGiever » Tue. Dec. 06, 2016 10:23 pm



 
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McGiever
Member
Posts: 10130
Joined: Sun. May. 02, 2010 11:26 pm
Location: Junction of PA-OH-WV
Stoker Coal Boiler: AXEMAN-ANDERSON 130 "1959"
Hand Fed Coal Boiler: BUCKET A DAY water heater
Hand Fed Coal Stove: Warm Morning 414A
Coal Size/Type: PEA,NUT,STOVE /ANTHRACITE
Other Heating: Ground Source Heat Pump and some Solar

Post by McGiever » Tue. Dec. 06, 2016 10:29 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:
keystoker_coal_boiler_2.jpg
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CoalisCoolxWarm
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Posts: 2323
Joined: Wed. Jan. 19, 2011 11:41 am
Location: Western PA
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

Post by CoalisCoolxWarm » Tue. Dec. 06, 2016 11:35 pm

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: Setup Help Required

Here's the flange on the DHW coil
DHW Rusted.jpg
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DWHFlangeBefore.jpg
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StainlessBolts.jpg
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Hope these help! :cheers:

 
Qtown1835
Member
Posts: 705
Joined: Sat. Nov. 08, 2014 11:47 am
Location: Quakertown, PA
Stoker Coal Boiler: Keystoker '81 KA4 (online 1/16/17)
Coal Size/Type: WAS Lehigh Rice (TBD)
Other Heating: EFM SPK600

Post by Qtown1835 » Wed. Dec. 07, 2016 9:50 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.

 
lzaharis
Member
Posts: 2366
Joined: Sun. Mar. 25, 2007 8:41 pm
Location: Ithaca, New York
Stoker Coal Boiler: Keystoker KAA-4-1 dual fuel boiler
Hand Fed Coal Boiler: former switzer CWW100-sold
Coal Size/Type: rice
Other Heating: kerosene for dual fuel Keystoker/unused

Post by lzaharis » Wed. Dec. 07, 2016 10:41 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.

 
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McGiever
Member
Posts: 10130
Joined: Sun. May. 02, 2010 11:26 pm
Location: Junction of PA-OH-WV
Stoker Coal Boiler: AXEMAN-ANDERSON 130 "1959"
Hand Fed Coal Boiler: BUCKET A DAY water heater
Hand Fed Coal Stove: Warm Morning 414A
Coal Size/Type: PEA,NUT,STOVE /ANTHRACITE
Other Heating: Ground Source Heat Pump and some Solar

Post by McGiever » Wed. Dec. 07, 2016 12:53 pm

`
Last edited by McGiever on Wed. Dec. 07, 2016 12:54 pm, edited 1 time in total.

 
User avatar
McGiever
Member
Posts: 10130
Joined: Sun. May. 02, 2010 11:26 pm
Location: Junction of PA-OH-WV
Stoker Coal Boiler: AXEMAN-ANDERSON 130 "1959"
Hand Fed Coal Boiler: BUCKET A DAY water heater
Hand Fed Coal Stove: Warm Morning 414A
Coal Size/Type: PEA,NUT,STOVE /ANTHRACITE
Other Heating: Ground Source Heat Pump and some Solar

Post by McGiever » Wed. Dec. 07, 2016 12:54 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".

 
lzaharis
Member
Posts: 2366
Joined: Sun. Mar. 25, 2007 8:41 pm
Location: Ithaca, New York
Stoker Coal Boiler: Keystoker KAA-4-1 dual fuel boiler
Hand Fed Coal Boiler: former switzer CWW100-sold
Coal Size/Type: rice
Other Heating: kerosene for dual fuel Keystoker/unused

Post by lzaharis » Wed. Dec. 07, 2016 5:20 pm

Hello Mcgiever,

Whoopsie, :oops:
Seeing the AA model stoker in the brochure made
me think it had the same unit.

 
Qtown1835
Member
Posts: 705
Joined: Sat. Nov. 08, 2014 11:47 am
Location: Quakertown, PA
Stoker Coal Boiler: Keystoker '81 KA4 (online 1/16/17)
Coal Size/Type: WAS Lehigh Rice (TBD)
Other Heating: EFM SPK600

Post by Qtown1835 » Wed. Dec. 07, 2016 7:49 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.


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