KSM-Multistoker XXL With PCT400 O2 Controller

Transcription

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

2 EU Declaration of Conformity We the undersigned, PRODUCER: KSM-STOKER A/S ADDRESS: NAESSUNDVEJ 440, CITY: DK-7960 KARBY PHONE: FAX: WEBSITE: hereby declare that under - KSM-Multistoker, series No. CE nr 2006/97/56/EEC/016 - has been manufactured in conformity with the prescriptions of the EU Machinery Directive (directive 98/37/EF) - and that its construction has been approved of in conformity with directive 97/23/EC for pressure exposed equipment, section B1 - the common European standard EN Place Date Signature

3 Index for KSM-Multistoker XXL manual. 1.0 Introduction Fuel Wood Pellets Wood Chip Grain Alternative Fuels Warranty Standard warranty Water quality Control Panel Display Pushbuttons Starting up the boiler Shut down the boiler Software instructions Logs Run Boiler temp Set temperature C Go pause temp + C Back to run mode - C Max output % Min. output % Stoker screw Cycle time O2 / Manual controlled Max. fuel s Min. fuel s Oxygen Max. power oxy% set Min. power oxy% set Fuel stop O 2% Start up Stokerscrew Start fuel Start fuel Max. fuel s

4 7.3.2 Oxygen Go to startup O 2 % Oxy. differens Smoke temperature Go to run mode C Startup time min Startup output % Ignition Ignition delay s Fuel delay Ignition timeout m No ignition Semi Auto Automatic Auto w. empty Pause Stoker screw Pause fuel s Pause in minutes Empty-run in minutes Fan Output % Fan on time Oxy go to pause Fuel Accessories Transport auger Run as stoker screw After run stoker screw % After run before pause s Fuel delay Stop delay s Feeder timeout m Delay start next s Cell lock delay stop s Cell lock cycle s Fuel consumption Fuel kg

5 Fuel div Fuel s Reset fuel counter Ash auger Ash auger on s On when fuel sum m Moving floor Moving floor before pause s Moving floor run time s Pause at low output m Pause at high output m Firegrate 1 to Firegrate X on s Pause at low output s Pause at high output s Fan Boiler cleaner Run time in seconds Pause in hours Flue fan Flue fan prestart s Flue fan stop delay m Flue fan 100, 60, 40, 30, 20 and Logs (solid fuel) Cyclon/Bagfilter Cyclon ash on s Cyclon ash pause m Incl. Boiler deashing Bagfilter open temp Bagfilter close temp Filter ash on s Filter ash pause m Incl. Boiler deashing Hydraulic valve Hydraulic moving floor 1 in % Hydraulic moving floor 2 in % Start delay s Hydraulik timeout m

6 Lime dosage % Flue gas front gain Flue gas front offset Flue gas back gain Flue gas back offset Herz gain Herz offset Vac. gain Vac. offset Heating system Circ. Pump start C Circ. Pump SP Standby pump start C Boiler shunt SP Heat circuit Show pump info Buffer tank Buffer temp top C Buffer temp bottom C Shunt close time m Cascade Cascade Start slave power Stop slave power Delay m Hours as Master Run mode Port IP IP IP IP Test Date Service Alarm list Automatic Ignition Ignition type Start fuel

7 9.4 Description of the automatic ignition, step by step Ignition alarm Ignition restart Backend protection Buffer tank controller Cascade Cascade Setup Cascade Start slave power Stop slave power Delay start / stop Master role Run mode Port and IP address Buffer tank Display info Log info Boiler instruction Section view with description O2 Sensor O2 Sensor Calibration Air Nozzles Chamot stone Guideline for chamotstone in the burning chamber Chamotstone Maintenance: Combustion fans Fan Maintenance: Flue fan Flue Fan Maintenance: 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 Fire grates Moving floor Maintenance fire grate / moving floor Hydraulic unit Hydraulic oil Alarm Ash auger Automatic boiler cleaning Automatic Fuel Filling Device, Fire Damper / transport screw Fuel transport, parameter

8 14.2 Fuel transport, Displayed Fuel transport step by step Transport Log Flamdamper motor Hydraulic feeding system. (Moving floor) Maintenance Fuel sensor Hydraulic power pack Switching valve Hydraulic oil Alarm Hydraulic roof Precautionary Measures Fire Protection, thermal Personal Protection Electric Protection Fuses Maximum Heat Thermostat Water pressure switch WEB interface Log file SMS warning system Precautionary Measures Fire Protection, thermal Personal Protection Electric Protection Fuses Over Heating Switch Water pressure switch Maintenance Gear Fire Protection Air Nozzles Screw Tube Firebricks Combustion Air Fan Seals Smoke fan 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 Service plan Interruptions of the run

9 23.1 Unburned fuel in the ashes The boiler becomes sooty Black display Combustion air fan does not run during plant run The screw does not run Backfire Clinker Bothering smoke Condensed water in flue gas outlet Alarm list Installation instructions The boiler room Stoker Placing Flue gas outlet Piping Anti-freeze measures Check the screw direction of rotation Sprinkler, water connection Starting Up Accessories Piping Diagram Power Diagram Dimension drawings Formula WEB Setup

10 1.0 Introduction KSM-Multistoker XXL are produced in size from 199 to 2500kw. KSM-Multistoker XXL has a large combustion chamber, designed in a way to be able to burn the most of that biomass, that are available, such as woodchip, saw dust, wood pellets, grain, chaff etc. KSM-Multistoker XXL is provided with modulating Oxygen control, that ensure a perfect combustion at any circumstance. This PCT400 Oxygen controller are one of the most advanced on the marked. KSM-Multistoker XXL has been developed with focus on a minimum of daily maintenance. KSM-Multistoker XXL is provided with a water cooled burn head 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 bottom and one tilted ash auger for transporting the ash into a suitable container. KSM-Multistoker XXL is equipped with a cleaning system, that clean the heat exchangers automatic. The dust from this cleaning process goes into a ashbin on the side of the boiler. KSM-Multistoker XXL is as standard provided with flame damper for automatic feeding. The KSM-Multistoker XXL meets the requirements for CE marking according to 98/37 / EC The KSM-Multistoker XXL meets the requirements for EEC Directive 97/23/EC pressure equipment Module B1. The KSM-Multistoker XXL is tested according to EN303-5:2012 Boiler class

11 2.0 Fuel. The KSM-Multistoker type XL are designed to use a lot of different type of fuel. The boiler are tested and approved on the Danish Technology Institute, running on wood pellets with a water content at 8%, and wood chip with a water content at 20%.. However, both our customers and we have made the experience that the use of grain will result in a very fine economy. 2.1 Wood Pellets Wood pellets are produced at an increasing number of places in this country, all types are equally applicable. However, there may be a difference in the size offered by the various suppliers. For this reason it is recommended, when changing fuel supplier, to check that the pellet size is correct and that the proper air volume is added. Always store the wood pellets in a dry place, otherwise they will crumble and leave quite a bit of sawdust. The tested output, are guaranteed when using pellet, produced after the standard ENplus A1, with a output at 4,8kW/kg. 2.2 Wood Chip You can get Wood Chip in a lot 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 OENORM M Size: G50 Water content: W20 Output 2,9kW/kg. 2.3 Grain Grain is very easy to store and, in addition, it burns well - but grain has the unfortunate quality that it forms rather a lot of clinker during the combustion, and this clinker may cause some problems in the combustion chamber. But if 1-2 % of calcium is added every time the fuel container is filled, this will largely reduce the formation of clinker. KSM would therefore suggest to remove the remaining clinker once every second week, or when needed. The clinker volume will be different following the specific type of grain or corn applied, and may even vary from one field to the other. Wheat should be preferred as this type of grain will cause the smallest amount of ashes. The calorific value is the same for the various types of grain. 2.4 Alternative Fuels. The biomass fuel types combustible in your stoker plant are only limited by your imagination, among them might be: Wood pellets Grain Cocoa pellets Peas Olive stones

12 3.0 Warranty 3.1 Standard warranty Declared wear parts 1: Sensors, electric and electronic parts Boiler body 2-3 : 6 months 1 years 5 years Within this period end users do not have to pay for wear and tear parts so long as the commissioning protocol was written. The guarantee periods start from the commissioning date, therefore the commissioning date must be forwarded to KSM-Stoker A/S within 10 days after the commissioning. If the KSM-Stoker A/S Installer Partner fails to deliver the commissioning protocol the guarantee starts with the invoice date. After the expiration of the standard warranty KSM-Stoker A/S Installer Partner can purchase the 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. Declared wear parts: sealing, insulation, firebricks, heat element in the electric ignition, Lambda probe, grate, auger and turbulators 2. To keep Warranty on the boiler body, the boiler is not allowed to run on a lower temperature than 70 C, and the quality of the water have to full fill the description on next page. 3. The boiler must have a backend protection, to avoid corrosion. The return temperature on the water must be above 62 C, and the delta T maximum 15 C. In case this is not full filled there is no guarantee on the boiler body. 4. If the boiler are running, with broken or missing fire bricks (chamot stone), the is no warranty, on the burning chamber

13 3.2 Water quality The boiler is designed to operate with system water having the following physical characteristics and chemical properties. It is imperative that the system is totally free from air at all times. System Water Quality Requirement NAME UNIT VALUE ph-value [1] Water hardness (<500kW) Water hardness (>500kW) [mol/m 3 ] [ dh] [mol/m 3 ] [ dh] <0.5 <2.8 <0.1 <0.6 Chloride [g/m 3 ] <60 Oxygen (O2) [g/m 3 ] <0.1 Iron (Fe) [ppm] <0.1 Where the following common additives are used, these should remain within the range given below. In all instances the system water quality requirement must be maintained: Typical Protective Additives NAME UNIT RANGE Phosphate (P2O5) Polysilicate (SiO2) Alkaline Polyamide [g/m 3 ] 5 30 [g/m 3 ] [g/m 3 ] Sulphite (SO3) [g/m 3 ] Other suitable protective additives may be utilised, provided the system water quality requirement above is achieved. The above definitions have been extracted from ONORM H5195 part 1 specification for water quality. Cheviot Heat & Power Ltd provides this document on the understanding that it cannot accept responsibility for the implementation of the standards by any individuals or organisations and it is for the client to ensure that the system is operated accordingly. It is imperative that the water quality standard provided above is achieved and sustained to maintain the machine s warranty and ensure the continued longevity of the heat exchanger

14 4.0 Control Panel The PCT400 control from KSM-Stoker A/S is a full modulating O2 controller with integrated PID regulator. The PID regulator, will on normal condition always adjust the boiler output to fit the demand from the heating system. If the demand is so low, that it exceeds the lowest output for the boiler, the boiler will go into pause mode, or if it is equipped with automatic ignition, stop and wait until there is a demand again. The controller is equipped with a 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 access to the internet, smartphones, tablet or PC can all be used. 4.1 Display. On the screen-picture, it is obviously illustrated with a green LED when the single parts are activated and if you stop the stoker screw the LED turns red. Bellow two screens are illustrated with an explanation of every single information. Boiler set. Temp Actual Temp. Smoke Temp. O2 value Boiler status Output Cycles time which Running time for tells when the stoker screw the stoker screw is running again

15 Asch screw 1 Asch screw 2 Fan 3 and 4 Stoker screw 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 are excellent tools to follow the process of the boiler

16 4.2 Pushbuttons. The panel is equipped with three pushbuttons which changes indications depending on where you are in the program. When the boiler is in the normal run screen the designations are as follows: START STOP MENU START : Activates the stoker screw as long as the button is pushed. If you push a little longer the whole system will start, if it is in stop. STOP : A short push and the stoker screw will stop (the LED turns red). If you push a little longer 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 menu button. Please press BACK to leave the alarm. When you enter menu the buttons has replaced indications to: UP DOWN PLEASE SELECT With the UP and DOWN you can scroll to your desired adjustment. To make the adjustment please push the SELECT button. In the selected parameter the indications turn to: + - SAVE And at last when you have saved the indications will turn to: UP DOWN BACK It means that it is the same three buttons which has a lot of different functions

17 5.0 Starting up the boiler When you are going to start up the boiler for the first time, it should be done as instructed below. 1. Power on the boiler. 2. Start up the boiler, by making a long press at start. 3. Feed in an appropriate amount of fuel into the burner. If the boiler is with automatic ignition, the fuel must reach the ignition nozzle. (please see the picture below 4. Press shortly at stop, and the stoker auger will stop and sign RED on the display. 5. After the controller have recognized that the O2 level is high, the ignition will go 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, by pressing the 8. Don t leave the boiler before the O2 level is below 12%. The low O2 level indicate that the fire is burning well. Please notice following: 1. If the fuel is wet please notice that the burning chamber is not overfilled, it can kill the fire, so if needed, you have to stop the stoker auger shortly. 2. An overfilled burn head can produce a lot of smoke gasses, and when the flame comes on there is a risk off a gas explosion. To avoid these two mentioned situations, we recommend that you never leave the boiler, before the fire are stable

18 6.0 Shut down the boiler Before the boiler goes into pause mode or stop after the Stop button have been presses, there is 2 parameters that have to be 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 other case the empty run timer has to be 0. If the Stop button are going to pressed again while the boiler are in Shut down the boiler will stop immediately

19 7.0 Software instructions Menu structure. The menu structure in the PCT400 is designed in the same way as we know it from example Windows. The menu is divided in different, so it should be easy to go to the wanted function. In the following chapters, all function and parameter will be carefully explained. In parents after the menu line, we have put in the standard value. 7.1 Logs. In the KSM boilers from 13 to 95kw it is possible to us logs, as supplement to the pellets or wood chip, and for this the PCT400 have a special function. We don t use this function in a XXL boiler 7.2 Run. Menu / Run The run chapter contains all parameters which is significance for the different functions in run mode Boiler temp Menu / Run / Boiler temp In this chapter you can find all parameters concerned the boiler temperature while operating Set temperature C Menu / Run / Boiler temp / Set temp C (75 C) The working temperature of the boiler. To keep the corrosion warranty on the boiler, you are not allowed to go below 70 C Go pause temp + C Menu/ / Run / Boiler temp. / Go to pause +C (5 C) It is the limit of how many degrees the temperature can go above the boilers set temperature before the boiler are forced to go in pause mode. If the value is to low, the controller don t have the optimal to modulate the boiler output down, without hitting the pause mode Back to run mode - C Menu / Run / Boiler temp / Back to run mode C (1 C) The value of how many degrees the temperature is have to go below SP before the boiler startup again Max output % Menu / Run / Boiler temp / Max output % (100%) The standard value is 100%, but if the installed boiler is too big, it can be a good idea to reduce the maximum output

20 Min. output % Menu / Run / Boiler temp / Min output % (20%) The lowest output which the boiler to operate with. The ideal setting depends on the fuel and the boiler s installation. However as starting point we recommend to use 20 %, then the controller will modulate the boiler output from 20 % to 100 % Stoker screw. Menu / Run / Stokerscrew Parameters that control the stoker auger in run mode Cycle time. Menu / Run / Stokerscrew / Cycle time (15) The time is free to be adjusted. However, we recommend that it is set between 10 and 20 sec. The cycle time is the time it takes from the Stokerscrew start until it starts again. What value is the best depend on the fuel type. The easiest way to get a stabile O2 level, is if we feed in small amount of fuel quite often, and not a lot of fuel with a long pause between O2 / Manual controlled Menu / Run / Stokerscrew / O2/Manual controlled (0) Never set this value higher than 0,8 x the cycle time. If very difficult fuel is used, it might be an advantage to disconnect the O2 sensor and control the stokerscrew manual. When the value 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 modulating, and the value in chapter have to be set to 100%, and the boiler will run on/off Max. fuel s. Menu / Run / Stokerscrew / Max. Fuel s. (5,0) To avoid that the burning head will be overfilled, it is possible to limit how long time the stoker screw maximum is allowed to operate. The best value for this parameter is found by reading how long time the stoker screw is operating when the boiler is at 100 % output and then add 25 % to this value. But in some case, by very bad or wet fuel, the max. fuel, can be needed to be lower Min. fuel s. Menu / Run / Stokerscrew / Min. Fuel s. (0,1) It is also possible to adjust the stoker screw s minimum fuel conveying. Normally the value is set to 0,1 s. and only in special occasions another setting is selected. Could be very light fuel Oxygen. Menu / Run / Oxy The O2 measurements are important to get the best combustion. The measured O2 level, is the O2 that are let in the flue after the combustion. With a high output the combustion can use the most of the O2 and the opposite by low output, then the rest O2 will be higher

21 Max. power oxy% set. Menu / Run / Oxy / Max. power oxy% set (8%) A O2 level at 8% is perfect for the most common dry fuel, but if the fuel is wet or in a another way difficult to burn, it make sense to choose a higher O Min. power oxy% set Menu / Run / Oxy / Min power oxy% set (14%) By low output we recommend the O2 to be set at14 %. If you get black smoke from the chimney by low output, it makes sense to choose a higher O2, when the boiler run at low output Fuel stop O2% Menu / Run / Oxy / Fuel stop O2% (6%) If the boiler have got too much fuel, so the O2 goes below the set value, the stoker screw will stop feeding, and wait until the O2 is above the limit again. 7.3 Start up. Menu / Startup At the situation where the boiler go from stop to run, or from pause to run mode, there are some parameters that controls the way to start up. If the boiler are installed with automatic ignition, please read the instruction for this, better to understand the next instructions Stokerscrew. Menu / Startup / Stokerscrew 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 Start fuel. Menu / Startup / Stokerscrew / 1. Start fuel The value of fuel which is placed is indicated in seconds. And it is free to adjust. When the boiler is leaving pause and are going back to run mode again, we have to add some start fuel, to lighten up the fire again. And make sure that the O2 drops before the startup time is over. If the boiler is supported with automatic ignition, the 1. Start fuel have to be so long, that the fuel will be maximum 0-1 centimeters from the ignition nozzle. If the amount of fuel in the burning head is too high, and the nozzle is covered, there is a risk of an flue gas explosion. If the amount of fuel in the burning head is low, the hot air from the igniter, have no chance to light up the fuel Start fuel. Menu / Startup / Stokerscrew / 2. Start fuel 2. Start fuel is normally set to half value of the 1. Start fuel. If the boiler has automatic ignition, the 2. Start fuel will be activated, if the O2 should fail to get below the limit, which is indicated in chapter , and the boiler have to be restarted

22 Max. fuel s. Menu / Startup / Stokerscrew / Max. fuel s. The basis setting is 75 % of maximum operating time indicated in chapter When the boiler is in start-up mode, it is important that the burn head will not be overfilled with fuel. The settings in this parameter can prevent that. It is very important, that the value is not to high, especially if the boilers run on wet og other bad fuel Oxygen. Menu / Startup / Oxy To make sure that the controller knows if the fire is on or if the ignition should be activated, there is some limit values for the O2, that have to be set Go to startup O2 % Menu / Start-up / Oxy / Go to start-up O2 % (16%) Normally the % are basis for this parameter. If the O2 is over the indicated value, the controller will go in start-up mode and activate the automatic ignition if such is mounted, If not the fan will start pulsing to ignite the fire. More detailed instructions for automatic ignition, are written in chapter Oxy. differens Menu / Startup / Oxy / Oxy. Difference (2%) With Automatic Ignition use the value 1,5%, and with no ignition use the value 2,0% When the controller 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 ignition the boiler will switch to run mode, when the O2 level is below Go to start-up O2 % - Oxy. Difference (16%-2%) < 14% Instructions for how it works with automatic ignition, go to chapter Smoke temperature. Menu / Start-up / Smoke temp The smoke temperature is helping to inform the controller if the fire is properly ignited or if the boiler needs to be cleaned Go to run mode C Menu / Start-up / Smoke temp / Go to run mode C (30 C) Normally we don t use this function, at set it to 30 C. If the boiler run without O2 sensor, it is possibly to use the smoke temperature, to recognize if the fire is on, and the controller can switch into run mode Startup time min. Menu / Startup / Startup time m. (20 min.) In connection with startup of the boiler it is allowed that the boiler uses a specified time to bring the O2 down below the value which is indicated in chapter If it does not succeed within expiration of the start-up time, the boiler goes into start-up timeout. Depending on the fuel and the type of the boiler the time is set so the boiler has a chance to bring the O2 down without going into alarm mode

23 If the time is set to long, it might have the effect that the boiler is overfilled before the controller notice that there is no fire in the chamber Startup output % Menu / Start-up / Output % (30%) When the boiler are in start-up mode, it is important, that the fans don t run to fast. If the fan run to hard, during the start-up, there is a risk to blow out the flame. When using bad or wet fuel, it can be necessary to blow harder, to get the boiler on Ignition Menu / Start-up / Ignition You can get the boiler with automatic Ignition, but it is important to know how and when we can use the ignition. For further instruction for the automatic ignition step by step, please go to chapter 8. In the next chapter we will go through all the parameter, which have an effect on the ignition Ignition delay s. Menu / Start-up / Ignition / Ignition delay s (60 sek.) Before we wish the ignition to activate, we have to be sure that there is no embers left in the burning chamber that can fire up the boiler itself. After stop or pause, the boiler always starts up in run mode. If the O2 is above the level is above the value in chapter , when the ignition delay s. has expired, the controller switch to ignition or start-up, if no ignition are installed Fuel delay. Menu / Start-up / Ignition / Fuel delay s. (30 sek) It is important, that the fuel are not moved while the ignition is started. That is why the stoker screw is stopped, when the ignition is activated, until the O2 have dropped the needed % and the Fuel delay s. has expired, then the stoker screw start again. If the fuel delay is too long, there is a risk that the O2 will not come below the limit before the Ignition timeout m. have expired, because there is not enough fuel in the burning head Ignition timeout m. Menu / Start-up / Ignition / Ignition timeout m. (3 min) To be prevent the risk of flue gas explosion, there is a limit for how long time the boiler can try to start the fire. If the time is to short, the ignition fan doesn t have enough time to fire up the boiler No ignition. Menu / Start-up / Ignition / None If the boiler is not mounted with an automatic ignition, those None Semi Auto. Menu / Start-up / Ignition / Semi Auto If you only want to use the ignition when it is started manual, the function is to be used. After the boiler have been started, it will use pause mode, when it have reached the wanted temperature

24 Automatic. Menu / Start-up / Ignition / Auto Boilers running on pellets, and installed with a round screw pipe can use the automatic ignition, and start and stop as needed Auto w. empty Menu / Start-up / Ignition / Auto w. empty If the fuel are very quick burning, it is best to use the Auto w. empty function, then the auger channel will be emptied before the boiler shutdown. 7.4 Pause. Menu / Pause If the boiler has reached the temperature indicated in chapter the boiler switches to pause mode. When the boiler are in pause mode there is some parameter we have to be aware off, but if the boiler have automatic ignition, not all of them is active Stoker screw. Menu / Pause / Stoker screw If no ignition, we have to run the stoker screw of two reasons: To transport enough fuel to keep the embers alive To secure that we don t get a burn back Pause fuel s. Menu / Pause / Stoker screw / 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 screw in start-up (chapter ) Pause in minutes. Menu / Pause / Stoker screw / Pause in min. (10 min.) How often the screw is supposed to run depends on the fuel and the drag in the chimney Empty-run in minutes. Menu / Pause / Stoker screw / Empty-run min. (0 min.) When choosing automatic ignition with empty-run we have to decide for how long the boiler has to run to ensure that there is no material inside the screw pipe which could cause a back-fire. The time has to be checked in first empty-run and adjusted if needed Fan. Menu / Pause / Fan Every time we feed in some fuel in pause, we also have to supply with some combustion air, and that is what we control with the next couple of parameter Output %. Menu / Pause / Fan / Output % (10%) We only want to blow a little, when we make the pause feeding. We don t want real flame in pause, only embers, so the fan should not need more than % output

25 Fan on time. Menu / Pause / Fan / Fan on time s. (10 sek.) For the same reason as explained in the previous chapter, we don t want to run the fan for a long time. We normal run the fan for only 10 seconds Oxy go to pause Menu / Pause / Oxy go to pause (15 %) Before the boiler are allowed to switch to pause, we want the fuel in the burn head, to be burned away. If we switch to pause, when there is a lot off fuel in the burn head, we will become a lot off black smoke, and that we don t want. But if the O2 higher than the limit, we know that the fuel is burned, and we can switch to pause. 7.5 Fuel Menu / Fuel The controller has 5 different programs, used for 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 Program 4: Diverse Program 5: Light fuel Fuel of same weight pr m 3 is generally running on the same program. Although the PCT400 O2 system is very flexible, and it is rarely not needed to change program/adjustment even if you are changing the fuel. 7.6 Accessories. Menu / Accessories The boiler from KSM, can be delivered with a lot of different kind of accessories, and to control that different parameters are needed. Those parameters will be explained in the next chapter Transport auger. Menu / Accessories / Transport auger The transport auger, provides fuel from the extern fuel stock. The controller is prepared to run with up to four transport screws

26 Run as stoker screw. Menu / Accessories / Transport auger / Run as stoker screw (no) When using very dry or light fuel, it can be helpful to let the stoker screw runs all the time, to avoid backfire and let the transport auger runs as dispense auger (stoker screw). Just select yes or no After run stoker screw %. Menu / Accessories / Transport auger / After run stokerscrew % (150%) When the transport auger is running as dispense auger, the stoker screw have to run longer, than the transport auger, so the stoker screw is not overfilled. The after run setting are in %. If the settings are 150%, the stoker screw will run 7,5sek if the transport auger run for 5sek After run before pause s. Menu / Accessories / Transport auger / After run before pause s. (15 sek.) Before the boiler switch into pause mode, it is important that the stoker screw runs empty. How long time it have to run to be empty, is different from boiler to boiler Fuel delay. Menu / Accessories / Transport auger / Fuel delay m. (1 min.) The transport auger should not start and stop more than needed, because it load the gearbox and the electric motor. When the value is set to 1 min. the transport auger will not start, before 1 min after the fuel sensor indicate that fuel is needed Stop delay s. Menu / Accessories / Transport auger / Stop delay s. (2 sek.) To make sure that the transport auger doesn t stop, as soon the fuel sensor is activated by a piece of woodchip. That s why it is possible to delay the transport screw from stopping Feeder timeout m. Menu / Accessories / Transport auger / Feeder timeout m. (30 min.) The function Feeder timeout, will stop the transport auger, if the augers have been running for more than the indicated time. This could have happened if the fuel stock is empty Delay start next s. Menu / Accessories / Transport auger / Delay start next s. (0 sek.) In some installations it can be helpful, to be able to control when the next transport auger will start. Standard is right away (0). If the fuel can block up between 2 augers, we can give a bit off time to remove the fuel, befor the next transport auger start again Cell lock delay stop s. Menu / Accessories / Transport auger / Cell lock delay stop s. (0 sek.) If the boiler are installed with cell lock, and used for straw, it make sense to let the cell lock run extra by each time. The reason is to empty the cell lock total, so the is no risk that some straw will block the fuel sensor, and make the controller believe there is enough fuel

27 Cell lock cycle s. Menu / Accessories / Transport auger / Cell lock cycle s. (0 sek.) If some straw anyway are blocking the fuel sensor, we can force the cell lock to rotate each 20 sek., to remove the straw. The running time for the cell lock in this cycle, is the time set in parameter Fuel consumption We have the opportunity to register the consumption of the fuel used in the boiler. Although, it is not suitable for wood chips because the variation is to large relative to how much fuel the transport screw will bring forward. To make the controller calculate the consumption of fuel, 3 values are needed, as written in the next 3 chapter. For further description this function please go to chapter Fuel kg. Menu / Accessories / Transport auger / Fuel kg. (1) Measured quantity can be written with values from Fuel div. Menu / Accessories / Transport auger / Fuel div. (10) Weight decimals 1 = kg, 10 = 0,1-25,5 kg and 100 = 0,01-2,55 kg Fuel s. Menu / Accessories / Transport auger / Fuel s. (0 sek.) The time that the auger has been running during the measuring Reset fuel counter Menu / Accessories / Transport auger / Reset fuel counter (yes) When you get a new load off fuel you can reset the counter in the menu Ash auger. Menu / Accessories / Ash auger To run the boiler with the automatic ash auger, there are two parameters to notice Ash auger on s. Menu / Accessories / Asch auger / Ash auger on s. (10 sek.) When the Ash auger is activated the auger shall not run less than five seconds to ensure an effective transport of the ash On when fuel sum m. Menu / Accessories / Asch auger / On when fuel sum m. (10 min) How often the ash screw has to run is chosen from the type of fuel and how much fuel has been transported into the boiler. The Ash auger will be started, when the sum of the stoker s feeding time is reached

28 7.6.3 Moving floor. Menu / Accessories / Moving floor On the XXL boiler, the moving floor are installed, below the fire grate, to clean out in that area Moving floor before pause s. Menu / Accessories / Moving floor / Moving floor before pause s. (20 sek.) This function is not used on XXL boiler Moving floor run time s. Menu / Accessories / Moving floor / Moving floor run s. (5 sek.) This time have to be 20 sek. and never changed Pause at low output m. Menu / Accessories / Moving floor / Pause at low output m. When the boiler run at low output the moving floor has to go very rarely. As basis it is set to 240 minutes., or 4 time the value used at high output Pause at high output m. Menu / Accessories / Moving floor / Pause at high output m. When the boiler run at high output the moving floor has to go regularly. As basis it is set to 60 minutes Firegrate 1 to 3 Menu / Accessories / Firegrate 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 the fire grates move to little, there is a risk that the fuel will accumulate in the back which can results that the top stones can be pushed up and crack. However, if they are running too much, the fuel is not burned properly before it goes into the ash auger Firegrate X on s. Menu / Accessories / Firegrate X / Firegrate X on s. As the boiler is equipped with 2 to 3 firegrate, depending of the boiler size. The running time for the firegrate, depend on the type of fuel that a being used. The most common run time is 2 seconds. How often the fire grates shall operate depends on the next two parameters Pause at low output s. Menu / Accessories / Fire grate X / Pause at low output s. When the boiler run at the lowest output, the pause at the grate 1 can be 40 seconds. For grate 2 and 3, the pause have to be longer. 50 and 60 sek. The pause by low output is normal 4 times the pause by high output

29 Pause at high output s. Menu / Accessories / Fire grate X / Pause at high output s. When the boiler run at high output, the pause at the Grate 1 can be 10 seconds. For grate 2 and 3, the pause have to be longer. 12 and 15 sek Fan. Menu / Accessories / Fan The XXL boilers are mounted with several fans. The output of the fans is controlled by the demand of the boiler output. The speed of each fans on the different outputs can be adjusted differently. To adjust the fans, go to the menu shown below. Menu / Accessories / Fan / Fan and insert 100. Menu / Accessories / Fan / Fan 1 60 and insert 60. Menu / Accessories / Fan / Fan 1 40 and insert 40. Menu / Accessories / Fan / Fan 1 30 and insert 30. Menu / Accessories / Fan / Fan 1 20 and insert 20. Menu / Accessories / Fan / Fan 1 0 and insert 1. It is the same process for the adjustment for all the used fans Boiler cleaner. Menu / Accessories / Boiler cleaner These parameters control how often and how much the heat exchanger shall be cleaned Run time in seconds. Menu / Accessories / Boiler cleaner / Runtime s. (20 sek.) How much the cleaner have to run, depend on the type of fuel. But it has to run enough, so the heat exchanger is clean. That will ensure a low smoke gas temperature which results in the best efficiency Pause in hours. Menu / Accessories / Boiler cleaner / Pause in hours (4) How often the cleaner shall operate is set in hour and it depends on how much dust etc the fuel provides. Operating with the cleaner every 6. hour is very appropriate Flue fan. Menu / Accessories / Flue fan If the boiler is installed with a flue fan, there is some parameter to control how it shall be running. The flue fan help to get a good combustion and to ensure that no smoke goes backwards in the stoker channel

30 Flue fan prestart s. Menu / Accessories / Flue fan / Prestart s. (10 sek.) To prevent smoke problems during start-up, it is possibly to start the flue fan up before, the rest of the system stars. We call It Prestart and 10 seconds is appropriate time for this function Flue fan stop delay m. Menu / Accessories / Flue fan / Stop delay min. (1 min.) When the boiler goes into pause mode, it can happen that there will come black smoke from the chimney. But if the flue fan doesn t stop at once it goes into pause, we can reduce the black smoke. 1 minute is appropriate delay stop time for the flue fan Flue fan 100, 60, 40, 30, 20 and 0. Menu / Accessories / Flue fan / Flue fan 0-100% The speed on the Flue fan are controlled by an Inverter on a XL Boiler. And because the Flue fan are controlled by an Inverter, ALL the parameter 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 fan / Flue fan 40 and insert 100 Menu / Accessories / Flue fan / Flue fan 30 and insert 100 Menu / Accessories / Flue fan / Flue fan 20 and insert 100 Menu / Accessories / Flue fan / Flue fan 0 and insert Logs (solid fuel) Menu / Accessories / Logs The function are not used at a XL boiler Cyclon/Bagfilter Menu / Accessories / Cyclon/bagfilter The PCT400 controller are able to control all the main function on multicyclon and bagfilter system. Only the cleaning system for the bagfilter bags, are not included Cyclon ash on s. Menu / Accessories / Cyclon/bagfilter / Cyclone ash on s. (15 sek.) This parameter controls the running time for ash auger at the multicyclone Cyclon ash pause m. Menu / Accessories / Cyclon/bagfilter / Cyclone ash pause m. (15 min.) This parameter controls the pause time for ash auger at the Multicyclone

31 Incl. Boiler deashing Menu / Accessories / Cyclon/bagfilter / Incl. Boiler deashing (No) If the ash auger from the multicyclon, deliver the ash into the boilers ash auger, the boiler deashing system must run at the same time. If this parameter are set to Yes this will happened Bagfilter open temp Menu / Accessories / Cyclon/bagfilter / Bagfilter open temp (100 C) The smoke are not allowed to enter into the bagfilter, if the temperature is low. So only if the set temperature is passed, the bypass valve will open to the bagfilter Bagfilter close temp Menu / Accessories / Cyclon/bagfilter / Bagfilter close temp (200 C) And the smoke are not allowed to enter into the bagfilter, if the temperature is to high, it will destroy the bags. So the temperature exceeds the limit, the bypass valve will close to the bagfilter Filter ash on s. Menu / Accessories / Cyclon/bagfilter / Filter ash on s. (15 sek.) This parameter controls the running time for ash auger at the Bagfilter Filter ash pause m. Menu / Accessories / Cyclon/bagfilter / Filter ash pause m. (15 min.) This parameter controls the pause time for ash auger at the Bagfilter Incl. Boiler deashing Menu / Accessories / Cyclon/bagfilter / Incl. Boiler deashing (No) If the ash auger from the bagfilter, deliver the ash into the boilers ash auger, the boiler deashing system must run at the same time. If this parameter are set to Yes this will happened Hydraulic valve. Menu / Accessories / Hydraulic valve The PCT400 controller can control 2 set of hydraulic valve, so it is possibly free to make a mix of fuel from 2 different fuel stock Hydraulic moving floor 1 in %. Menu / Accessories / Hydraulic valve / Hydraulic moving floor 1 % The Hydraulic moving floor has a cycle on 10 seconds and if set to 50 % means that the Hydraulic moving floor is operating in 5 seconds and is in pause in 5 seconds. This function demands special valves on the pump station

32 Hydraulic moving floor 2 in %. Menu / Accessories / Hydraulic valve / Hydraulic moving floor 2 % This function has the same options as Hydraulic moving floor 1. If you operate Hydraulic moving floor 1 by 70 % then will Hydraulic moving floor 2 operate by 30 % which means that the fuel is mixed with approximately Start delay s. Menu / Accessories / Hydraulic valve / Start delay s.(5) To avoid that the hydraulic unit will start and stop in short step, we are able to delay the start signal from the sensor. That give the unit longer run time when it is on, and that is better for the components Hydraulik timeout m. Menu / Accessories / Hydraulic valve / Hydraulic timeout m. (30) If the Hydraulic Unit, have been running longer than the limit time without any stop, an alarm will pop up on the display saying Hydraulic timeout, the reason is mostly that the storage is empty Lime 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 time for the stoker screw. Start with 5 % and then go a little up and down until you have found the setting which gives the minimum clinker Flue gas front gain Menu / Accessories / Flue gas front gain (100) Gain value for the high temperature sensor that can be placed in the front of the burning chamber. (Special function) Flue gas front offset Menu / Accessories / Flue gas front offset (100) Offset value for the high temperature sensor that can be placed in the front of the burning chamber. (Special function) Flue gas back gain Menu / Accessories / Flue gas back gain (100) Gain value for the high temperature sensor that can be placed in the back of the burning chamber. (Special function) Flue gas back offset Menu / Accessories / Flue gas back offset (100) Offset value for the high temperature sensor that can be placed in the back of the burning chamber. (Special function)

33 Herz gain Menu / Accessories / Herz gain (57) Gain value for the 0-10v signal from the flue fan inverter. Needed to calibrate the value shown on the display to be equal the value on the inverter Herz offset Menu / Accessories / Herz offset (100) Offset value for the 0-10v signal from the flue fan inverter. Needed to calibrate the value shown on the display to be equal the value on the inverter Vac. gain Menu / Accessories / Vac. gain (57) Gain value for the 0-10v signal from the pressure sensor. Needed to calibrate the value shown on the display to be equal the value on the sensor Vac. offset Menu / Accessories / Vac. offset (100) Offset value for the 0-10v signal from the pressure sensor. Needed to calibrate the value shown on the display to be equal the value on the sensor Heating system. Menu / Heating system In the following chapters, you will find the parameter, that control the components in the heating system. Circulation pump, backend protection, buffer tank ect. More detailed instruction, can be read I chapter 10, 11 and Circ. Pump start C Menu / Heating system / Cir. Pump start C (60 C) The circulation pump will start, when the boiler temperature exceeds the inserted value Circ. Pump SP Menu / Heating system / Circ. Pump SP (0 C) With this function, the controller is able to adjust the circulation pump flow, with 0-10v, to keep a constant temperature on the flow pipe, to the building Standby pump start C. Menu / Heating system / Standby pump start C (40 C) Some client don t want the boiler to be cold, it is not used in some periods. So if the boiler temperature will drop below the inserted value, the standby pump will run, and supply the boiler with hot water from other sources

34 7.7.4 Boiler shunt SP. Menu / Heating system / Boiler shunt SP (62 C) Back end protection off the boiler is important, to protect the boiler against corrosion. With a temperature sensor placed in the return, the controller can control the temperature going back to the boiler. The control signal is 0-10V, and can control either 3-way valve or a mixer pump Heat circuit. Menu / Heating system / Heat circuit This function is not active yet Show pump info. Menu / Heating system / Show pump info. (No) If this parameter, it set to Yes all information about the pumps and backend protection will be shown on the display Buffer tank Menu / Heating system / Buffer tank If the needed temperature sensor are installed in the buffer tank, the PCT400, can start and stop the boiler according to the wanted temperature in the buffer tank. In chapter 11, there is a detailed description of this function 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 buffer tank Buffer temp bottom C Menu / Heating system / Buffer tank / Buffer temp bottom C (60 C) When the buffer tank bottom temperature goes above this value, the boiler will be shut down and the shunt valve between the boiler and the buffer tank will close Shunt close time m. Menu / Heating system / Buffer tank / Shunt close time m. (25 min.) In order to prevent the boiler to be overheated, when the shunt valve are going to be closed, the valve will be closed during the displayed time. When shunt valve are total closed the circulation pump will be stopped as well Cascade Menu / Heating system / Cascade If more boilers are installed in the same boiler room, it is possibly with the Cascade controller, to split the load between the installed boilers, according to the load from the heating system. In Chapter 12, a more detailed description of the function is placed

35 Cascade Menu / Heating system / Cascade / Cascade (NA.) The boiler that is wanted to be a part of the Cascade net, need to be added a function, to get the cascade controll up running. The 3 different state the boiler can get is listed below. NA: MSTR: SLV: Cascade is not activ The boiler work as Master The boiler work as Slave To start up the Cascade function, you have to set one off the boilers as Master and the rest have to be set as Slave. As soon as it is running the system take care of the rest itself Start slave power Menu / Heating system / Cascade / Start slave power (90) If the load on the boiler is above this limit, a ekstra boiler to be started. It is the master that giv this start command to the next boiler Stop slave power Menu / Heating system / Cascade / Stop slave power (40) If the load on the boilers in the chain is below this value, the last slave in the chain, will be stopped. It is also the Master, that send the stop command Delay m. Menu / Heating system / Cascade / Delay m. (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 of delay have expired, before the start or stop command will be send Hours as Master Menu / Heating system / Cascade / Timer som master (168) To split the load and the role as Master, between the boilers, we can chose how long time a boiler shall be master, before it giv the role as Master to the next boiler in the chain. If the value is set to 0, the Master role will never go to a another boiler Run mode Menu / Heating system / Cascade / Run mode Since the Cascade controller from KSM is the most flexible on the marked, it is needed to tell the boiler, how we want it to communicate with the rest of the boiler in the installation. For this function, we have to put in a Run mode code, explanation off the code are written below. The code to put in, is the way this boiler shall work. Code Description 1. KSM boiler with automatic ignition, that start and stop when it get the command from the master. 2. KSM boiler without ignition, that just switch to pause mode, when it get the stop command from the master

36 3. KSM boiler type 1., that is connected to a boiler that don t have a PCT400 controller, but will be controlled with a relay, it can be another brand of biomass boiler, a gas or oil boiler. 4. KSM boiler type 2., that is connected to a boiler that don t have a PCT400 controller, but will be controlled with a relay, it can be another brand of biomass boiler, a gas or oil boiler Port Menu / Heating system / Cascade / Port Port no. on the boiler that are placed next in the chain IP 1 Menu / Heating system / Cascade / IP 1 Ip adresse 1 on the boiler that are placed next in the chain IP 2 Menu / Heating system / Cascade / IP 2 Ip adresse 2 on the boiler that are placed next in the chain IP 3 Menu / Heating system / Cascade / IP 3 Ip adresse 3 on the boiler that are placed next in the chain IP 4 Menu / Heating system / Cascade / IP 4 Ip adresse 4 on the boiler that are placed next in the chain. 7.8 Test. Menu / test In test it is possibly to test all motor and function. With the arrows you can scroll to that function you wish to test. When the cursor is on the function you wish to test just press Menu to activate. After you have pressed you can see an ON after the function. When you wish to stop just press Menu again and you can see an OFF after the function and the function stop. The function are spilt in 5 section, so it is easier to find the wanted function. How they are split you can see below. Menu / test / Boiler Menu / test / Feeder Menu / test / Cyclon/Bagfilter Menu / test / Heating system Menu / test / Alarm

37 7.9 Date Menu / Date If the boiler is not connected to the internet, you have to set the time and date manual, but it is easy to do, just fill out each line below. Menu / Date / 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 of power the clock must be set again Service. Menu / Service The options in the service menu is recommended not to adjust without proper instructions from KSM-Stoker A/S

38 8.0 Alarm list. Alarm Text Cause Solution Startup timeout High O2 to long time Check if there is enough fuel in the burning head. Restart the plant Module alarm Overload switch or fuse blowen Hopper cover open Hopper open Close it Prime switch Boiler temp > max Software alarm Water pressure SW Water pressure dropped Refill water Safty temp SW Boiler is overheated Pump broken Hydraulic timeout Hydraulic have been running No more fuel to long Hopper alarm Fuel storage nearly empty Fuel needed O2 sensor broken New O2 probe needed Transport SW Transport system have been running to long No more fuel See if there is some blocking, and remove the problem Alarm fluefan 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 Check the oile pressure hydraulic unit overheated Damper timeout Flame damper SW Check SW and Hydraulic oil level Oil is missing RefillMore oil needed Hydraulic oil temp Check oil pressure switch Check oil pressure switch Fan alarm Broken fan or inverter Check fan and inverter HZ alarm Flue fan or Inverter broken HZ < 5 for 15 sek Vac. alarm Door open or dirty boiler Pa < 5 for 15 sek Alarm Bypass SW Problems with bypass valve on bag filter Ignition timeout No flame in time Check start portion Alarm boiler temp. Low Alarm Smoke temp. high To high demand or boiler dirty Boiler dirty or to high output Door open or dirty boiler Pa < 5 for 15 sek Clean boiler or reduce demand

39 On each alarm a black or yellow box will pop up on the display. In the box the message will tell quite exactly what have caused the alarm. Stoker screw 1 Modul 10 (P3) :10:00 A alarm example is shown above, and as written the problem is the stoker screw 1, connected to module 10. 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 supply to the module is re-established and you afterwards press start. The yellow alarms disappear by itself when the problem has been solved. Prime switch If it against the expectation should happen that there still is an alarm which is not disappeared although the problem was solved, please restart the system

40 9.0 Automatic Ignition. You can get boiler from KSM-Stoker with automatic Ignition, but it is important to know how and when we can use the ignition. In the KSM Controller we have 4 different way to use Ignition. 8.2 Ignition type. None: We don t use ignition at all, just let the boiler use pause mode when it has reach the boiler set temperature. The boiler then has to be started manual, with oil or similar. Semi Auto: You have to activate the Ignition manual. It only works if the boiler has been in stop mode, and you start it up, if the O2 level is high, the igniter goes on. After have been lightening up the boiler switch to use normal pause mode when it has reach the set temperature for switching to pause. The most common way to run boiler on woodchip with moister high than 25%, and the most common way to run boiler type FX, XL and XXL range. and you don t want to start the boiler with manual, with oil or similar. Auto: This function is for pellets boiler only. The boiler will when it reaches the 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 kW and the XL type, with ignition is installed. Auto with empty run: This function is used for F-Auto boiler running on dry wood chip. The boiler will when it reaches the set temperature, stop the feeding from the fuel storage, but the stoker will keep on running until the O2 level is high and the empty run time is out. The boiler then goes into pause and wait until the temperature have dropped in the system, and the boiler will start up again. Importen: If you have to start the boiler for the first time, or after have run out of fuel, DON T let the boiler startup itself. You have to feed in the fuel, to the correct level manual, and stop the auger. The ignition will light up the fuel, and when you can see the O2 level start dropping, you can restart the auger, and the controller takes over. 9.3 Start fuel To get a correct and quick ignition, it is important that the amount of start fuel, are correct (see also section ) By the correct amount of fuel, the fuel shall reach the ignition nozzle, but not cover it

41 9.4 Description of the automatic ignition, step by step. 1. The boiler goes into Run mode, if the O2 level is higher than the limit Go to start up O2% after the Delay ignition timer has run out, it switches to Ignition and goes to step 2, but if the O2 level is low it stays in run mode. 2. The Stoker auger feed in 1. Start fuel, and stop. 3. Ignition goes on, and at the same time the present O2 will be saved in the memory. 4. When the O2 drops more that the Oxy. difference value, the combustion fans start, on the power set in Startup/ Output %, and help the igniter to get more flame, if not it go to step After the timer Fuel delay are out, the Stoker starts to feed in fuel. 6. When the O2 again drop more that the Oxy. difference value, the ignition stops, but the combustion fans keep on running, on the power set in Startup/ Output %. 7. When the O2 for the 3. time drop more that the Oxy. difference value, the controller goes into run mode. If not, it goes to step 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 the display "Ignition Timeout" 12. The fans go on, and the flue fan keep running in time known as "Flue fan delay stop" to be sure all gasses are blown out, so no risk of explosion in case off restart B. Startup timeout. 15. If the O2 don t drop enough to go to step 7, before the end of the timer "Startup timeout" 16. A alarm will come up on the display "Startup timeout" 17. The fans go on, and the flue fan keep running in time known as "Flue fan delay stop" to be sure all gasses are blown out, so no risk of explosion in case off restart 9.6 Ignition restart. 20. The user can only restart the boiler after ending step 12 or If the ignition is restarted, without the boiler being in Run mode for more than 15 min., it is only able to use 2. start portion 22. If you want to restart the boiler you press "START" (arrow up) and the screw feed in "Start portion 2" 23. The program go directly to the step 3 above

42 10.0 Backend protection. Back end protection off the boiler is important, to protect the boiler against corrosion. With a temperature sensor placed in the return, the controller can control the temperature going back to the boiler. The control signal is 0-10V, and can control either 3-way valve or a mixer pump. The backend protection, can be configured in 3 different ways. 1. ON/OFF according to the chosen temperature, with a hysteresis at 5 C, this setup is normal used when the backend protection is a simple pump. 2. ON/OFF and with a PID regulator to control the 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. The valve is regulated with 0-10V Since there are several types of 3-way valves, it is possible to select two types of analog outputs AO1 which is for valves that are NC B-AB and AO2 are is for valves that are NO B-AB. The boiler must have a temperature sensor installed in the return, otherwise it is not possibly to use the backend protection. The boiler must have a backend protection, to avoid corrosion. The return temperature on the water must be above 62 C, and the delta T maximum 15 C. In case this is not full filled there is no guarantee on the boiler body

43 11.0 Buffer tank controller The buffer tank can be controlled in 2 different ways. 1. With 2 temperature sensor in the buffer, 1 in the top and 1 in the bottom and a pump between the buffer and the boiler. 2. With 2 temperature sensor in the buffer, 1 in the top and 1 in the bottom, a 3-way valve and a pump between the bypass and the boiler. Function: Stop the boiler: When the temperature on the buffer tank bottom sensor reach the SP, the 3-way valve start closing. The wanted close time can be adjusted in the buffer menu, and the time have to be so long that the boiler has a chance to modulate down the output. 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 boiler: When the temperature on the buffer tank top sensor, goes below the SP, the circulation pump will start and the the 3-way valve will start to regulate as normal. 199XXL running: On the diagram below, we can see how a 200kw boiler with Ignition and buffer controller can run. Safty function, to be sure the boiler not will be overheated: When the 3-way are closed, there is a risk that the boiler can be overheated. If the boiler reaches the allowed boiler max. temperature -10 C. The 3-way valve open and the pump start again. As soon as the temperature have dropped 5 C again, the closing sequins starts again

44 12.0 Cascade If more boilers are installed at the same installation, it is very handy to let the cascade software start and stop the boilers, to so the output fit with the needs. One boiler starts as Master, and the rest as Slave, the Master start the Slave if the load on the Master have been over the limit for a specified time. If the load still is over the limit after the specified time, the Master will start the next Slave. If the load is dropping, the upper side will happen, the Master will stop the Slaves. To be sure that the Master not run for full load all the time, the Master boiler move the Master role, to the next boiler 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 Master faults and goes into alarm mode, it sends the Master role to the Slave in the chain. If all Slaves are activated, the Master will activate the Oil or Gas boiler, if one of those is a part of the chain. The boilers in the Cascade chain, with PCT400 controller, communicate by LAN, and each boiler needs a IP address and Port no. Other brand of Biomass, Oil or Gas boiler, we name as Helper, and are controlled by a potential free relay Cascade Setup. To get the Cascade running, some parameter has to be set, all this parameter are in the menu below, and an explanation will follow in the next chapters. Menu / Heating system / Cascade

45 Cascade Menu / Heating system / Cascade / Cascade (NA.) The boiler that is wanted to be a part of the Cascade net, need to be added a function, to get the cascade control up running. The 3 different state the boiler can get is listed below. NA: MSTR: SLV: Cascade is not active The boiler work as Master The boiler work as Slave To start up the Cascade function, you have to set one off the boilers as Master and the rest have to be set as Slave. As soon as it is running the system take care of the rest itself Start slave power If the master has been running on an high output for a longer time that set in the delay timer, the master can start up an slave to get help. We normal set the start limit to be between If the load still is over the limit after a new delay time, the master will start one more slave, or a helper, if no more slave are present in the chain. Menu / Heating system / Cascade / Start slave power (90) Stop slave power Menu / Heating system / Cascade / Stop slave power (40) This function is works in 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 Delay start / stop Menu / Heating system / Cascade / Delay m. (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 of delay have expired, before the start or stop command will be send Master role To split the load and the role as Master, between the boilers, we can choose how long time a boiler shall be master, before it gives the role as Master to the next boiler in the chain. Menu / Heating system / Cascade / Hours as master (168) If we set the value to 168 hours, the master will move the role to the next boiler in the chain, is the same as 7 days. If the value is set to 0, the Master role will never go to a another boiler. The value 0 is always used, if the master only has a helper, controlled by a relay, and no other slave. If the Master faults and goes into alarm mode, it sends the Master role to the Slave in the chain. If all Slaves are activated, the Master will activate the Oil or Gas boiler, if one of those is a part of the chain

46 Run mode Menu / Heating system / Cascade / Run mode Since the Cascade controller from KSM is the most flexible on the marked, it is needed to tell the boiler, how we want it to communicate with the rest of the boiler in the installation. For this function, we have to put in a Run mode code, explanation off the code are written below. The code to put in, it the way this boiler shall work. Code Description 1. KSM boiler with automatic ignition, that start and stop when it get the command from the master. 2. KSM boiler without ignition, that just switch to pause mode, when it get the stop command from the master. 3. KSM boiler type 1., that is connected to a boiler that don t have a PCT400 controller, but will be controlled with a relay, it can be another brand of biomass boiler, a gas or oil boiler. 4. KSM boiler type 2., that is connected to a boiler that don t have a PCT400 controller, but will be controlled with a relay, it can be another brand of biomass boiler, a gas or oil boiler Port and IP address Since the boiler in the Cascade chain communicate over the network, all boilers must have their own IP address and port no. Normal the same no. as we use 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 / Heating system / Cascade / IP 2 Menu / Heating system / Cascade / IP 3 Menu / Heating system / Cascade / IP 4 That means that on boiler 1 we set the IP address and port no. on boiler 2, and on boiler 2 we set the IP address and port no. on boiler 3. If boiler 3 is the last in the chain, it gets the IP address and port no. on boiler Buffer tank If the boiler in a Cascade installation is connected to a buffer tank, all boilers need to have 2 temperature sensors in the buffer tank, and the sensors have to be setup as normal in a single boiler installation. When the boiler is running, it is only the Master that react at to the temperature readings from the buffer tank, the Slave will still get the start /stop commands from the Master. When using a buffer tank in a Cascade installation, the delay time Slave On/Off, must be much longer Display info If the boiler are running in a cascade installation, some code information will be shown in the lower left corner of the display. This code give us information, about the different stage that the boiler can be in, a explanation is listed up below. 1. S : The boiler is slave. 2. [M]H:120: The boiler have been Master for 120 Hours

47 3. SS Slave status A: Slave ON eller Off B: Master I: OFF (Have no command for the slave) II: DON (Delay timer counting before start slave ) III: ON (Slave is on) IIII: DOFF (Delay timer counting before stop slave) 4. R: Number of received commands 5. S Number of send commands 12.4 Log info. In the loggen all the command, the masteren send to the slave, will be written :15:26 Sent to slave :90. CMD:6 value: :15:32 Sent to slave :90. CMD:5 value: 1 CMD: X is the command, and Value: X the action or result Commands(CID=command Id): Value 1 CID_ON_BOILER 1 2 CID_OFF_BOILER 0 3 CID_ON_HELPER 1 4 CID_OFF_HELPER 0 5 CID_COUNT_BOILERS result 6 CID_COUNT_HELPERS result 7 CID_BE_MASTER

48 13.0 Boiler instruction 13.1 Section view with description. Return Flow O2 Sensor Smoke outlet Cleaning door Cleaning spiral Front door Back door Inspection Glass Secundary Fan fan Air nozzel Stoker auger Air nozzel Chamot stone Concrete Arc Ash auger Moving floor Primary Air inlet Moving 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 O2 Sensor The XXL boiler have O2 controlled combustion. This controller only works perfect, if everything is perfect. The points below is important that they is in perfect condition. 1. O2 Sensor is clean 2. O2 Sensor are in a good shape 3. O2 Sensor is calibrated correct. 4. All gasket rope in door and cleaning door are in good shape

49 O2 Sensor Calibration To be sure the O2 Sensor are in a good shape, it have to be checked and calibrated minimum once a year. To do that follow the instruction below. 1. Demount the O2 sensor from the smoke Outlet. (see picture) 2. Power on the boiler 3. Keep the sensor connected to the cable 4. After 3 min. it should show 20-21% on The display. 5. If the readings fail 3-4%, try to Calibrate the O2 sensor, see below. 6. Is the difference bigger, the O2 sensor must be replaced. ( Part no ) Menu to calibrate. Main Menu uk Service o Calibrate O2 Tenperature sensor O2 sensor 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 always be calibrated Air Nozzles. The XXL boilers are mounted with secondary air nozzles in the sides, as on the picture, to the right. If the fuel is wet we need air directly in the flame, but by dry fuel, the most of the secondary air have to be supplied above the flame, so it can be mixed with the gasses. To be able to control the combustion in the best way, the nozzel can be open and close to fit each case. By turning the nozzle it is possibly to control the direction of the air, because the hole are drilled in a 30 angle

50 To get access to the nozzles, the covers on the side have to be taken of. The nozzles are open when they are pressed in the 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 Chamot stone The burning chamber is full or partly covered with chamot stone, produced from heat resident concrete, to give the best combustion

51 The roof have in the burning chamber have two functions. 1. Give the smoke a longer way through the boiler, that give a better cooling of the smoke and will result in a higher boiler efficiency. 2. The heat from the roof will reflect down into the fuel, and helping drying out wet fuel By changing the length of the roof, it is possibly to regulate the temperature in the burning chamber. Depending on the used fuel, the side in the burning chamber will covered or not covered with chamot stone 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 15-25% 100% 0% or only in the front Pellets 6-15% 100% 0% Straw 10-25% 50% 0% Chamotstone Maintenance: On the yearly service on the boiler, all stone have to be checked, and changed if needed. When replacing the roof, or a part of it the space between the stone have to be sealed with suitable mortar, the same mortar can be used to fix the sidestone if they are being replaced. If a stone have a simple crack there is no reason to change it, so long as the steel plate are covered

52 13.5 Combustion fans The XXL boiler have 4 up to 6 Fans, depending on the boiler size. All the fan can be controlled indpendet The address and Fan no. is always the same, as indicated below. Primary fan, blows the air to the combustion trough the fire grate, in different zones, how many zone, depend on the 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 the fire grate. Primary Fan 2 Primary Fan 1 Secundary Fan 3 and 4 All the fan, have the air intake connected to the boiler bottom part, this have 2 reasons, we cool down the bottom section on the boiler, and we get preheated air to the combustion, and that is great when we burn fuel with high water content

53 The boilers have a inverter for each fan. It give the opportunity to adjust the output different on the different Primary and the Secondary fan. The standard settings for the fans are indicated in chapter In the back of this user manual, a user manual for the 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 Fan Maintenance: By the yearly service on the boiler, the fan shall be removed and cleaned properly. It is not enough just to clean them with compressed air, the fan wheel must be cleaned with a brush. If the fan wheel are not cleaned properly, the effect of the fan will be reduced

54 13.6 Flue fan The boiler is supplied with a flue fan that is operating with a variable speed drive. This Variable speed drive, adjust the speed on the flue fan according to the signal from the pressure gauge, to keep the right under pressure inside the boiler. The boiler has a Analog Pressure transmitter installed, that measure the pressure inside the boiler, and the transmitter send a 0-10v signal to the Variable speed drive, to speed up or to slow down the smoke fan, to keep the right under pressure. Hose for connecting the boiler and the pressure transmitter, have to be cleaned 3-4 times a year. To clean 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 parameter P39 on the inverter. If P39 is set at -40, it give under pressure at 40 Pa ± and -60 gives a under pressure at 60 Pa ± In the back of this user manual, a user manual for the Variable Speed Drive placed. The signal, that control the Flue fan inverter, are send to the PCT400 as well, so it is possibly, to get the Pa and the Hz on the display, and saved the value in the log. Pct V The start/stop signal to the inverter is controlled with the small PCT277 board. The PCT277 get run signal from the main board on output 6. Led for signal coming from mainboard Led on when the output goes to the flue fan inverter

55 Flue Fan Maintenance: If the flue fan start to run faster to keep the correct under pressure in the boiler, we need to clean, either the hose between the pressure transmitter and the boiler or the flue fan wheel itself. 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 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, and with the correct brush it is easy to clean the wheel proper trough the on. Cleaning door

56 13.7 Fire grates. The KSM-Multistoker XXL has a moving floor which means that the fire grates in the burning chamber, are moveable. This contributes that the XXL boiler is really good at burning difficult fuel. The grates are divided in sections measuring 30 cm. The 1 st section is not moveable, the 2 nd Section is movable, the 3 rd Section is not moveable and the 4 th Section is movable. In the boiler 750 XXL and 1000 XXL there is additional two grates. The 5 th grate is not moveable and the 6 th is movable. The grate where the fuel is delivered has to remove a most of material and therefore this grate 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 to little the fuel will accumulate in the back of the boiler and there is danger that the top stones are lifted above the burning chamber which results in the stones falls down and crashes. If the grates are running too much it results in the fuel is not burned appropriately before it dumps down in the ash screw. You do not get the full value of your fuel and you risk transporting glows out in the ash system. On this picture you can see the mentioned parts. Ash screw Grate 2 Fixed grate Primary air Moving grate 1 Fixed grate Service door Adjustment possibilities is described in section

57 13.8 Moving floor. The KSM-Multistoker XXL has as previously mentioned moving floor in the bottom of the burninghead. And when the grates are moving the dust and ash will fall between the grates. This dust and ash has to be removed underneath the grates to ensure that the movement of the grates does not block. Therefore there is mounted a scraping system which transports the ash forward and at last into the ash channel. On the picture 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 is running the spindle goes all the way in and out before it stops. If the spindle does not come the whole way out, it might be that there is a piece of clinker in the opening. To remove it you can try to run manually with the scrape several times ( TEST ), if that does not work you have the clean the ash channel and take off the first flat grate to come down to the front scrape. The adjustment possibilities are described in chapter

58 Maintenance fire grate / moving floor. Minimum once pro year you should check if the grates and the moving floor are running perfect.. At the annual service, you need to take out the fire grates, to be able to clean it properly below, and see 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 just lay loose on the shaft. When the grates are taken out, they have to be cleaned, before putting them back. Especially the air openings must be clened, to ensure that there is free passage If the grates are worn out a lot. They have to be changed

59 To get access to the hydraulic cylinder for the fire grate 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 the hydraulic cylinder must be checked for possible oil leak

60 13.9 Hydraulic unit The fire gate and the moving floor are driven by hydraulic. The pump is a load sensing pump, such pump, automatic 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. Valve that closes to the pressure gauge Standby pressure 50-55Bar Plug for oil level and temperature alarm Oil filling point Each fire grate has its own cylinder

61 Hydraulic oil Level of oil, have to be 5cm below the filling point. KSM recommend, to change the oil each 2. year Alarm The hydraulic system can give up to 3 different alarms. Hydraulic alarm: Oil level: Oil temperatur: If the electrical motor are equipped with temperature control, this alarm will come up if it get to hot. 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. In the case of too high oil temperature, this alarm will be activated, and it is not possibly to run the system, before oil are cooled down. There can be 3 reasons to this alarm. 1. Standby pressure are too high (must be adjusted) 2. It is too hot in the boiler room 3. To little oil at the unit

62 13.10 Ash auger. The XXL boiler have automatic ash auger in the boiler and a tilted ash auger on the side, to transport the ash into a suitable ash container. It is important that the connection from the tilted ash auger to the ash container is closed tight for 3 reasons: 1. We do not want dust in the boiler room 2. If it is not closed tightly the boiler controller will get false O2 readings 3. The flue fan have to run quicker, to keep the correct under pressure in the boiler. Adjustments of the ash auger are done as described in chapter It is important that the bottom ash screw is filled / covered with ash. If not the is a risks of: 1. The boiler gets false air inside. 2. There is transported glowing ash into the ash bin. 3. The ash auger is exposed to unnecessary heat. On this picture you can see the ash auger in the bottom of the boiler. You also can see the front of the fire grate which pushes the ash down to the ash auger. It is also possible to let the horizontal ash screw out the wall. The lifting auger can be mounted like on this picture with the ash bin

63 13.11 Automatic boiler cleaning. Along with the development of the KSM-Multistoker XXL, it has become easier to maintenance your boiler. The boiler have as standard automatic heat exchanger cleaning system. But even though the boiler is equipped with these automatic cleaning spiral, the heat exchanger pipe, must be cleaned manually minimum once a year. In all smoke 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 the loses into the chimney and give the boiler a higher efficiency. The spirals are driven by small clutches which are mounted on the inside of the door The motor that turn the spirals, are placed on the outside of the door. Bushing Main bearing All the small bushing, must be greased minimum Twice a year, as well as the main bearing in the Middle, behind the gearbox

64 To open the cleaning door the spirals has to be disconnected from the clutches. This is how to do so: 1. Set the switch on 0 2. In the controller, go into test mode and activate the heat exchanger cleaner 3. Let the cleaner 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 the clutches on the door is turn 90 compared to the clutches on the spirals. Then you are sure that you can close the door and that the spirals graps. Adjustment of the smoke pipe cleaner is done as described in chapter

65 14.0 Automatic Fuel Filling Device, Fire Damper / transport screw. KSM-Multistoker XXL is mounted with an automatic filling device which automatically is filling fuel from an extern stock. Such device is shown on the picture below. Servicecover, if fuel should accumolate the cover will be pressed up against the mounted doorcontact and the transport system will be stopped. Down pipe, which always has to be empty to avoid back fire. Motor for flame damper, which opens the flame damper. The motor have a spring return function, so in case lack of power, the flame damper will close automatically. The inspection door, from where the sensors can be cleaned IS A DANGER for getting pinched and may only be opened when the boiler is 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: Sensor: Should as a minimum be cleaned once pro month or as required. Rubber list: Lists both for the inspection gate and where the flame damper closes tightly in the top have to be really tightly closed to avoid back-fire Fuel transport, parameter. In this chapter there will be a describe the feeding cycle. At the picture below, arrows and text shows all the functions, that work in the feeding process. On the next pages, we will illustrate the feeding process, step by step. In the menu there are several parameters, that have effect on the feeding cycle, but the 2 parameter below are the most important, when we run the feeder in the standard way. Main Menu uk Accessories o Transport auger Start delay m.:... 0 Stop delay s.:

66 14.2 Fuel transport, Displayed. Transport auger Transport SW Flame damper motor Flamedamper Switch Fuel sensor The light, that indicate the transport SW, have to be green all the time, that indicate that the service lid is closed and Ok. If the transport auger overfills the flame damper or a big lump of chip block the outlet on the transport auger, the service lid will be pressed up and the 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 client will get a text message, with the alarm. If the lid just open shortly, with a big chip, and close again, the feeding will keep on running. Transport SW The yellow alarm box, will disappear itself, as soon as the reason are cleared, and the service lid are closed again 14.3 Fuel transport step by step. Step 1. Fuel sensor When the fuel sensor become green, the fuel in front of the sensor is used

67 Step.2 Damper motor When the time Start delay m. has expired, the flame damper motor will be activated, and become green. Step 3 Flame damper Switch When the damper 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 that alarm. 1. The damper motor doesn t open 2. The damper switch is not correct adjusted 3. The damper switch is broken 4. The damper is blocked, and can t open full

68 Step 4 Transport auger When the controller have got the signal from the flame damper switch, the transport augers will be activated. The controller can run up to 4 transport augers. There 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 fuel sensor, become grey, there is fuel in front of it. And when the time Delay stop s. has expiered, the transport augers stop and the flame damper close. Now the process starts again at step

69 14.2 Transport Log In the log file it is possibly to see what state the transport system are in, or what state in was in, when a fault come up. Here below is an explanation for the different state for the transport system, that are written in the log file :18:29 Trans from 0 to :18:30 Trans from 1 to :18:57 Trans from 2 to :18:59 Trans from 3 to :19:02 Trans from 4 to :19:04 Trans from 5 to :19:07 Trans from 6 to 0 0: The fuel sensor is covered. 1: The fuel sensor is uncovered and is waiting for expiration of the timer, menu/accessories/transport/delay start m. 2: Delayed start of the transport has expired and the fire damper motor is activated and is waiting for signal from the Belimo SW which declares that the fire damper is open. 3: The Belimo SW is activated and the transport starts. 4: the sensor is covered and awaits expiration of the timer, menu/accessories/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 :19:05 Fuel: from 5 to 6 (34811) The value in the parenthesis is the overall operation time in seconds for the transport and is used in the calculation of fuel consumption. This is only useable when you run with pellets from an extern silo Flamdamper motor To be sure the transport system work correctly, the damper have to be adjusted properly for two reasons The damper must close properly, so it is airtight, that reduce the risk of burn back, to adjust it, see the information below. 1.Loosen the clamp 2. Activate the damper in test 3. Close the flap 5 4. Tighten the clamp proper The damper switch must also be adjusted correct, so the transport auger, don t start before the damper are fully open.. 1. Deactivate the damper in test 2. Check the damper are closed 3. Check the black screw stay at 6,5 4. With the screw at 6,5, the transport auger will start before the damper is fully open. If you have a Honeywell damper motor, you are not able to adjust the switch, as written above

70 15.0 Hydraulic feeding system. (Moving floor). Hydraulic moving floor, is the preferred feeding system in big installation, where the fuel are woodchip. The fuel storage can be in the same level as the boiler room, or in the cellar, below the boiler room, we just need to have in mind, that the tilted auger can work perfect, it the angle on the auger I bigger than 45 : The hydraulic feeding system, include the following component: 1. From 1 up to 5 set of moving rams in the fuel storage. 2. The hydraulic cylinder 3. Hydraulic power pack 4. Fuel sensors to start the hydraulic 5. Fuel auger at the end of the storage 6. Tilted fuel auger max. 8m in 45 Function: 1. When the boiler needs fuel, 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 lamp on the screen for the sensor, also change to green 4. The Hydraulic cylinder start to move. 5. When the ram reaches the end, the hydraulic pressure will rise, and the pressure controlled valve will change the oil flow, and the cylinder will change direction. 6. When the sensor is activated by the fuel, the hydraulic stop again. The fuel sensors are placed in set with 2 sensors by each cylinder, the left sensor are the master, and the right the slave The sensor we use indicate with a red light, the measure point, that is very handy, when we adjust the sensor. On the picture below, it is possibly to see this red light from the sensor, but a bit weak in the flash light from the camera

71 15.1 Maintenance Fuel sensor The surface on the infrared eye, must be cleaned now and then, if not, the sensor will start to send the signal full even the auger is empty. Adjustment: To be sure that the auger is not overfilled, the sensor has to be adjusted correct. Correct adjustment is when the channel is half full as on the picture below. The hydraulic stop, when both sensors in a set is activated. Gren light = power ON Yellow light = Fuel present Adjusting 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 of the sensor, always start with the left one, (master). 1. Turn the adjusting screw left to the end, on both sensors. 2. Fill up the auger channel with the wanted amount of fuel. (as on the picture above) 3. Turn the adjusting screw, on the left sensor, right until the yellow light, goes on 4. The green light on the slave sensor, goes on 5. Turn the adjusting screw, on the right sensor, right until the yellow light, goes on. 6. Do the step 1 to 5 on all the installed sensor

72 Hydraulic power pack Switching valve. The power pack is equipped with a pressure-controlled switching valve, that change the direction of the hydraulic cylinders. When the cylinder reach the end the pressure will rise, and the valve switch direction. The switching pressure, have to Be between 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 checked after the system have been running for 2 weeks. Justerskruer Pressure gauge Hydraulic oil Level of oil, have to be 5cm below the filling point. KSM recommend that the oil is changed each 2. Year. Valve that closes to the pressure gauge Plug for oil level and oil temperature alarm. Oil filling cap

73 Alarm The hydraulic system can give up to 4 different alarms. Hydraulic alarm: Oil level: Oil temperature: Hydraulic timeout If the electrical motor are equipped with temperature control, this alarm will come up if it get to hot. 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. In the case of too high oil temperature, this alarm will be activated, and it is not possibly to run the system, before oil are cooled down. If the fuel storage is empty, it makes no sense to keep on running the hydraulic power pack, longer than the time limit, set in the menu Hydraulic roof The hydraulic system operate the hydraulic roof as well, the control panel is normal placed outside the building and have key lock, so only approved staff have access. The roof itself open by 2 or 3 cylinders depending on size. As standard the roof have steel profile plate, but can be delivered with what kind the client ask for

74 16.0 Precautionary Measures. The KSM-Stoker meets with all current EU regulations regarding Small & Medium Bio fuel Boilers Fire Protection, thermal. The KSM-Stoker is provided with a thermal valve with a sensor and also a pressure tank with a nonreturn valve, to avoid losing the water in the tank even if its water supply should fail. The sensor registers if the screw tube runs too hot i.e. up to more than 95 o C and should this occur, the thermal valve will turn on the water in the pressure tank and the water will extinguish the fire and ember. Once this has been done, the thermal valve will cool down and the water is automatically turned off again, in order to avoid a flooding. If the valve is overheated please notice if it closes tightly because it otherwise will leak water Personal Protection. The KSM-Stoker is fitted with a safety switch on the silo lid; this switch will cut 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 Electric Protection Fuses. The KSM-Stoker control is furnished with overload protection on each motor which is triggered if the screw motor should be exposed to overcharge. Furthermore, fuses are mounted inside the control as a protection of the control itself and its other components Maximum Heat Thermostat. The KSM-Stoker is provided with a sensor for interruption of the control in case the boiler has been heated to more than 95 o C. If this sensor has been activated, it must be manually re-set by means of the small pressure button. The maximum heat thermostat is mounted in the upper left corner of the Control Panel Water pressure switch. The controller has 2 terminals, that are prepared for connecting a water pressure switch. If the switch has been released, because lack of pressure, you will get small yellow warning sign on the display with the text Water pressure. This sign will disappear by itself when the water pressure is back

75 17.0 WEB interface With PCT400 controller it is possibly to access the boiler trough internet. It is possibly to see how the boiler is running, but what is more interesting, it is possibly to adjust nearly all parameter with the WEB interface. Some function is not safe to adjust remotely, and are therefore not possibly to change. All the parameter is protected with a password, so you need to know that to be able to change any parameter value. To change a parameter, you just 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 the boiler is online for a time you will get curves, showing how it is running, as on the picture above. To get the boiler connected to the internet, some setup at the service menu are needed, and to do that, following information is needed. 1. Extern IP address: (Can be found by entering in your browser). 2. The stoker s given IP address: Sub mask: Gateway: DNS: Password

76 Your router has to be set up to forward port 90 to the stoker s IP address. (should be done by an IT-skilled person). Setup internet connection: 1. Go to Menu / Service / Konfig / IP. 2. Enter the stoker s given IP address. 3. Enter Sub mask address. 4. Enter Gateway address. 5. Enter DNS address. ( google dns, can be used) 6. Enter the wanted 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 watch down in the right side of the screen, shall show date and time correctly. To connect to the stoker via the internet you have to write the IP address in the browser ip:port nr. Example With special setups it is the stoker s intern IP address which is used. However this is only for IT specialist

77 18.0 Log file If the stoker cycle time is set to 10 sek. Information about the boiler condition will be written in the log file each 10 sek. Below there is an example, from a log file :35:08 TempSP Temp Power SmokeT OxySP Oxy% s.t Cycle Vac. Hz :37: :37: :37: :37: :37: :37: :38: :38:12 Trans from 0 to :38:13 Trans from 1 to :38: :38: :38: :38:46 Trans from 2 to :38:48 Trans from 3 to :38: :38:52 Trans from 4 to :38:54 Trans from 5 to :38:55 Trans from 6 to :38: :39: :39: :39: :39: :39:41 Trans from 0 to :39:42 Trans from 1 to :39: :39: :40: :40:15 Trans from 2 to :40:17 Trans from 3 to :40: :40:22 Trans from 4 to :40:24 Trans from 5 to :40:25 Trans from 6 to :40: :40: :40: :40: :41: :41: :41:19 Trans from 0 to :41:20 Trans from 1 to :41:21 Trans from 0 to :41:22 Trans from 1 to :41: :41:29 Run(10) -> Shutdown(19) :41:30 Trans from 2 to :45:39 Shutdown(19) -> Pause(20) :45:40 Trans from 0 to :45:41 Trans from 1 to :45:45 Pause(20) -> Pause(11) :45:45 SS from 2 to :46:14 Trans from 2 to :46:16 Trans from 3 to :46:19 Trans from 4 to :46:21 Trans from 5 to :46:22 Trans from 6 to :47:45 SS from 6 to

78 19.0 SMS warning system The PCT400 can, when it is connected to the internet, communicate the SMS server by KSM-Stoker in Denmark. And when it is connected to the SMS server, the client is able to receive all kind of boiler alarm, as SMS text on his mobile phone. List of available alarm text is written here below, with description. Alarm No. SMS Text Description 007 Startup timeout High O2 to long time 008 Module problem Overload switch or fuse blowen 009 Hopper cover open Close it 010 Boiler temp > max Software alarm 011 Boiler have lost water Water pressure gone 012 Boiler is overheated High temp switch 014 Hydraulic timeout Hydraulic have been running 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 Fluefan alarm Check Fan and inverter 024 Transport SW Service lid is open 026 Module comm alarm Check module 027 Alarm hydraulic pump Electrical motor at the hydraulic unit overheated 028 Flame damper SW Check SW and 029 Hydraulic oil level More oil needed 030 Hydraulic oil temp Check oil pressure switch 031 Fan alarm Check fan and inverter 032 HZ alarm fluefan Flue fan or Inverter broker HZ < 5 for 15 sek 033 Vac. Alarm fluefan Door open or dirty boiler Pa < 5 for 15 sek 034 Alarm bypass SW Problems with bypass valve on bag filter 035 Ignition timeout No flame in time 036 Alarm boiler temp. Low To high demand or boiler dirty 037 Alarm Smoke temp. high Boiler dirty or to high output

79 20.0 Precautionary Measures. The KSM-Stoker meets with all current EU regulations regarding Small & Medium Bio Fuel Boilers Fire Protection, thermal. The KSM-Stoker is provided with a thermal valve with a sensor and also a pressure tank with a nonreturn valve, to avoid losing the water in the tank even if its water supply should fail. The sensor registers if the screw tube runs too hot i.e. up to more than 95 o C and should this occur, the thermal valve will turn on the water in the pressure tank and the water will extinguish the fire and ember. Once this has been done, the thermal valve will cool down and the water is automatically turned off again, in order to avoid a flooding. If the valve is overheated, please notice if it closes tightly because it otherwise will leak water Personal Protection. The KSM-Stoker is fitted with a safety switch on all auger lid; this switch will cut off the electric power to the stoker if the lid is opened. This is to protect you against any damage while working with the auger Electric Protection Fuses. The KSM-Stoker control is installed with overload protection on each motor which is triggered if the screw motor should be exposed to overcharge. Furthermore, fuses are mounted inside the control as a protection of the control itself and its other components Over Heating Switch. The KSM-Stoker is provided with a sensor for interruption of the control in case the boiler has been heated to more than 105 o C. If this sensor has been activated, it must be manually re-set by the small push button. The maximum heat thermostat is mounted in the upper left corner of the Control Panel. On the monitor screen there will appear a small yellow warning sign with the text Overheat. This sign will disappear by itself when the overheating thermostat is reconnected Water pressure switch. The controller has 2 terminals, that are prepared for connecting a water pressure switch. If the switch has been released, because lack of pressure, you will get small yellow warning sign on the display with the text Water pressure. This sign will disappear by itself when the water pressure is back

80 21.0 Maintenance. The KSM-Stoker is constructed in a way so as to minimize the maintenance as much as possible; however there are a few things that call for your attention Gear. From the factory, the strong gear has been filled with lubricant and this needs no topping up. However, pay attention if oil spots appear on the floor that might originate from the gear. In that case, contact your plant supplier Fire Protection. Once a year, turn off the small tap on the pressure tank and then dismount the tube on the thermal valve. Direct the tube into a bucket and open the tap. After this, dismount the thermal valve and clean away old sawdust from the hole leading into the screw. After flushing and cleaning, re-screw the tube and the valve don t forget to turn on the water tap again Air Nozzles. Before starting up a new heating season, make sure that the air nozzles have not burnt and are broken. 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 Screw Tube. As occasion requires, clean this tube for clinker once or twice during each heating season, in the area where the tube runs into the burner head. Be particularly careful to remove any clinker in the corners seeing that this may otherwise prevent the fuel from moving forward and will thus block the screw Firebricks. It is easy to replace the broken bricks, always use firebricks supplied by KSM to be sure to get the correct quality. (see chapter 13.4) 21.6 Combustion Air Fan. If the stoker is placed in dusty surroundings, the combustion air fan should be dismounted for cleaning before the start of a new heating season. Dust will gather on the fan blades and this will reduce the efficiency of the combustion air fan. For easy removal use a fan pistol connected to a compressor Seals All seals around doors must fit tightly, in order to avoid flue gas escape and false draught. Damaged seals must be changed

81 21.8 Smoke fan. If the flue fan start to run faster to keep the correct under pressure in the boiler, we need to clean, either the hose between the pressure transmitter and the boiler or the flue fan wheel itself. 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 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, and with the correct brush it is easy to clean the wheel proper trough the on. At the same time as cleaning the fan wheel it would be a good idea to remove the blue air tube on the vaccum measurer. After the tube is removed from the pressostat it should be cleaned with a compressor to ensure free air penetration into the boiler. Cleaning door