KSM-Stoker KSM-Multistoker XXL User manual

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User manual.
KSM-Multistoker XXL
With PCT400 O
2
Controller
Dealer:
Save money !
Install a
KSM-Stoker

- 2 -
____________________________________________________________________________
We the undersigned,
PRODUCER: KSM-STOKER A/S
ADDRESS: NAESSUNDVEJ 440,
CITY: DK-7960 KARBY
PHONE: [phone]
FAX: [phone]
Email: [email protected]k
WEBSITE:www.ksm-stoker.dk
hereby declare that
- KSM-Multistoker _____ _____, series No. ___________ CE nr 2006/97/56/EEC/016
-has been manufactured in conformity with the prescriptions of the EU Machinery Directive
(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
under
-the common European standard EN 303-5.
Place -----------------------------------------------------------------------
Date -----------------------------------------------------------------------
Signature -----------------------------------------------------------------------
EU Declaration of Conformity

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Index for KSM-Multistoker XXL manual.
1.0 Introduction....................................................................................................................................... 10
2.0 Fuel.................................................................................................................................................... 11
2.1 Wood Pellets................................................................................................................................. 11
2.2 Wood Chip.................................................................................................................................... 11
2.3 Grain.............................................................................................................................................. 11
2.4 Alternative Fuels........................................................................................................................... 11
3.0 Warranty............................................................................................................................................ 12
3.1 Standard warranty......................................................................................................................... 12
3.2 Water quality................................................................................................................................. 13
4.0 Control Panel..................................................................................................................................... 14
4.1 Display.......................................................................................................................................... 14
4.2 Pushbuttons................................................................................................................................... 16
5.0 Starting up the boiler......................................................................................................................... 17
6.0 Shut down the boiler......................................................................................................................... 18
7.0 Software instructions......................................................................................................................... 19
7.1 Logs............................................................................................................................................... 19
7.2 Run................................................................................................................................................ 19
7.2.1 Boiler temp............................................................................................................................. 19
7.2.1.1 Set temperature °C ......................................................................................................................... 19
7.2.1.2 Go pause temp +°C ......................................................................................................................... 19
7.2.1.3 Back to run mode -°C ...................................................................................................................... 19
7.2.1.4 Max output % ................................................................................................................................. 19
7.2.1. Min. output % ................................................................................................................................. 20
7.2.2 Stoker screw........................................................................................................................... 20
7.2.2.1 Cycle time. ...................................................................................................................................... 20
7.2.2.2 O2 / Manual controlled .................................................................................................................. 20
7.2.2.3 Max. fuel s. ..................................................................................................................................... 20
7.2.2.4 Min. fuel s. ...................................................................................................................................... 20
7.2.3 Oxygen................................................................................................................................... 20
7.2.3.1 Max. power oxy% set...................................................................................................................... 21
7.2.3.2 Min. power oxy% set ...................................................................................................................... 21
7.2.3.3 Fuel stop O
2
% .................................................................................................................................. 21
7.3 Start up.......................................................................................................................................... 21
7.3.1 Stokerscrew............................................................................................................................ 21
7.3.1.1 1. Start fuel. ................................................................................................................................... 21
7.3.1.2 2. Start fuel. ................................................................................................................................... 21
7.3.1.3 Max. fuel s. ..................................................................................................................................... 22

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7.3.2 Oxygen................................................................................................................................... 22
7.3.2.1 Go to startup O
2
% .......................................................................................................................... 22
7.3.2.2 Oxy. differens.................................................................................................................................. 22
7.3.3 Smoke temperature. ............................................................................................................... 22
7.3.3.1 Go to run mode °C .......................................................................................................................... 22
7.3.4 Startup time min..................................................................................................................... 22
7.3.5 Startup output %..................................................................................................................... 23
7.3.6 Ignition................................................................................................................................... 23
7.3.6.1 Ignition delay s. ............................................................................................................................... 23
7.3.6.2 Fuel delay. ....................................................................................................................................... 23
7.3.6.3 Ignition timeout m. ......................................................................................................................... 23
7.3.6.4 No ignition. ..................................................................................................................................... 23
7.3.6. Semi Auto. ...................................................................................................................................... 23
7.3.6.6 Automatic. ...................................................................................................................................... 24
7.3.6.7 Auto w. empty ................................................................................................................................ 24
7.4 Pause. ............................................................................................................................................ 24
7.4.1 Stoker screw........................................................................................................................... 24
7.4.1.1 Pause fuel s. .................................................................................................................................... 24
7.4.1.2 Pause in minutes. ........................................................................................................................... 24
7.4.1.3 Empty-run in minutes. .................................................................................................................... 24
7.4.2 Fan.......................................................................................................................................... 24
7.4.2.1 Output %. ........................................................................................................................................ 24
7.4.2.2 Fan on time. .................................................................................................................................... 2
7.4.3 Oxy go to pause...................................................................................................................... 25
7.5 Fuel................................................................................................................................................ 25
7.6 Accessories.................................................................................................................................... 25
7.6.1 Transport auger...................................................................................................................... 25
7.6.1.1 Run as stoker screw. ....................................................................................................................... 26
7.6.1.2 After run stoker screw %. ............................................................................................................... 26
7.6.1.3 After run before pause s. ................................................................................................................ 26
7.6.1.4 Fuel delay. ....................................................................................................................................... 26
7.6.1. Stop delay s. .................................................................................................................................... 26
7.6.1.6 Feeder timeout m. .......................................................................................................................... 26
7.6.1.7 Delay start next s. ........................................................................................................................... 26
7.6.1.8 Cell lock delay stop s. ...................................................................................................................... 26
7.6.1.9 Cell lock cycle s. .............................................................................................................................. 27
7.6.1.10 Fuel consumption ......................................................................................................................... 27
7.6.1.10.1 Fuel kg. .................................................................................................................................. 27

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7.6.1.10.2 Fuel div. ................................................................................................................................. 27
7.6.1.10.3 Fuel s. .................................................................................................................................... 27
7.6.1.10.4 Reset fuel counter ................................................................................................................ 27
7.6.2 Ash auger. .............................................................................................................................. 27
7.6.2.1 Ash auger on s. ............................................................................................................................... 27
7.6.2.2 On when fuel sum m. ..................................................................................................................... 27
7.6.3 Moving floor.......................................................................................................................... 28
7.6.4.1 Moving floor before pause s. .......................................................................................................... 28
7.6.3.2 Moving floor run time s. ................................................................................................................. 28
7.6.3.3 Pause at low output m. .................................................................................................................. 28
7.6.3.4 Pause at high output m. ................................................................................................................. 28
7.6.4 Firegrate 1 to 3....................................................................................................................... 28
7.6.4.1 Firegrate X on s. .............................................................................................................................. 28
7.6.4.2 Pause at low output s. .................................................................................................................... 28
7.6.4.3 Pause at high output s. ................................................................................................................... 29
7.6.5 Fan.......................................................................................................................................... 29
7.6.6 Boiler cleaner......................................................................................................................... 29
7.6.6.1 Run time in seconds. ...................................................................................................................... 29
7.6.6.2 Pause in hours. ............................................................................................................................... 29
7.6.7 Flue fan. ................................................................................................................................. 29
7.6.7.1 Flue fan prestart s. .......................................................................................................................... 30
7.6.7.2 Flue fan stop delay m. .................................................................................................................... 30
7.6.7.3 Flue fan 100, 60, 40, 30, 20 and 0. ................................................................................................. 30
7.6.8 Logs (solid fuel)..................................................................................................................... 30
7.6.9 Cyclon/Bagfilter..................................................................................................................... 30
7.6.9.1 Cyclon ash on s. .............................................................................................................................. 30
7.6.9.2 Cyclon ash pause m. ....................................................................................................................... 30
7.6.9.3 Incl. Boiler deashing ........................................................................................................................ 31
7.6.9.4 Bagfilter open temp ........................................................................................................................ 31
7.6.9. Bagfilter close temp ........................................................................................................................ 31
7.6.9.6 Filter ash on s. ................................................................................................................................. 31
7.6.9.7 Filter ash pause m. .......................................................................................................................... 31
7.6.9.8 Incl. Boiler deashing ........................................................................................................................ 31
7.6.10 Hydraulic valve.................................................................................................................... 31
7.6.10.1 Hydraulic moving floor 1 in %. ...................................................................................................... 31
7.6.10.2 Hydraulic moving floor 2 in %. ...................................................................................................... 32
7.6.10.3 Start delay s. ................................................................................................................................. 32
7.6.10.4 Hydraulik timeout m. .................................................................................................................... 32

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7.6.11 Lime dosage %..................................................................................................................... 32
7.6.12.1 Flue gas front gain............................................................................................................. 32
7.6.12.2 Flue gas front offset .......................................................................................................... 32
7.6.13.1 Flue gas back gain............................................................................................................. 32
7.6.13.2 Flue gas back offset........................................................................................................... 32
7.6.14.1 Herz gain........................................................................................................................... 33
7.6.14.2 Herz offset......................................................................................................................... 33
7.6.15.1 Vac. gain ........................................................................................................................... 33
7.6.15.1 Vac. offset......................................................................................................................... 33
7.7. Heating system............................................................................................................................. 33
7.7.1 Circ. Pump start C.................................................................................................................. 33
7.7.2 Circ. Pump SP........................................................................................................................ 33
7.7.3 Standby pump start C............................................................................................................. 33
7.7.4 Boiler shunt SP....................................................................................................................... 34
7.7.5 Heat circuit............................................................................................................................. 34
7.7.6 Show pump info..................................................................................................................... 34
7.7.7 Buffer tank ............................................................................................................................. 34
7.7.7.1 Buffer temp top C ........................................................................................................................... 34
7.7.7.2 Buffer temp bottom C .................................................................................................................... 34
7.7.7.3 Shunt close time m. ........................................................................................................................ 34
7.7.8 Cascade .................................................................................................................................. 34
7.7.8.1 Cascade ........................................................................................................................................... 3
7.7.8.2 Start slave power ............................................................................................................................ 3
7.7.8.2 Stop slave power ............................................................................................................................ 3
7.7.8.3 Delay m. .......................................................................................................................................... 3
7.7.8.4 Hours as Master .............................................................................................................................. 3
7.7.8. Run mode ....................................................................................................................................... 3
7.7.8.6 Port ................................................................................................................................................. 36
7.7.8.7 IP 1 .................................................................................................................................................. 36
7.7.8.8 IP 2 .................................................................................................................................................. 36
7.7.8.9 IP 3 .................................................................................................................................................. 36
7.7.8.10 IP 4 ................................................................................................................................................ 36
7.8 Test................................................................................................................................................ 36
7.9 Date............................................................................................................................................... 37
7.10 Service......................................................................................................................................... 37
8.0 Alarm list........................................................................................................................................... 38
9.0 Automatic Ignition............................................................................................................................ 40
8.2 Ignition type.................................................................................................................................. 40
9.3 Start fuel........................................................................................................................................ 40

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9.4 Description of the automatic ignition, step by step....................................................................... 41
9.5 Ignition alarm................................................................................................................................ 41
9.6 Ignition restart............................................................................................................................... 41
10.0 Backend protection. ........................................................................................................................ 42
11.0 Buffer tank controller...................................................................................................................... 43
12.0 Cascade ........................................................................................................................................... 44
12.1 Cascade Setup. ............................................................................................................................ 44
12.1.1 Cascade ................................................................................................................................ 45
12.1.2 Start slave power.................................................................................................................. 45
12.1.3 Stop slave power.................................................................................................................. 45
12.1.4 Delay start / stop .................................................................................................................. 45
12.1.5 Master role ........................................................................................................................... 45
12.1.6 Run mode............................................................................................................................. 46
12.1.7 Port and IP address............................................................................................................... 46
12.2 Buffer tank .................................................................................................................................. 46
12.3 Display info................................................................................................................................. 46
12.4 Log info....................................................................................................................................... 47
13.0 Boiler instruction............................................................................................................................. 48
13.1 Section view with description..................................................................................................... 48
13.2 O2 Sensor.................................................................................................................................... 48
13.2.1 O
2
Sensor Calibration........................................................................................................... 49
13.3 Air Nozzles. ................................................................................................................................ 49
13.4 Chamot stone............................................................................................................................... 50
13.4.1 Guideline for chamotstone in the burning chamber............................................................. 51
13.4.2 Chamotstone Maintenance:.................................................................................................. 51
13.5 Combustion fans ......................................................................................................................... 52
13.5.1 Fan Maintenance:................................................................................................................. 53
13.6 Flue fan ....................................................................................................................................... 54
13.6.1 Flue Fan Maintenance:......................................................................................................... 55
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. ........................................................................................................................ 55
13.7 Fire grates.................................................................................................................................... 56
13.8 Moving floor. .............................................................................................................................. 57
13.8.1 Maintenance fire grate / moving floor. ................................................................................ 58
13.9 Hydraulic unit ............................................................................................................................. 60
13.9.1 Hydraulic oil ........................................................................................................................ 61
13.9.2 Alarm ................................................................................................................................... 61
13.10 Ash auger. ................................................................................................................................. 62
13.11 Automatic boiler cleaning......................................................................................................... 63
14.0 Automatic Fuel Filling Device, Fire Damper / transport screw...................................................... 65
14.1 Fuel transport, parameter. ........................................................................................................... 65

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14.2 Fuel transport, Displayed............................................................................................................ 66
14.3 Fuel transport step by step. ......................................................................................................... 66
14.2 Transport Log.............................................................................................................................. 69
14.3 Flamdamper motor...................................................................................................................... 69
15.0 Hydraulic feeding system. (Moving floor). ................................................................................... 70
15.1 Maintenance................................................................................................................................ 71
15.1.1 Fuel sensor ........................................................................................................................... 71
15.1.2 Hydraulic power pack.......................................................................................................... 72
1 .1.2.1 Switching valve. ............................................................................................................................ 72
1 .1.2.3 Hydraulic oil .................................................................................................................................. 72
1 .1.2.3 Alarm ............................................................................................................................................ 73
15.1.3 Hydraulic roof...................................................................................................................... 73
16.0 Precautionary Measures.................................................................................................................. 74
16.1 Fire Protection, thermal............................................................................................................... 74
16.2 Personal Protection. .................................................................................................................... 74
16.3 Electric Protection Fuses............................................................................................................. 74
16.4 Maximum Heat Thermostat........................................................................................................ 74
16.5 Water pressure switch................................................................................................................. 74
17.0 WEB interface................................................................................................................................. 75
18.0 Log file............................................................................................................................................ 77
19.0 SMS warning system ...................................................................................................................... 78
20.0 Precautionary Measures.................................................................................................................. 79
20.1 Fire Protection, thermal............................................................................................................... 79
20.2 Personal Protection. .................................................................................................................... 79
20.3 Electric Protection Fuses............................................................................................................. 79
20.4 Over Heating Switch................................................................................................................... 79
20.5 Water pressure switch................................................................................................................. 79
21.0 Maintenance.................................................................................................................................... 80
21.1 Gear............................................................................................................................................. 80
21.2 Fire Protection............................................................................................................................. 80
21.3 Air Nozzles. ................................................................................................................................ 80
21.4 Screw Tube. ................................................................................................................................ 80
21.5 Firebricks. ................................................................................................................................... 80
21.6 Combustion Air Fan.................................................................................................................... 80
21.7 Seals............................................................................................................................................ 80
21.8 Smoke fan. .................................................................................................................................. 81
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. ........................................................................................................................ 81
22.0 Service plan..................................................................................................................................... 82
23.0 Interruptions of the run ................................................................................................................... 83

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23.1 Unburned fuel in the ashes.......................................................................................................... 83
23.2 The boiler becomes sooty. .......................................................................................................... 83
23.3 Black display............................................................................................................................... 83
23.4 Combustion air fan does not run during plant run...................................................................... 83
23.5 The screw does not run ............................................................................................................... 83
23.6 Backfire....................................................................................................................................... 84
23.7 Clinker......................................................................................................................................... 84
23.8 Bothering smoke. ...................................................................................................................... 84
23.9 Condensed water in flue gas outlet............................................................................................. 84
24.0 Alarm list......................................................................................................................................... 85
25.0 Installation instructions................................................................................................................... 86
25.1 The boiler room........................................................................................................................... 86
25.2 Stoker.......................................................................................................................................... 86
25.2.1 Placing.................................................................................................................................. 86
25.2.2 Flue gas outlet...................................................................................................................... 86
25.2.3 Piping................................................................................................................................... 87
25.2.4 Anti-freeze measures............................................................................................................ 87
25.2.5. Check the screw direction of rotation ................................................................................. 87
25.2.6. Sprinkler, water connection ................................................................................................ 88
25.2.7 Starting Up........................................................................................................................... 88
26.0 Accessories...................................................................................................................................... 88
27.0 Piping Diagram............................................................................................................................... 89
28.0 Power Diagram. .............................................................................................................................. 90
29.0 Dimension drawings ....................................................................................................................... 91
30.0 Formula WEB Setup....................................................................................................................... 92

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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 5.

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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
7133.
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

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3.0 Warranty
3.1 Standard warranty
Declared wear parts
1:
6 months
Sensors, electric and electronic parts 1 years
Boiler body
2-3
: 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.

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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] 8 - 9.5
Water
hardness
(<500kW)
[mol/m
3
]
[°dH] <0.5 <2.8
Water
hardness
(>500kW)
[mol/m
3
]
[°dH] <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
(P
2
O
5
)
[g/m
3
] 5 – 30
Polysilicate
(SiO
2
)
[g/m
3
] 20 – 60
Alkaline
Polyamide
[g/m
3
] 10 – 50
Sulphite (SO
3
) [g/m
3
] 10 – 30
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.

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4.0 Control Panel
The PCT400 control from KSM-Stoker A/S is a full modulating O
2
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

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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.

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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.

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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.

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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 O
2
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.

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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.
7.2.1 Boiler temp
Menu / Run / Boiler temp
In this chapter you can find all parameters concerned the boiler temperature while operating.
7.2.1.1 Set temperature °C
Menu / Run / Boiler temp / Set temp °C (75°C)
The working temperature of the boiler. To keep the corrosion warranty on the boiler, you are not allowed
to go below 70°C
7.2.1.2 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.
7.2.1.3 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.
7.2.1.4 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.

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7.2.1.5 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 %.
7.2.2 Stoker screw.
Menu / Run / Stokerscrew
Parameters that control the stoker auger in run mode.
7.2.2.1 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 O
2
level, is if we feed in small amount of fuel quite often, and not a lot of
fuel with a long pause between.
7.2.2.2 O2 / Manual controlled
Menu / Run / Stokerscrew / O
2
/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 O
2
sensor and control the
stokerscrew manual.
When the value is set to “0” the stoker screw is controlled by the O
2
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 7.10.12 have to be set to
100%, and the boiler will run on/off.
7.2.2.3 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.
7.2.2.4 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.
7.2.3 Oxygen.
Menu / Run / Oxy
The O
2
measurements are important to get the best combustion.
The measured O
2
level, is the O
2
that are let in the flue after the combustion.
With a high output the combustion can use the most of the O
2
and the opposite by low output, then the
rest O
2
will be higher.