Hoval STU Series Installation, Operation And Maintenance Instructions
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Hoval STU Series Installation, Operation And Maintenance Instructions

Hoval STU Series Installation, Operation And Maintenance Instructions

Wood-pellet fired hot water boiler (150-1000kw)
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Installation, Operation and

Maintenance Instructions.

STU wood-pellet fired hot water boiler
(150-1000kW).
STUman May 2010 (WS2)

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Summary of Contents for Hoval STU Series

  • Page 1: Maintenance Instructions

    Installation, Operation and Maintenance Instructions. STU wood-pellet fired hot water boiler (150-1000kW). STUman May 2010 (WS2)

  • Page 2: Table Of Contents

    These instructions should be read and understood before attempting to install, commission or operate this unit. Material in this publication may not be reproduced without the company's written permission. Hoval Limited, Northgate,Newark, Notts NG24 1JN Tel: 01636 593413 or 593435 Fax: 01636 673532 e-mail: service@hoval.co.uk or spares@hoval.co.uk Website: www.hoval.co.uk...

  • Page 3: Introduction

    British Standard and Codes of Practice, Building Regulations and Local Authority Bylaws. Commissioning/Combustion Report Hoval, or Hoval Approved Engineers would normally commission the boiler. Thereafter Hoval recom- mended that any Biomass Combustion equipment should only be placed into operation and maintained by suitably trained and authorised personnel.

  • Page 4: Installation & Use

    Wood Pellet fuel to be delivered by specialist vehicle as utilised by the appointed fuel supplier to site. Fuel delivery via bulk blower vehicles fitted with suitable low-pressure blowers. Hoval do not recommend or endorse any particular fuel supplier or manufacturer however it is...

  • Page 5: Boiler Delivery, Offloading, Storage

    Note: Hoval approved engineers will assemble the stoker and the fuel feed system but would normally expect the installer to wire between the various motors and dampers on the stoker and the control panel unless it is mounted on the boiler or unless the wiring instruction is given at the time of order.
  • Page 6 Hoval STU Wood Pellet Boiler Stoker Detail Each boiler is supplied with a fully integrated pellet-burning stoker comprising combustion retort(s), modulating delivery auger(s), a transfer box, fully modulating primary (FD), secondary (ID) fans and lambda control. The transfer box is integrated with a bulk pellet store via either angled pick-up auger(s) or a flexible centreless auger arrangement depending on site layout.

  • Page 7: Technical Data

    Hoval STU Wood Pellet Boiler Technical Data STU Wood-Pellet Boiler Type 1000 • Output Maximum 1200 • Output Minimum Nominal Output 1085 • Full Load (nominal Output) Efficiency nCV % 88.4 89.0 89.6 90.1 90.7 90.7 90.7 91.6 92.6 93.5 •...
  • Page 8 Hoval STU Wood Pellet Boiler Dimensions and Technical Information STU Boiler Key: Dimensions: Flow (mm) 2441 2428 2523 2523 3038 3078 3078 3539 Returns - One either side, both to (mm) 1657 1644 1644 1644 2159 2159 2159 2619 be connected to a common inlet header...
  • Page 9 Hoval STU Wood Pellet Boiler Dimensions and Technical Information Key: Flow Connections: 1000 STU Boiler 1000 Returns, one either side, both (mm) Flow (PN6) DN125 DN150 to be connected to a common (mm) 3134 3282 Return (PN6) 2xDN125 2xDN150 inlet header...
  • Page 10 Hoval STU Wood Pellet Boiler Dimensions and Technical Information Modular Twin Cyclone Modular Twin Cyclone unit supplied with the STU800 and the STU1000 boilers, along with floor mounted Induced Draught fan (not shown) The unit and ID fan are to be mounted adjacent to (alongside or at rear) of the boiler to suit specific plant room layout. See Page 11 for...
  • Page 11 Hoval STU Wood Pellet Boiler Dimensions and Technical Information Typical Layout Hoval STU Boiler with modular twin cyclone, floor mounted ID fan and connecting ductwork. Hatched ducting NOT by Hoval To suit specific plant room layouts. Note easy radius bends in ducts.

  • Page 12: Cf Filter - Description, Technical Performance, Typical Units & Layout

    CF Biomass Filter Hoval CF Biomass Filter. Advanced air filtration for biomass heating. The Hoval CF Biomass Filter is an optional bespoke engineered air filtration device designed to remove air borne particles from the combustion gasses of biomass pellet heating boilers.

  • Page 13: Technical Information

    CF Biomass Filter Technical Information Boiler Filter Maximum Dimensions (mm) Weight Maximum Maximum Compressed boiler particulate (approx) flue gas temperature Height Length Depth output emission flow °C consumption level 200°C m STU 150 CF 150 <5mg/m 1510 1295 1255 0.36 STU 200 CF 200 <5mg/m...
  • Page 14 CF Biomass Filter Typical units (Measurements in mm) CF 500 unit Clearance of 1000mm required above the unit for filter withdrawal & replacement.
  • Page 15 CF Biomass Filter Typical units (Measurements in mm) Twin CF 1000 unit Induced Draught Inspection lids Inspection lids Cladding and Lagging 75mm thk Cladding and Lagging 75mm thk Control panel RCA 25 DD pulse valve Control panel Compressed air reservoir Flue Gas Outlet RCA 25 DD pulse valve...
  • Page 16 CF Biomass Filter Typical Layout STU 200 Wood Pellet Boiler with CF 200 Biomass Filter Hatched ducting not by Hoval. Note easy radius bends should be used. Outlet Outlet Outlet Outlet STU 200 Wood Pellet Boiler STU 200 Wood Pellet...

  • Page 17: Design Guidelines / Entry To Fuel Store

    Alternatively better boiler size matching or a cascade of boilers should be considered to deliver the required turndown. Hoval can offer a suitably sized buffer or storage vessel to match installed boiler output to anticipated loading. Fuel Storage With regard to the bulk storage or wood pellet fuel store the following simple guidelines offer advice to assist in the design and sizing for a successful installation.
  • Page 18 Consider the possible use of load cells or level probes within the bunker to indicate fuel used. Hoval can offer a number of silo based fuel store options or advise on most appropriate use of available space for a bespoke build fuel store.

  • Page 19: Typical Plantroom Layouts

    Hoval STU Wood Pellet Boiler Typical Plantroom layouts The following examples illustrate different ways STU boilers can be integrated with an appropriate pellet store. These are not to scale and should not be used as a detailed design guide. They are intended as an indication of possible solutions only.
  • Page 20 Hoval STU Wood Pellet Boiler Typical Plantroom layouts GENERAL ARRANGEMENT OF A STOKER AND A FABRIC SILO. GENERAL ARRANGEMENT OF STU BOILER WITH TWIN EB BOOT TABLES AND PROFILING...
  • Page 21 Hoval STU Wood Pellet Boiler Typical Plantroom layouts GENERAL ARRANGEMENT OF STU BOILER AND A FABRIC TROUGH BUNKER INDICATIVE LAYOUT OF STU BOILER WITH GRP SILO...

  • Page 22: Boiler Door Handing

    Hoval STU Wood Pellet Boiler Boiler door handing Boiler door handing As standard the boilers are fitted with hinges on the right hand side when viewing the boiler from the front. If instruction is given at the time of placing the order this can be switched to a left hand hinge arrangment. Alternatively, boilers can be handed on site by following...

  • Page 23: Boilerhouse Ventilation, Open Vented/Pressurised Systems

    A primary make up water and expansion tank is required for open For independently pressurised systems the flow connection must be vented systems. With low head on calorifier primary system, Hoval fitted with an automatic air vent, a safety valve (sized to the relevant Technical Department should be consulted.

  • Page 24: Flues And Chimneys

    Guidance for sizing flues and chimneys is given in CIBSE A condensate drain point is provided in the boiler flue outlet and HVCA guides and also Hoval Technical Data Sheets. box and this should be piped to drain via a drain trap to prevent Flues should conform to the relevant British Standards, flue gases escaping.

  • Page 25: Filling The System With Water

    C at all times by the use of suitable bypass/diverting controls. Differentials between the flow and return should not exceed 25K. Where a differential is to exceed 25K advise Hoval as considerations are necessary and alternative solutions may be appropriate.

  • Page 26: Control Details And Safety Features

    Hoval STU Wood Pellet Boiler Control Details and Safety Features In addition to the stoker control panel (see below) a boiler flow temperature gauge is fitted at the front of the boiler. LRP Controller and Display Screen The stoker control panel can be fitted or mounted on either side...

  • Page 27: Space Requirements

    Please check the water level in the water dump container on a weekly basis. This should be within 50mm of the top of the container. Always replace the cap after checking and / or topping up. In the event that the water dump has been activated please contact Hoval Service. Please see Appendix C, for further details on the above.
  • Page 28 The LRP control requires the installation of a new sensor in the flow pipe work immediately off the boiler supplied loose by Hoval for fitting by the installer. The installation will require a 3/4" socket welding into the flow pipe above the boiler to accommodate the flow sensor, this sensor is the pivotal point of the stokers' modulation system (See Fig 1).
  • Page 29 Hoval STU Wood Pellet Boiler Control Details and Safety Features To Reset Alarms When a fault has occurred the 'Fault' light will be illuminated on the front of the LRP unit. Press 'Set', Highlight the 'Manual/Status' option on the display, Press 'Set'.

  • Page 30: Control Details And Safety Features

    Hoval STU Wood Pellet Boiler Control Details and Safety Features Parameters within the Quick Query screen Boiler Setpoint (All Levels) Temperature to which the stoker will modulate. Boiler Off Setpoint (All Levels) Temperature to which the boiler will switch off.

  • Page 31: Commissioning

    If the above are not completed and commissioning is unable to commence, clients will be charged for the abortive visit. Generally Hoval approved engineers will assemble the stoker and fuel feed system at site prior to com- missioning. However before the boiler and stoker can be fully commissioned it is essential that the following are com- pleted by the installer to ensure the equipment can be set to work in an effective manner;...
  • Page 32 Hoval STU Wood Pellet Boiler Commissioning • The electrical installation with the appropriate wiring diagram for the boiler and stoker and for correct fan/motor rotation. • That the stoker has not been damaged since installation and that there is a suitable supply of fuel available on site.

  • Page 33: Operating Instructions

    'stand-by' when not required or when the the stoker and this can be used to bring the boiler back to full fire connected load has been satisfied. Hoval recommend that it can within a few minutes without any outside or manual attention. In be held in this kindle condition for up to a maximun of 72 hours.
  • Page 34 BMS should be configured to operate the boiler for a short but KINDLE/IGNITION switch to Ignition. Isolate the boiler continuous period (minimum 1 hour). Once this has occurred the electrically and report the fault to Hoval Service. boiler will resume kindle mode until next called by the BMS. Standard Ignition (Manual)

  • Page 35: Operating Instructions

    Hoval STU Wood Pellet Boiler Operating Instructions • Once the door has opened it should be possible to stand • The boiler door can then be opened using the tommy bar in front of the combustion chamber and inspect the fire, provided and ash/clinker removed with the rake supplied boiler surfaces etc.

  • Page 36: Maintenance - Inspection & Servicing

    (e.g. Pyruma) on refractory lined doors. Where a door is lined with ceramic fibre it is unlikely to suffer damage in normal use but in the unlikely event please consult Hoval.

  • Page 37: Pick-Up Auger (Bunker Worm)

    Auger and the condition of the shear pin in the Delivery Auger - it may well have broken first and caused the Pick-Up pin to shear. N.B. If you are unable to turn the worm section or the replaced pin breaks straight away, contact Hoval Service.

  • Page 38: Appendix A - Grp Silo Specification Sheet

    Hoval STU Wood Pellet Boiler Appendix A GRP SILO SPECIFICATION SHEET Ø2.85m...

  • Page 39: Appendix B - Thermal Safety Heat Exchange Details

    Hoval STU Wood Pellet Boiler Appendix B Note: The thermostatically operated valve has a "red" test button which will prove the valve opens when pressed & held in.

  • Page 40: Appendix C - Boiler Familiarisation Information

    Hoval STU Wood Pellet Boiler Appendix C - Boiler Familiarisation Information Water dump Container Water dump thermal valve Clamp on burnback thermostat. STU Boiler Sleeve for water dump thermal valve sensor. Important: The sensor must be located in this sleeve...
  • Page 41 Hoval STU Wood Pellet Boiler Appendix C - Boiler Familiarisation Information Remove cap and check the water level weekly. Water should be within 50mm of the top of the water dump container. Replace lid after checking and / or re-filling.
  • Page 42 Hoval STU Wood Pellet Boiler Appendix C - Boiler Familiarisation Information Pellet Drop box Proximity level switch in pellet delivery auger transfer box Access cover to delivery auger to drive coupling shear pin Stoker delivery auger to drive coupling brass shear pin.
  • Page 43 Hoval STU Wood Pellet Boiler Appendix C - Boiler Familiarisation Information Mains cold water supply Induced Draught Fan Thermal valve preset to open at 95 °C Actuator for Induced draught fan damper Cooling coil heat exchanger (s) Smoke box condensate...
  • Page 44 Hoval STU Wood Pellet Boiler Appendix C - Boiler Familiarisation Information Combustion Chamber pressure switch Combustion chamber pressure sensing point with interconnecting pipework to pressure switch. Clean this out weekly Pellet pick - up Forced draught fan with auger motorised damper...
  • Page 45 Hoval STU Wood Pellet Boiler Appendix C - Boiler Familiarisation Information Refractory fibre boiler door lining Cut out for sight glass opening Combustion chamber sight glass on front of boiler door View of Combustion Chamber with pellets in the retort at the...
  • Page 46 Hoval STU Wood Pellet Boiler Appendix C - Boiler Familiarisation Information Removable smoke tube spiral retarder Boiler heat exchanger Removable refractory arch bricks Remove insulated red cover below boiler door and lift off metal in- spection panel to gain access to the optional...

  • Page 47: Appendix C - Boiler Familiarisation Information

    Hoval STU Wood Pellet Boiler Appendix C - Boiler Familiarisation Information Lift off metal inspection Optional 3kW electric panel ignition unit...

  • Page 48: Appendix D - Operating, Cleaning And Fault - Finding Procedures

    Hoval STU Wood Pellet Boiler Appendix - D Operating, Cleaning and Fault - Finding Procedures DE-ASHING THE BOILER Use personal protection equipment (Gloves, Goggles and Dust mask - type 3M3385 or equivalent) It is necessary to clear the ash from the combustion chamber, with the Rake provided, on a regular basis.

  • Page 49: Turning The Boiler Off

    Hoval STU Wood Pellet Boiler Appendix - D Operating, Cleaning and Fault - Finding Procedures CLEANING THE BOILER HEATING SURFACES Use personal protection equipment (Gloves, Goggles and Dust mask - type 3M3385 or equivalent) Prior to cleaning, switch the Wood burner to the “Off” position via the KINDLE/OFF/AUTO selector switch mounted on the control panel Allow the boiler to cool down (2 hours approx).
  • Page 50 Hoval STU Wood Pellet Boiler Appendix - D Operating, Cleaning and Fault - Finding Procedures TO LIGHT THE BOILER Manually Open the door. Switch the Wood burner KINDLE/OFF/AUTO selector switch to "Auto" and allow the machine to run until the pellets are level with the top of the retort tuyeres in the boiler.

  • Page 51: Appendix D - Operating, Cleaning And Fault - Finding Procedures

    Hoval STU Wood Pellet Boiler Appendix - D Operating, Cleaning and Fault - Finding Procedures In The Event of a Fault Condition/ Power Interruption 1) In the event of a fault condition turn the “Kindle/off/auto” switch on the wood burner control panel to the “Off” position.

  • Page 52: Notes

    Hoval STU Wood Pellet Boiler Notes.
  • Page 53 Hoval STU Wood Pellet Boiler Notes.
  • Page 54 Hoval Ltd Northgate Newark Notts NG24 1JN Tel No's: (01636) 59413 or 593435 (Service Desk direct dial numbers) (01636) 593412 (Spares Desk direct dial) Fax: (01636) 673532 e-mail: service@hoval.co.uk spares@hoval.co.uk STUman May 2010 (WS2)

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