Hoval STU 200 Installation, Operation And Maintenance Instructions Download Page 1

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Installation, Operation and

Maintenance Instructions.

STU wood-pellet fired hot water boiler

(150-1000kW).

STUman June 2010 (WA)

Summary of Contents for STU 200

Page 1: ...Installation Operation and Maintenance Instructions STU wood pellet fired hot water boiler 150 1000kW STUman June 2010 WA...

Page 2: ...7 18 Typical Plantroom Layouts 19 21 Boiler Door Handing 22 Boilerhouse Ventilation Open Vented Pressurised Systems 23 Requirements for pressure limiter s in accordance with BSEN 12828 23 Flues and Ch...

Page 3: ...hnical servicing or parts enquiries telephone fax or e mail Hoval quoting the boiler s serial number as above Tel 01636 593413 or 593435 Fax 01636 673532 e mail service hoval co uk or spares hoval co...

Page 4: ...nd use of this appliance Fuel Quality Requirement The design of the boiler stoker pellet handling system and store is dependant on using the correct quality wood pellet fuel The pellets should be form...

Page 5: ...d An optional ignition start system is available on request but this must be specified at the time of order The boiler comprises of a welded steel shell with a water jacket surrounding an oval combust...

Page 6: ...tes an airless kindle feature This allows the boiler under normal operation to be held in stand by mode when heat is not required for up to 72 hours and maintains a small ignition source within the st...

Page 7: ...28 5 87 6 11 Water Flow Rate 82 71 C kg s 3 4 4 3 5 4 6 5 8 2 9 2 10 9 13 0 17 4 21 7 Hydraulic Resistance at 80 60 C kPa 0 2 0 3 0 4 0 6 0 6 0 8 1 1 1 6 1 8 1 9 Water Flow Rate 80 60 C kg s 1 9 2 4...

Page 8: ...285 K mm 240 235 235 235 235 235 235 275 L mm 1008 1116 1116 1116 1516 1516 1516 1516 Connections 1 Flow PN6 DN50 DN80 DN80 DN80 DN80 DN80 DN80 DN100 2 Return PN6 2xDN50 2xDN80 2xDN80 2xDN80 2xDN80 2x...

Page 9: ...ns c w thermostatic control valve connection 3 4 to be connected to a cold water mains supply Drain pipework by others to be run via tundish to drain See Appendix B for further details Boiler mounted...

Page 10: ...he boiler to suit specific plant room layout See Page 11 for a typical plant room layout Cyclone 800 1000 A mm 1389 1439 B mm 744 768 C mm 2368 1540 D mm 2227 2422 E mm 2615 2872 F mm 900 950 G mm 274...

Page 11: ...mensions 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 layou...

Page 12: ...iltration in use The elements are easily replaced by vertically removing the existing elements from the unit and replacing with a new element Accordingly it is essential to locate the filter with a mi...

Page 13: ...ught Fan Incoming Electrical Supply Type Motor kW Absorbed power kW STU 150 CF 150 Halifax 1 5 0 89 3N 50Hz 400 230V 10A max STU 200 CF 200 Halifax 1 5 0 86 3N 50Hz 400 230V 10A max STU 250 CF 250 Hal...

Page 14: ...CF Biomass Filter Typical units 14 Measurements in mm CF 500 unit Clearance of 1000mm required above the unit for filter withdrawal replacement...

Page 15: ...spection lids Cladding and Lagging 75mm thk Control panel RCA 25 DD pulse valve Compressed air reservoir Particulate discharge tray Clearance of 1000mm required above the unit for filter withdrawal re...

Page 16: ...outlet Outlet Outlet Fluing to chimney Typical Layout STU 200 Wood Pellet Boiler with CF 200 Biomass Filter Hatched ducting not by Hoval Note easy radius bends should be used 16 Side Elevation View o...

Page 17: ...ke build bunker store These typically require a larger floor area and are less effective in terms of the available recoverable volume of fuel Some profiling of the bunker base should be considered min...

Page 18: ...l consumption would be estimated based on the loading placed on the boiler Wood Pellet fuel store to be sized to accommodate a minimum of 10 15 days anticipated fuel use 3 Delivery Size The fuel suppl...

Page 19: ...ots active pick up locations c Gate valve required to isolate individual silos 2 STU wood pellet boiler 3a Flexible auger Note requirements for long radius bends 1 5 2m Note maximum length of 15m 3b A...

Page 20: ...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: ...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: ...re fully tightened 5 Loosen locknuts on the new opening side so that a seal is obtained all round the fibre joint Important Always have two nuts tightened to prevent the door falling It is essential t...

Page 23: ...lancing outlet so that the air pressure in the boilerhouse does not exceed 12 5 Pa Where mechanical inlet and mechanical extract system is applied the design extraction rate should not exceed one thir...

Page 24: ...ly important on any horizontal section The flue should include a pressure relief and or draught stabiliser fitted adjacent to the boiler flue connection Flues should be supported independently to prev...

Page 25: ...ll promote corrosion unless treated For these reasons Hoval strongly recommend that when necessary the system be thoroughly cleaned prior to the use of a stable inhibitor which does not require contin...

Page 26: ...ons The following are the most common parameters available for display IMPORTANT 3 Phase 32A 400V supply is required for stoker and control panel operation Boiler Flow set point Wood pellet feed speed...

Page 27: ...ler or where requested can be supplied separately for mounting on a wall within the plant room Site wiring will be re quired to connect the pellet auger feed motors FD and ID fan motors each must be c...

Page 28: ...rotection thermostat is manually reset However it is important that the cause of the burnback has been established and rectified before allowing the stoker to re start The condition of the burnback th...

Page 29: ...set points view menus Level 3 As Level 2 with change all settings and view all parameters Level 4 As Level 3 with edit menus and configure the controller strategy To change user level hold the ESC ke...

Page 30: ...using the controller The parameters shown here will be directly related to your plant applications and requested access levels to suit your experience These parameters may be changed by you e g if a s...

Page 31: ...I On O Off Delayed FD Fan All Levels Indicates whether the Stoker Fan is called to run I On O Off Trickle Feed Rate Level 4 This sets the pellet feed time during kindle Altering the Boiler setpoint Se...

Page 32: ...tomatic air vent is fitted at high level on the flow pipework connected to the boiler A suitable safety valve has been fitted directly onto the boiler together with associated discharge pipework No is...

Page 33: ...rmostat is adjusted to suit the system design flow and temperature The control and high limit thermostats are set in accordance with the LRP stoker control thermostat The boiler safety valve is suitab...

Page 34: ...ithout excessive manual input The stoker will automatically adjust the firing range to match the load with damper control on both the forced and induced draught fans Continuous O2 monitoring of the fl...

Page 35: ...irelighters Close the Boiler Door Set the Wood Burner selector switch ID FAN ONLY OFF AUTO to the AUTO position This will operate the stoker without adding any further fuel into the retort and will al...

Page 36: ...e boiler door can then be opened using the tommy bar provided and ash clinker removed with the rake supplied with the equipment Care needs to be taken not to disturb the fuel within the retort and onl...

Page 37: ...correctly NOTE No continuous make up of water should be taking place In this event check where a leak may be occurring or if pumping over is taking place Maintenance Boiler and Stoker Servicing In ad...

Page 38: ...tor so that the shear pin slot is at the top using the shear pin bar provided align the slot on the worm section remove broken pin and fit replacement If there is a jam or pin failure on the Pick Up A...

Page 39: ...39 Hoval STU Wood Pellet Boiler GRP SILO SPECIFICATION SHEET 2 85m Appendix A...

Page 40: ...40 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 41: ...ensure correct operation of the wa ter dump device Removable cap Water dump container fitted with level monitoring float switch Boiler drain connection two per boiler Water dump thermal valve preset t...

Page 42: ...Isolate the boiler control panel via the main isolator switch on the panel facia before removing this cover Remove cap and check the water level weekly Water should be within 50mm of the top of the w...

Page 43: ...od Pellet Boiler Appendix C Boiler Familiarisation Information Manual reset burn back thermostat set to 60 C Manual reset button remove cover to access as shown Boiler Door Microswitch Combustion Cham...

Page 44: ...rmation Pellet Drop box Two No proximity level sensors in pellet deliv ery auger transfer box Access cover to delivery auger to drive coupling shear pin Stoker delivery auger to drive coupling brass s...

Page 45: ...nduced draught fan Actuator for induced draught fan damper Smoke box condensate drain piperwork with trap Mains cold water supply Thermal valve preset to open at 95 C Cooling coil heat exchanger s con...

Page 46: ...mber pressure sensing point with interconnecting pipework to pressure switch Clean this out weekly Appendix C Boiler Familiarisation Information Forced draught fan with motorised damper Forced draught...

Page 47: ...Pellet Boiler Appendix C Boiler Familiarisation Information View of combustion chamber with pellets in the retort at the correct level for lighting Refractory fibre boiler door lining Cut out for sig...

Page 48: ...hanger Appendix C Boiler Familiarisation Information Remove insulated red cover below boiler door and lift off metal in spection panel to gain access to the optional 3kW electric ignition unit located...

Page 49: ...49 Hoval STU Wood Pellet Boiler Appendix C Boiler Familiarisation Information Optional 3kW electric ignition unit Lift off metal inspection panel...

Page 50: ...2 Switch the Wood burner to the I D Fan Only position found on the ID FAN ONLY OFF AUTO selector switch mounted on the control panel 3 Take care when opening the large door 4 Only the fine ash should...

Page 51: ...g catchment doors are sealed when refitted 8 Refit the spiral retarders 9 Clean the small hole for the combustion chamber pressure switch sensing point which is found on the L H S of the combustion ch...

Page 52: ...the Off position and report the fault TO LIGHT THE BOILER Manually 1 Open the door 2 Switch the Wood burner I D FAN ONLY OFF AUTO selector switch to Auto and allow the machine to run until the pellets...

Page 53: ...tripped see below or shear pin failure burn back thermostat malfunction or a prolonged power interuption This can also be caused by leaving the ID fan running continuously on the ID FAN ONLY OFF AUTO...

Page 54: ...54 Hoval STU Wood Pellet Boiler Notes...

Page 55: ...55 Hoval STU Wood Pellet Boiler Notes...

Page 56: ...3435 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 June 2010 WA Hoval follows a policy of continued improv...

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