Moderator Unica Max 100 kW Operating Instructions Manual Download Page 1

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Moderator Spółka z o.o.

Ul. 11 Listopada 16a
17-200 Hajnówka
POLAND

Unica Max 80

160 kW Boiler

Operating Instructions

Summary of Contents for Unica Max 100 kW

Page 1: ...Moderator Spółka z o o Ul 11 Listopada 16a 17 200 Hajnówka POLAND Unica Max 80 160 kW Boiler Operating Instructions ...

Page 2: ... 13 2 7 Installation protection 17 2 7 1 Open system 17 2 7 2 Closed systems 18 2 7 3 Thermal protection 21 3 Burning 22 3 1 Controller description operation and maintenance 22 3 2 Boiler ignition 23 3 3 Burning 24 3 4 Boiler and Chimney Cleaning 25 3 5 Planned shutdown of the boiler 26 3 6 Emergency Shutdown of the Boiler 26 4 Boiler Troubleshooting 27 4 1 Maintenance and overhauls 27 5 Safe oper...

Page 3: ...stood before commencing with these activities 1 Overview 1 1 Safety Instructions The main condition of safe boiler operation is its correct connection to the central heating installation The manufacturer has undertaken all efforts to ensure safe operation of the device This will only be possible after all connection and operation requirements discussed in these instructions are met and complied wi...

Page 4: ... this manual indicates a danger Please carefully read the corresponding section so as to avoid dangerous situations in future Keep in mind that in the boiler room various surfaces may have different temperatures You have to pay special attention to the fact that temperature of doors may be significantly higher than the temperature of other boiler surfaces This also applies to the smoke breeching a...

Page 5: ...r resulting from the boiler being used incompatibly with operating instructions i e in result of using incorrect fuels leaving ash after the heating season faults resulting from central heating system freezing incorrect or blocked exhaust gas extraction system no water in the system boiler use for purposes different than its intended use specified in operating instructions in case of incorrect mat...

Page 6: ...s of the boiler are specified for fuels with humidity content of up to 30 and with calorific value of Q 17 084 kJ kg for wood and of Q 29 924 kJ kg for coal The higher the moisture content the lower the calorific value note an increase of moisture content causes calorific value to drop which means that one will need twice as much fuel to achieve the same heating effect A considerable part of therm...

Page 7: ...ney Do not burn PVC products under any circumstances e g butter or margarine boxes transparent plastic bottles jewel boxes CD boxes or toys plastic building materials polyamide PA products such as textiles Some plastics identified as PE PP PET may be burned provided that their volume does not exceed 5 of the fuel volume e g of wood and the combustion temperature is not lower than 850o C Approximat...

Page 8: ...n flanges with installation bolts set other elements depend on the purchased version and are not included in the base boiler price Additional non fixed equipment G drain valve G 1 safety valve SYR 5067 thermal protection only in 80 100 kW models In Unica Max 80 160 kW boilers the thermometer is installed inside the control panel Therefore additional thermometer nor pressure gauge is not required T...

Page 9: ... breeching 180mm 10 Chimney damper lever 11 Air exhaust fan 12 Supply pipe 13 Thermal protection sensor G muff 80 100kW 14 1 stub pipe for safety valve connection 15 Thermostat installation G muff 16 Ash pan cleanout cover 17 G muff for drain valve installation 18 Controller 1 2 3 4 5 6 7 8 9 11 9 13 14 15 10 12 16 17 18 in models prepared for installation of SMOK automatic biomass burning feeder ...

Page 10: ...e boiler and threatens fire or may cause an explosion The boiler is delivered in assembled state Boiler may be positioned directly on the floor with 1 gradient towards the front wall the top point of the boiler after the installation shall be the place close the supply pipe During boiler installation it is necessary to ensure its accessibility in such a way so that boiler room walls do not make ac...

Page 11: ...sure correct operation of the boiler manufacturer recommends installation of a four way mixing valve or a heat accumulation tank Boilers have G3 ø80 flange connections Weld counter flanges be to installation supply and return pipes then install seals and bolt the joint together using screws enclosed with the boiler In order to properly connect the boiler it is necessary to install all accessories ...

Page 12: ...ly matched fast blow fuse and differential current protector shock protector The value and the type of the fuse is specified in the controller s operating and maintenance documentation No other equipment must be connected to that line 6 The enclosure containing electric equipment may only be opened by competent electric engineers knowledgeable with the device operation 7 Location of power receptac...

Page 13: ... their standard equipment include an automatic combustion process control system The control system comprises of elements shown on fig 2 and on fig 3 Fig 2 Unica MAX 100 automatic control equipment front upper part C B A A Blower B Connecting line C Controller with ecoMAX 200 regulator ...

Page 14: ...or connecting power supply and controller s auxiliary equipment are shown on fig 4 Fig 4 Additional accessories 1 Power supply cable 2 Hot water reservoir temperature sensor D F E Fig 6 b Fig 6 a D Combustion gases exhaust fan E Connection sockets F Combustion gases temperature sensor 1 2 Fig 6 a 4 3 ...

Page 15: ...sor 3 Hot water pump 4 Central heating pump 5 Power supply cable Fig 6 Connectors rear wall of the boiler also shown on fig 6 a item E Fig 6 shows sockets located on the rear wall of the boiler which are used to connect 1 Combustion gases temperature sensor 2 Combustion gases exhaust fan Power supply connection Boiler connection to the electric installation involves plugging one end of the power s...

Page 16: ...ich charges the hot water reservoir shall be connected to the socket item 3 fig 5 using a cable with cross section of at least 3x0 75mm2 Having finished with connections the pump cable shall be terminated with the computer type power supply plug item 4 fig 4 The hot water reservoir temperature sensor shall be connected to its input item 2 fig 5 Connecting the room thermostat This operation may be ...

Page 17: ...n 2 7 1 Open system Moderator boilers operating in open central heating systems must be connected according to requirements of the PN 91 B 02413 standard so that excess heat in the form of steam shall be removed through an open connection RP overflow pipe to atmosphere Fig 7 Protection of the installation for boilers in open central heating systems KOMIN CHIMNEY ZAWÓR BEZPIECZEŃSTWA SAFETY VALVE C...

Page 18: ... 2 7 2 Closed systems Only Unica Max boilers which are rated 80 and 100 kW may be operated in closed systems The thermal protection used by Moderator Sp z o o protects boilers rated up to 100 kW only In case of higher power ratings a heat exchanger or another device dissipating excess heat shall be used so that the maximum water temperature in the boiler does not exceed 110O C The protection shall...

Page 19: ...ALVE ZBIORNIK AKUMULACYJNY HEAT ACCUMULATION TANK WĘŻOWNICA COIL INSTALACJA GRZEWCZA HEATING INSTALLATION ZASILANIE Z SIECI WATER PIPE SUPPLY ODPROWADZENIE WODY WATER DRAINAGE Special attention shall be paid in case of closed system operation of boiler versions designed for manual charging The manufacturer recommended SYR 5067 thermal protection device will only and exclusively be effective if pre...

Page 20: ...20 Boiler installation without a reliable device to dissipate the excess thermal power is unacceptable ...

Page 21: ... opens at 97O C After the ejection valve opens hot water flows out of the installation and cold water may flow in from the supply line this cools down the boiler When boiler temperature drops to 94O C the ejection valve closes Thermally controlled filling valve and temperature sensor help to restore the correct flow pressure in the heating installation When the temperature reaches 88 C also the fi...

Page 22: ...r with the boiler has significantly contributed to reduction of chimney stack losses It also allows to detect very fast nearing out of fuel condition This reduces thermal losses related to the fuel less fan operation and extends the boiler readiness for fuel refilling The user does not have to hurry with fuel refilling as fast detection of the out of fuel condition will maintain heat in the boiler...

Page 23: ...iously verified the cause of the boiler overheating Temperature is indicated on the thermo manometer 8 dial T The pressure in the central heating system is also shown on the thermo manometer P dial The thermo manometer does not require electric power to operate and therefore its indications remain valid after power supply outage Thermometer T indications may differ by several degrees from the indi...

Page 24: ... builds up Note avoid burning fine fuels in which dusts concentration exceeds 5 Pay special attention when burning very dry sawdust moisture content up to 10 do not compact them tightly in the combustion chamber Having charged sawdust leave free space in the rear part of the chamber to ensure air access Failure to meet these requirements may result with gases from combustion chamber backdrafting d...

Page 25: ...ired is reduced chimney draught Insufficient air will cause the boiler to smoke excessively Fig 10 Boiler cleaning diagram Cleaning may only be performed on boilers that were shut down In case of heavy contamination of the boiler chemical agents may be used to remove boiler deposits but only such agents which have been authorized for marketing i e bearing the CE mark and instructions of use Combus...

Page 26: ...ng from power outage pumps stop or from leaving doors of the boiler open The central heating installation shall be protected by a safety valve set to 2 bars additionally the manufacturer shall protect the boiler by a safety valve preset to 2 5 bar however in case of an emergency condition such protections are insufficient The boiler must be additionally protected with a thermal protection valve wh...

Page 27: ...d chimney Clean the chimney by burning dry wood for 2 days in temp at least 70O C Frequent use of wet fuel Burn out with dry fuel Too low return temperature Raise the return temperature to the recommended 55O C Install a mixing valve Fuel burns too fast despite doors closed Chimney cross section too large Use chimney damper 4 1 Maintenance and overhauls Boiler maintenance during the heating season...

Page 28: ... heating season April September pay special attention when using the boiler for heating the household hot water only Boiler power will be too high relative to the absorption capacity of the boiler therefore it will be necessary to charge less fuel than during normal burning in winter season and to monitor the thermometer If the temperature raises above 80 C it will be necessary to open the shut of...

Page 29: ...tionally protected by a steel screen However keep in mind that the plug is a temporary solution which shall only be used until the feeder is installed This means that in result of intensive burning the plug may deform If the automatic feeder is fitted the hole needs not to be plugged Burning fuels without properly plugging the hole may cause a fire 2 If a feeder with ceramic head is connected it s...

Page 30: ...coal 165 175 129 125 165 175 129 125 165 175 129 125 165 175 160 150 Comb gases mass flow Rated power Q kg s wood coal Minimal power Qmin kg s wood coal 0 072 0 067 0 026 0 024 0 090 0 086 0 029 0 026 0 108 0 105 0 033 0 030 0 138 0 136 0 040 0 038 Water resistance mbar 1 4 1 6 1 75 1 9 Boiler class 3 3 3 3 Breeching dimensions 280 280 280 280 Water pressure required for thermal protection bar 2 3...

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