Moderator Spółka z o.o.
Ul. 11 Listopada 16a
17-200 Hajnówka
POLAND
www.moderator.com.pl
Moderator
UNICA SENSOR
10 ÷ 60kW Boilers
Operating Instructions
Page 1: ...Moderator Spółka z o o Ul 11 Listopada 16a 17 200 Hajnówka POLAND www moderator com pl Moderator UNICA SENSOR 10 60kW Boilers Operating Instructions ...
Page 2: ...er description operation servicing 23 3 2 Igniting 25 3 3 Burning 25 3 4 Boiler and Chimney Cleaning 26 3 5 Planned shutdown of the boiler 28 3 6 Emergency Shutdown of the Boiler 28 4 Boiler Troubleshooting 29 4 1 Maintenance and overhauls 29 5 Safe operation conditions 29 6 Disposal 31 7 Connecting the boiler to automatic feeders 31 7 1 The boiler may be used with Automatic Biomass Burning Feeder...
Page 3: ... 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 with Failure to perform any action due to involved costs of additional equipment installation will certainly ...
Page 4: ...uations 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 and supply and return piping When in boiler room always pay special attention Keep in mind that ashes and fue...
Page 5: ...lts resulting from central heating installation freezing incorrect or blocked flue system loss of water in the installation utilization of the boiler for purposes other than its intended use as specified in the operating instructions in case of incorrect selection of the boiler output to the object s heat demand 6 All warranty claims must always be sent to the boiler seller Before submitting a cla...
Page 6: ...the boiler are specified for fuels with humidity content of up to 30 and calorific value of Q 17 084 kJ kg for wood and 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 thermal energy is ...
Page 7: ...arine boxes transparent plastic bottles jewel boxes cassettes CDs 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 Approximate data of different fuels Fuel type Burning time 1 cubic meter wei...
Page 8: ...ed equipment G drain valve G safety valve G for 10 and 15kW boilers SYR 5067 thermal protection in 40 60kW boilers the thermometer is installed on the control panel so additional thermometer needs not to be installed The electric control system is installed on the boiler housing and connected The blower installed on the top part of the boiler housing and is connected through the primary and second...
Page 9: ...lever 6 Fan 7 Return pipe 8 Top washout cover 20 and 25kW boilers 9 Supply pipe 10 Ash pan washout cover 11 Straight through valve G muff 12 Tech ST 81 controller 10 to 30kW boilers 13 G muff Fig 1a Unica SENSOR 25 kW boiler description of main parts 1 2 3 4 5 6 7 8 9 10 11 12 13 ...
Page 10: ...ile grate lever 6 Fan 7 Return pipe 8 Top washout cover 20 to 60kW boilers 9 Supply pipe 10 Ash pan washout cover 11 Thermometer 12 ecoMAX 200 controller 40 to 60kW boilers 13 G muff Fig 1b Unica SENSOR 50 kW boiler description of main parts 1 2 3 4 5 6 7 8 13 10 11 12 9 ...
Page 11: ...rs are 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 render fuel charging grate cleaning and access to the side washout a...
Page 12: ...boiler is manufactured as an all round unit that facilitates of various types of connections Please make sure that all unused holes and outlets are plugged The Boiler will operate correctly if the temperature inside the combustion chamber will be sufficiently high which means that the supply water on the boiler output shall have the temperature in the range of 70 to 80O C and that the water on ret...
Page 13: ... disconnected When filling open all venting valves in the installation and slowly close them until water overflows in the overflow pipe of the expansion vessel in case of open systems Lossless installations may be supplied with raw water as long as its hardness is less than 10 n Otherwise the water shall be pre treated Install boiler accessories handles and bakelite knobs 2 6 Connecting the boiler...
Page 14: ...nected to this line 6 The box in which electric accessories are contained may only be opened by a competent electric engineer knowledgeable with the equipment operation 7 Location of the power receptacle used for the boiler connection shall be selected in such a way so that the plug is easily accessible to allow quick boiler disconnection in case of an emergency 8 Wires shall be routed away from t...
Page 15: ...serted into an outlet of the electric power supply installation In case of a damage to the power supply cord replace it with a cord of the same type Connecting central heating circulating pump This operation shall be performed by a person with necessary qualifications to perform electric installation works Connect the circulating pump to Fig 4 socket identified as POMPA co using a cable with cross...
Page 16: ...o the socket Fig 4 identified as Pompa cwu using a cable with cross section of at least 3x0 75mm2 using suitable socket included The household hot water tank s temp sensor shall be connected to the socket located above the power supply socket Fig 4 Tech ST 81 controller rear view 1 Power supply socket 2 Hot household water pump socket 3 Household hot water temperature sensor socket 4 Central heati...
Page 17: ...boiler Other parts used to connect power supply and pumps driven by the controller are located in the box attached to the boiler Fig 6 Controller sockets rear view Fig 6 shows the real panel of the controller where the following sockets are located 1 Local thermostat 2 Hot household water temperature sensor 3 Hot household water pump 1 2 3 4 5 6 A C A Dmuchawa B Przewód łączący C Sterownik z regul...
Page 18: ...g a cable with cross section of at least 3x0 75mm2 While making the connection the pump cable shall be terminated with a computer type plug included Connecting the hot household water pump This operation shall be performed by a person with necessary qualifications to perform electric installation works The pump that charges the hot household water tank shall be connected to the socket using a cabl...
Page 19: ...ŃSTWA SAFETY VALVE CZUJNIK TEMPERATURY TEMPERATURE SENSOR KOCIOŁ BOILER STEROWNIK CONTROLLER WENTYLATOR BLOWER ZAWÓR SPUSTOWY DRAINAGE VALVE NACZYNIE WZBIORCZE PRESSURE VESSEL ZAWÓR MIESZAJĄCY MIXING VALVE ZBIORNIK AKUMULACYJNY HEAT ACCUMULATION TANK WĘŻOWNICA COIL INSTALACJA GRZEWCZA HEATING INSTALLATION ZASILANIE Z SIECI WATER PIPE SUPPLY Installation requirements pressure vessel with the volume...
Page 20: ...alve and additionally thermal protection permitting safe discharge of excessive thermal power Muffs welded in the upper jacket of the boiler facilitate installation of this equipment fig 8 Moderator boilers are manufactured according to the PN 303 5 standard which permits boiler operation in closed systems if specific requirements are complied with In case of versions adapted for automated operati...
Page 21: ... closed central heating systems Special attention shall be paid in case of boiler versions designed for manual charging The manufacturer s recommended SYR 5067 thermal protection is only and exclusively effective if pressure in water pipe network can be guaranteed at the min level of 2 3 bar and if safety valve is installed This means that the system may not operate if water from in house water in...
Page 22: ...ble pressure in the heating installation the ejection valve 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...
Page 23: ... boiler Periodical maintenance notes Maintenance activities involve periodic checking of electrical cabling conditions which is accessible outside the controller enclosure In case of a mechanical or thermal damage e g molten insulation of wires broken wire damaged controller enclosure it is necessary to stop the device disconnect it from the electric installation and then proceed to repair the dam...
Page 24: ... key functions parameter setting methods etc see the ecoMAX 200 controller operating instructions delivered with the boiler On the left side of the panel there is a Red control STB Temperature Limiter prevents excessive water heating in the boiler If it engages which happens when temperature exceeds 95 C blower will be switched off This condition is indicated by illuminating the red control In ord...
Page 25: ...the air supply system the pump coupled with the controller will start automatically NOTE For 3 to 4 days it is recommended to maintain continuous non stop burning in the boiler with the supply water at 70 to 80O C Further ignitions may be performed by programming boiler operation on the electronic controller according to principles described in the controller instructions When igniting do not fill...
Page 26: ...ng a boiler with air supply system the ash pan flap shall remain closed and it is recommended not to use the throttle However remember not to block the throttle as it may act as a safety valve in case of an uncontrolled combustion of gases If after the blower is started the throttle flap slightly raises due to too high draught it must be pressed down so that it lies flush with the frame The boiler...
Page 27: ...with CE mark and instructions of use Combustion gases leaving blocked chimney are dangerous The chimney and the conduit shall be kept clean they shall be cleaned before each heating season The air distribution system has been designed so that it autonomously cleans itself during operation However after the heating season ends it is necessary to check whether nozzles are not clogged cleaning to be ...
Page 28: ... any condition resulting from power outage pumps stop or from leaving doors of the boiler open The central heating installation shall be protected with a safety valve set to 2 bars additionally the manufacturer shall protect the boiler with safety valve factory preset to 2 5 bar however in case of an emergency condition such protections are insufficient The boiler must be additionally protected wi...
Page 29: ...in Blocked chimney Clean the chimney by burning dry wood for 2 days in temp at least 70o C Frequent use of wet fuel Burn through 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 Too high chimney cross section Use chimney damper 4 1 Maintenance and overhauls Boiler maintenance during the he...
Page 30: ...pril to 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 rises above 80 C it will be necessary to open the shutoff valve and let ...
Page 31: ...nally protected by a steel screen However keep in mind that the plug is a temporary solution until the feeder is installed This means that in result of intensive burning the plug may deform If the automatic feeder is fitted it is not needed to plug the hole Burning fuels without properly plugging the hole may cause a fire 2 If a feeder with ceramic head is connected slide in the head breeching fit...
Page 32: ...re operating a boiler and after some time decided to install the pellets burner this will not constitute a major problem First you will have to prepare a suitable place in the boiler room it is necessary to consult Moderator technical support and place an order When you receive your shipment replace doors on the vertical face of the boiler doors will be delivered along with the burner Before this ...
Page 33: ... 150 180 185 165 150 Comb gases mass flow Rated power Q kg s wood coal Minimum power Qmin kg s wood coal 0 023 0 021 0 007 0 006 0 030 0 026 0 009 0 008 0 040 0 034 0 012 0 010 0 045 0 039 0 013 0 011 0 049 0 043 0 015 0 013 0 055 0 050 0 017 0 015 0 049 0 043 0 019 0 017 Water resistance mbar 0 45 0 55 1 0 1 3 1 5 1 8 3 0 4 5 Boiler class 3 3 3 3 3 3 3 3 Water pressure required by the thermal pro...
