Moderator UNICA SENSOR 10 ÷ 60kW Boilers Operating Instructions
Contents
1. the boiler against low temperature material corrosion Boilers have connections in the form of threaded Gl72 stub pipes Connecting stub pipes with the installation shall be performed using appropriate connectors In order to properly connect the boiler it 1s necessary to install all accessories presented on Figures la and 1b shall be installed in the dedicated GY muff item 13 on fig la b then If the boiler is fitted with a thermal safety valve the valve s sensor install the safety valve In order to ensure correct operation of the boiler manufacturer recommends installation of a four way mixing valve or a heat accumulation tank Fig 2 Tcwu NW AN ree Pope III CWU 2 M A MODERATOR m JJ Pompa CWU Hot houtehold water pump Pompa M M Pump Fig 2 Sample installation with a four way mixing valve Connect water supply pipe through the G 2 valve 11 fig la using a flexible hose which after filling 1s completed shall be 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 to electric installation Electric installation and connectio2. of the Installation 2 38BRP2R gt gt P Pe 19 2 1 1 Open systems glt 8 2 5 ofl AR ere eee rege ch ere eee 19 z miiBGlasgd Systems GRUMMAN 4 Sethascnsnnasstusacawanacaiua dass Sugnaes eaeeneee ta anaee yee 20 2 1 3 tzu TSAIUIROR ENNY 22 3 Boiler operation a E oaae nreno deanai neta nreananaa netin nnanean 23 3 1 Controller description OPCTaTPOMPSCTVICIN G 00 cccccccccseessssesccecseccnaasseeececncecsens 23 gt EATS NGC OE Suoccouadeusdnec coven 25 Oye SUT e a OBRANE a a a 25 mae and Chimmey Cleaning oaza aska ASA 26 3 5 PlanncoShtgdown Of the GGi er 5ma a WAB ao 28 3 6 Emergency Shuti wza he Baler em AA coe eee 28 4 Boiler Troubleshooting 2m me mumuz re 29 4 1 Maintenance and overhau 8 a 29 5 Safe operation conditions SE e e PARA eine 29 6 Disposal 1 BAB ooo aaa aaa aaa aoc ca aL ea su sE EA OOOO 31 7 Connecting the boiler to automatic feeders 2XN TENOR 31 7 1 The boiler may be used with Automatic Biomass Burning Feeders Smok ZL and OZNA OO nn re 31 4 2 Boilers intended for pellets burners uueuusaaaoaaaaaczaceowasnsaaacacccan o 3P 8 BOMStespecifications ssieseirareerreesssssrreerersssearreerrtosnenannereeennannnannnnennn A 33 Due to on go
3. 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 the hot water flow into the central heating installation close the chimney damper start the blower If possible open hot water taps m the home e g in bathtub and drain the hot water Each Moderator boiler has a stub pipe for safety valve installation The valve must be unconditionally installed Additionally the manufacturer recommends installation of a thermal protection in case of a closed loop system see section 2 7 2 this is mandatory to protect the boiler against pressure build up Keep in mind that the thermal protection may only operate when the pressure in the installation is equal or greater than 2 3 bar and a safety valve is installed 30 6 Disposal Assuming correct operation the boiler shall operate without problems for about 15 years After that time its further operation may be economically unjustified The boiler is made of materials which are fully recyclable ts steel parts shall be scrapped Electrical components shall be provided for disposal to a specialist company 7 Connecting the boiler to automatic feeders 7 1 The boiler may be used with Automatic Biomass Burning Feeders Smok GZ and GC This section is applicable to boi
4. shutdown of the boiler After the fuel burns out open all doors and maximally open the damper in the smoke conduit Remove ash clean the boiler Do not drain the circulating water Cool down time is equal to the ignition time 3 6 Emergency Shutdown of the Boiler In case of emergency states such as exceeded 100 C temperature installation elements breaks and loss of water charge control amp automatic equipment or protection equipment failure or sudden pressure increase it 1s necessary to e remove fuel from the grate and move outside the boiler room e lower circulating water temperature by adding cold water to the water charge like during filling e maximally open the breeching throttle if installed In case of boilers operating in closed systems an emergency condition may be 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 with a thermal protection valve which will remove hot water from the boiler in case of an emergency condition while at the same time supplementing thus caused shortage of water in the boiler with cold water from water pipe installation in order to cool down th
5. 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 and supply and return piping When in boiler room always pay special attention Keep in mind that ashes and fuel in particular dry sawdust and chips may cause allergic reactions We recommend wearing protective gloves and dust masks Keep the boiler room clean Fuel left or spilled on the floor may cause a fire 1 2 Warranty Terms and Conditions l Manufacturer grants 36 month warranty for the unit which covers all workmanship and material faults 2 Manufacturer warrants fault free operation of the central heating which is further attested by the production plant s seal 3 Manufacturer requires the guidelines below to be followed e the first starting of the unit shall be performed by the manufacture s technical support representative 4 The warranty shall not include damages resulting from misuse or normal wear and tear refund of assembly costs travel costs damages resulting from modifications or repairs implemented or performed without manufacturer s consent indirect and consequential damages production outage related losses or any other economic loses co caused 5 The warranty shall not in
6. the connection the pump cable shall be terminated with a computer type plug included Temperature sensor of the hot household water tank shall be connected to input no Connecting the local thermostat This operation shall be performed by a person with necessary qualifications to perform electric installation works The local thermostat shall be connected to socket 1 of the controller terminating its cable with a RCA plug included with the boiler Operation of the controller when fitted with the local thermostat is described in the PLUM ecoMAX 200 controller documentation 2 7 Protection of the Installation 2 7 1 Open systems 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 Installation protection for boilers operated in open central heating installations Rs KOMIN ZASILANIE Z SIECI NACZYNIE WZBIORCZE ZAWOR BEZPIECZENSTWA row CZUJNIK TEMPERATURY W OWNICA ZD A peed INSTALACJA GRZEWCZA ZAWOR MIESZAJACY eS a E ZBIORNIK AKUMULACYJNY ZAW R SPUSTOWY KOMIN CHIMNEY ZAWOR BEZPIECZENSTWA SAFETY VALVE CZUJNIK TEMPERATURY TEMPERATURE SENSOR KOCIO BOILER STEROWNIK CONTROLLER WENTYLATOR BLOWER ZAWOR SPUSTOWY DRAINAGE VALVE NACZYNIE WZBIORCZ
7. AINAGE Fig 9 Installation protection for boilers operated in 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 intake is used e g if power supply outage prevents hydrophore switching on or in places where water supply outages are frequent In such situations the boiler shall not be installed in a closed system and its automatic version should be used which can not burn solid fuels with manual charging Fig 10 Thermal valve installation diagram 21 Boiler installation without a reliable device to discharge the excessive thermal power is forbidden 2 7 3 Thermal protection THERMAL PROTECTION ALLE BE DAN KA SSS EIA ak A SESS 4 4 NS A KR s wa gt fia me KRY zuza t A wa a N S ty i SAL Aim ht TPP Ne aha Le h SINS ES lake A 4 Z NE i gos dimensions in mm unless otherwise stated Applications 5067 thermal protection is designed to protect solid fuel boilers in heating installations fitted with thermostatic valves conforming to the PN EN303 5 Poli
8. E PRESSURE VESSEL ZAWOR MIESZAJACY MIXING VALVE ZBIORNIK AKUMULACYJNY HEAT ACCUMULATION TANK W OWNICA COIL INSTALACJA GRZEWCZA HEATING INSTALLATION ZASILANIE Z SIECI WATER PIPE SUPPLY Installation requirements e pressure vessel with the volume of at least 4 of the total water charge shape cylindrical type A acc to PN 91 B 02413 1 2 rectangular type B acc to PN 91 B 02413 1 3 e safety riser tube RB with inner diameter of 25 mm for boilers rated up to 25 kW inclusively 19 32 mm for boilers rated 40 to 60 kW e riser pipe RW with inner diameter of 25 mm e overflow pipe RP inner diameters as RW and RB e circulation pipe RC with inner diameter of 20 mm e venting pipe RO and signalling pipe RS with inner diameters of 15 mm installed on RB RW and RO pipes The protective equipment and No fittings permitting complete or partial closure of flow may be pipes shall be protected against freezing 2 7 2 Closed Systems Moderator boilers operating in closed systems must be equipped with air supply system designed by Moderator Sp z o o for Moderator boilers we advise against installation of other air supply systems safety valve 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 pe
9. Moderator Sp ka z o o Ul 11 Listopada 16a 17 200 Hajn wka POLAND www moderator com p Moderator UNICA SENSOR 10 60kW Boilers Operating Instructions TABLE OF CONTENTS Dear USer cccccsscssssccsscsccsscsccsccsccsscsccsccscccccsccss A tC LO aa 3 1 Overview ZO nn l Bo Pud o 0 3 1 1 Safety Instructions 0 6 c c cccccssssseeeseceaseetesesecessceess sees se gg ae OPAD 3 1 2 Warranty Terms and Conditions c 00040 s00 cc00000s0000eedaca gt agli 5 1 3 ii G E doooobocabdbob oda dodawac 6 1 3 1 Burning Other Fuels nosscccinerisriinerieccssinrccrscissina A A 7 1 4 Technical Description eessooooaa o aaa aoc cosaaacaaciacoc AW Ar 7 1 5 Equipment osssrsenssciicrsrcisicusciiionsernnrenscisrsnsnsrer ninen A 8 2 Installation cesecccssecccesstesessessessseseseseeeeeseceeeeessenneees sd A ee 8 2 1 General parameters cccccccccceseeseeeceseceesneeessesedseoee 0 er eee 8 2 2 Boiler ROOM 0 cccicccccccccssseessssessesessessecieaececeeeneseee sane Sl thee A 11 2 3 Boiler Installation 00000ssesesseeeceecceeeeee dents e 11 2 4 Connecting to the Chimmney 000000 2000 deh Aa 11 2 5 Boiler connection to the central heating SySteM ccccccccssssseesseecceceeeeeeeeseeeceeeeeeeaas 12 2 6 Connecting the boiler to electric installation eee aaaaaa aaa aaa aaa aaa aa aaa aaa aaa aaaaaaawec 13 2 1 Protection
10. ble temperature of supply water it 1s necessary to e use fuels with moisture contents of up to 30 e incase of higher moisture contents dry the fuel beforehand or mix it with dry fuel keeping in mind that the higher is the moisture content of the mixture the lower is the dose and excess air e when using fuels with varying granulation charge it alternatively fuel with large granules already glowing in the combustion chamber shall be supplemented with fine fuel e g saw dust as if the sequence is altered the fine fuel will spill through the grate e if necessary avoid opening the charging flap during ignition and while the boiler temperature builds up 25 Note avoid burning fine fuels in which dusts concentration exceeds 5 Pay attention when burning very dry sawdust moisture content up to 15 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 during sudden opening of the charging flap When the charging flap is opened this may cause sudden growth of the air volume in the combustion chamber and explosive combustion of dusts When operating a boiler with air supply system do not open the charging flap while the fan is operating Before supplementing the fuel switch off the controller A Adjustment of the boiler performance a
11. clude faults resulting from e failure to follow assembly guidelines stated in these operating instructions or resulting from regulations currently in force e incorrect servicing or maintenance or effects of boiler operation in a way which is incompatible with its operating instructions provisions use of incorrect fuel leaving ash after the heating season faults resulting from central heating installation freezing incorrect or blocked flue system loss of water in the installation e utilization of the boiler for purposes other than its intended use as specified in the operating instructions e 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 claim please make ready the following details e photocopy of page 5 of the operating instructions item 1 2 with entered date and legible signature of the user description of the fault a document to prove the equipment purchase boiler rated power e serial number 7 User statement hereby declare to have acknowledged myself with the Moderator boiler operating instructions and I hereby confirm that the equipment was delivered as ordered new complete and technically operational Above that a specialized company presented to me principles of the equipment operation and provided a complete set of documentation I hereby accept the Moderator boiler manufacturer s recommendations In cas
12. d evaporating water note using wet fuel directly contributes to shortening of boiler s operational life and causes it to wear out prematurely Hygrometers are used for moisture content measurements different types are used for sawdust and different for wood and these are necessary equipment which should be used when purchasing fuel to check the actual moisture content as well as during normal operation of the boiler 1 3 1 Burning Other Fuels Uncontaminated paper and cardboard may only be used for igniting fire in the boiler Mixtures of various clean paper and cardboard may only be burned with wood Papers and magazines must not be burned and should be recycled One shall keep in mind that impregnates inks and other components used for their production will significantly pollute the natural environment We also advise against burning plastics in various forms Keep in mind that smoke generated during combustion of plastics will contain substances which are poisonous and harmful to human and that these substances will fall down in direct vicinity of the chimney Do not burn PVC products under any circumstances e g butter or margarine 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 co
13. e boiler and to reduce the pressure section 2 6 Keep in mind that emergency conditions are likely to occur during summer when only household hot water is heated in the boiler To prepare for such conditions it is worth to consider installation of a heat accumulator capable of taking over the heating power surplus unavoidable in such circumstances ZN Glowing fuel must not be extinguished or cooled down with water 28 4 Boiler Troubleshooting Seal the place where the smoke nsufficient draught conduit enters the chimney Enlarge the chimney opening e g demolish a wall splitting the Too low chimney cross chimney into two flue ducts section combining it with the adjacent Boiler smokes brownish Too low chimney height ventilation channel at least 2m liquid present in the above the base of the negative pressure MODERATOR boiler increase chamber Another device a boiler or a Seal the place where the outlet cooker kitchen oven is from the boiler enters the chimney connected to the same so as to prevent cold air from chimney being sucked in Clean the chimney by burning dry Blocked chimney wood for 2 days in temp at least 70 C Raise the return temperature to the Too low return temperature recommended 55 C Install a mixing valve Fuel burns too fast despite Too high chimney cross l Use chimney damper doors closed section 4 1 Maintenance and overhauls Boiler maintenance during the heating season involve
14. e circulating pump to Fig 4 socket identified as POMPA co using a cable with cross section of at least 3x0 75mm using suitable socket included 15 Connecting domestic hot water pum This operation shall be performed by a person with necessary qualifications to perform electric installation works The pump used to charge the household hot water tank shall be connected to the socket Fig 4 identified as Pompa cwu using a cable with cross section of at least 3x0 75mm using suitable socket included The household hot water tank s temp sensor 3 shall be connected to the socket located above the power supply socket Power supply socket 2 Hot household water pump socket Household hot water temperature sensor socket Na Ain i Central heating pump j socket Fuse U ad Fig 4 Tech ST 81 controller rear view 16 2 6 2 Boilers rated 40 to 60 kW Unica SENSOR boilers rated 40 60 kW have preinstalled air supply system which consists of the following elements A see fig 5 A Dmuchawa B Przew d cz cy C Sterownik z regulatorem ecoMAX 200 Fig 5 Air supply system the photo shows a 40 kW rated 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 l
15. e of an unjustified service request to the Moderator company under a warranty repair undertake to bear all related costs man hours and costs of shipping to and from the service centre up to their full amount Date company name or first and last name legible signature Declaration of Conformity We Moderator Sp ka z 0 0 Ul 11 Listopada l a 17 200 Hajn wka POLAND tel 46 0 63 682 75 20 hereby declare under our own and sole responsibility that the product MODERATOR central heating boiler serial nos from 400 to which this declaration applies meets the following requirements and standards as applicable Directives Standards 97 23 WE EN PN 303 5 Hajn wka on 2004 02 01 1 3 Fuel ZN Use only fuels recommended by the manufacturer The Moderator boiler is designed to burn renewable fuels wood based and vegetable fuels pieced wood chips sawdust bark with moisture content of up to 30 Coal may be used as a substitute fuel Technical parameters of 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 wasted in the burning process for heating up the fuel an
16. gh the top side Screw on the head to the frame from the outside using enclosed screws The fuel container must be levelled 31 7 2 Boilers intended for pellets burners 1 Boilers purchased together with the burner Boiler in this case is delivered complete with additional doors to be assembled that allow the boiler to be operated with the burner Burner is delivered together with a container and a feeding pipe In order to install the burner disassemble doors on the front vertical face of the boiler and install doors equipped with a connecting adapter for the pellets burner they are packed inside the boiler chamber Proceed with installation according to the burner instructions enclosed with the boiler documentation Note Do not dispose of the disassembled doors They will be needed to Start up the boiler if the burner is disconnected 2 Burners purchased for a boiler already in operation Models 2010 and later If you are 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 it will be necessary to remove cast iron ante doors installed inside the frame After that proceed accordi
17. ing research amp development work the manufacturer reserves the right to make boiler design and documentation changes Consequently certain elements of the boiler as presented on photographs or drawings in these instructions may differ from elements as in delivered unit Dear User Thank you for your purchase of our equipment and congratulations on your good choice Moderator Sp ka z o o has been manufacturing boilers utilizing proprietary technological solutions developed in late 70 s in Hajn wka by engineer Mr Kazimierz Kubacki For almost thirty years these boilers have been undergoing multiple technological changes and upgrades This instruction manual is based on the latest information of the manufacturer Due to ongoing development works on the boiler the manual is only applicable for the boiler it is delivered with Moderator boilers are intended for heating water up to maximum temperature of 90 degrees Celsius in central heating and hot household water installations as well as in process installations wood dryers presses etc This manual has been designed to assist users in boiler installation Operation maintenance and servicing It shall be read and understood 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
18. lers prepared for future installation of APSB which could be ordered separately A boiler prepared for installation of an automatic feeder has an assembly hole allowing feeder connection 1 If you choose to install the automatic biomass feeder in future as of now the hole must be plugged To plug the hole a plug must be used which is mounted directly on the boiler The plug is made of special fire proof materials and is additionally 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 A 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 fitting matching it to the frame in the boiler install a seal level using head feet secure head alignment using bolts and then screw together the frame Before seating the inner gap between the breeching and the frame shall be sealed with a fire resistant rope or a fire resistant mortar fire resistance up to 1200 degrees Celsius The fuel container must be levelled 3 If a feeder with cast iron head is connected the head hearth must be slid into the hole in the boiler until resistance is felt so that the hearth cover loosely slides onto positioning hooks the cover is installed through the charging flap throu
19. mbustion temperature is not lower than 850 C Approximate data of different fuels h kg 404 1 4 Technical Descripiion This manual applies to boilers rated from 10 to 60 kW manufactured in the plate version Moderator boilers Fig 1 are boilers operating in the top burning system Walls and grate are water cooled the version supporting burners may be equipped with cast iron grate and made of quality sheet metal plates Manual top fuel charging mechanical ash removal from the grate bottom doors ash pan doors equipped with mechanical air supply throttle used in case of a power outage or in versions without an air supply system Boilers are equipped with directional air supply to the combustion chamber with autogenous primary and secondary air distribution On its way to the combustion chamber air is heated This significantly contributes to correct burning process 1 5 Equipment The boiler is delivered in assembled state Its standard equipment includes a thermometer and a cleaning kit Other additional elements depend on the purchased version and are not included in the boiler price The ash tray 1s only available for 10 25kW models Additional non fixed equipment GY drain valve G safety valve G 12 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 co
20. n principles 1 Before connecting the device it is necessary to read boiler s and controller s operating instructions 13 8 2 Before commencing with assembly repair or maintenance works and when performing all connections it is necessary to disconnect power supply from the device and verify that power lines are disconnected from mains Boiler house shall be equipped with 230V 50Hz electric installation compatible with relevant regulations applicable in this scope The electric installation regardless of its type shall be terminated with a power receptacle equipped with a protective earth terminal Use of power receptacles without properly wired protective earth terminal will constitute electric shock hazard The boiler shall be connected to a separately installed power supply line protected with suitably chosen fast blow fuse and differential current circuit breaker shock protection The value and the type of the fuse is defined in the controller s operational documentation No other equipment must be connected to this line The box in which electric accessories are contained may only be opened by a competent electric engineer knowledgeable with the equipment operation 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 Wires shall be routed away f
21. nd thus the supply water temperature shall be performed by changing operational parameters preset on the controller In exceptional situations e g in case of power supply outage this can be performed by adjusting the throttle or the ash pan doors adjustment slot or by changing the cross section of the combustion gases outlet in the smoke breeching When operating a boiler with air supply system the ash pan flap shall remain closed and it 1s 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 has factory preset hinges If during boiler starting combustion gases backdraft to the boiler room then hinges must be pressed down and at the same time the charging flap handle must be adjusted Always make sure that back drafting is not caused by closed flue damper or use of elbows or connectors making flue gases difficult to leave the boiler 3 4 Boiler and Chimney Cleaning Grate cleaning is performed when water temperature starts to drop and when the ash pan illumination reduces Ash shall be removed while the flame is reduced In order to ensure fuel economy keep internal chambers of the boiler and spaces between water tubes clean An indication suggesting that cleaning is
22. ney brick It is necessary to ensure access to washout doors installed on side walls of the smoke breeching which are intended for boiler s rear part cleaning Chimney outlet shall be located 75 cm above the roof ridge Square or rectangular chimneys shall be made of burnt brick round chimneys usually steel ones shall be insulated over the whole height with at least 5 cm mineral wool layer When installing the smoke breeching in the chimney one shall pay attention to the chimney damper lever it 1s necessary to provide a space needed for its easy opening and closing therefore the chimney damper lever will heat up To operate the f Remember that combustion gases entering the chimney are hot chimney damper always wear protective gloves Required Chimney Cross Section Dimensions kW cm x cm cm x cm diameter cm m wots exis san m 6 8 boa 20x20 m a so Pa um wsio sox s aso 2 5 Boiler connection to the central heating system The 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 80 C and that the water on return not less than 55 C Such operating parameters will protect
23. ng to burner installation instructions Note Do not dispose of the disassembled doors They will be needed to Start up the boiler if the burner is disconnected Models 2009 and earlier In this case when ordering the burner you will have to specify the spacing of boiler vertical doors hinges to allow us to produce replacement doors Then proceed as per instructions for 2010 models Note Do not dispose of the disassembled doors They will be needed to Start up the boiler if the burner is disconnected 32 8 Boiler specifications Parameter Boiler power rating kW m Combustion gases temp O Rated power wood coal Minimum power Qmin wood coal Comb gases mass flow Rated power Q kg s wood coal Minimum power Qmin kg S wood coal 4 5 the thermal protection bar Recommended minimum volume of the accumulation tank 1 33
24. ntrol 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 secondary air circulation and requires no user adjustments for detailed information on the air supply system see section 7 and operating instructions delivered with the boiler 2 Installation 2 1 General parameters Maximum supply temperature 90 C Maximum return temperature 70 C Minimum recommended return temperature 55 C Operating pressure 1 5 bar Thermal efficiency in case of manual charging for wood 78 7 for coal 80 Minimum combustion gases temperature 150 C P OS gt 10 11 12 13 Fig la Unica SENSOR 25 kW boiler description of main parts Charging flap Grate doors Ash pan doors Air throttle Mobile grate lever Fan Return pipe Top washout cover 20 and 25kW boilers Supply pipe Ash pan washout cover Straight through valve G2 muff Tech ST 81 controller 10 to 30kW boilers GY muff m a Charging flap Grate doors Ash pan doors Air throttle Mobile grate lever Fan Return pipe Top washout cover 20 to 60kW boilers Supply pipe 10 Ash pan washout cover 11 Thermometer 12 ecoMAX 200 controller 40 to 60kW boilers 13 GA muff CHO NADAAKRWN Fig 1b Unica SENSOR 50 kW boiler description of main parts 10 2 2 Boiler Room The boiler room shall meet requirement
25. ocated 1 Local thermostat 2 Hot household water temperature sensor 3 Hot household water pump 4 Central heating pump 5 Air blower 6 Power supply socket Connecting power supply The boiler is connected to the power supply network by inserting one end of the power supply cord delivered with the boiler to the socket 6 Fig 6 marked as 230V 50Hz which is located on the controller enclosure The other end terminated with the power plug must be inserted into an outlet of the electric power supply installation If the power supply cord is damaged it shall be replaced with a cable A of the same type with wires cross section of at least 3x0 75mm The maximum combined loading of OQ G outputs is JA Connecting the central heating circulating pump W This operation shall be performed by a person with necessary qualifications to perform electric installation works The circulating pump shall be connected to 4 socket using a cable with cross section of at least 3x0 75mm While making the connection the pump cable shall be terminated with a computer type plug included Connecting the hot household water pum EP ay 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 Q using a cable with cross section of at least 3x0 75mm While making
26. required is reduced chimney draught Insufficient air will cause the boiler to smoke excessively There are washouts installed on side walls of the flue damper Their purpose is provide access to boiler interior for cleaning Due to high temperature 26 of surfaces these washouts may be opened and cleaning may be performed only after the boiler has been shut down LIILSLRIRIERLALTAREFALI LIILRLRIRIERLARRAREFALI ETLTNITYFATALTFAAATAII _ ma ma E naa m z m m m ei m Fig 13 Boiler cleaning diagram ZN Cleaning may only be performed on boilers that were shut down before In case of heavy contamination of the boiler chemical agents removing boiler deposits may be used but only such which are allowed on the market 1 e 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 performed from the combustion chamber side and whether air ducts are not clogged in particular their outlets into the ash pan chamber It is also necessary to unscrew 2 the air blower and remove deposit that may accumulate on duct s horizontal connector 3 5 Planned
27. rmits boiler operation in closed systems if specific requirements are complied with In case of versions adapted for automated operation only and exclusively with burners protective systems are sufficient 5 5 4 3 l 2 485 2 i 3 1 2 4 3 a 10 to ISkW b 20 to 30kW c 40 to 60kW Supply muff G1 10 to 30kW G2 40 to 60kW Safety valve stub pipe G 10 to 15kW G34 20 to 60kW G thermometer stub pipe in 40 to 60kW boilers must be plugged The G2 muff of the thermal protection SYR type Washout cover AS UB Fig 8 Placement of muffs and stub pipes on the upper panel of Unica Sensor boilers 20 6 8A a e ZASILANIE Z SIECI es ZABEZPIECZENIE TERMICZNE ZAW R BEZPIECZE STWA ODPROWADZENIE WODY CZUJNIK ZAWORU TERMICZNEGO W OWYNWICA gt h CZUJNIK TEMPERATURY T INSTALACJA GRZEWCZA ZAW R MIESZAJ CY a ee AEE ee eee i ZBIORNIK AKUMULACYJNY ZAW R SPUSTOWY KOMIN CHIMNEY ZAWOR BEZPIECZENSTWA SAFETY VALVE CZUJNIK ZAWORU TERMICZNEGO THERMAL PROTECTION VALVE SENSOR CZUJNIK TEMPERATURY TEMPERATURE SENSOR KOCIO BOILER STEROWNIK CONTROLLER WENTYLATOR BLOWER ZAWOR SPUSTOWY DRAINAGE VALVE ZABEZPIECZENIE TERMICZNE THERMAL PROTECTION ZAWOR MIESZAJ CY MIXING VALVE ZBIORNIK AKUMULACYJNY HEAT ACCUMULATION TANK WEZOWNICA COIL INSTALACJA GRZEWCZA HEATING INSTALLATION ZASILANIE Z SIECI WATER PIPE SUPPLY ODPROWADZENIE WODY WATER DR
28. rom the parts of the boiler that may get hot and in particular away from hot elements of the flue breeching The controller must not be exposed to flooding or to conditions causing vapour condensation e g rapid ambient temperature changes 10 The controller must not be operated if its enclosure is damaged 11 Protect the controller against access of children 12 During thunderstorms the controller shall be disconnected from mains 2 6 1 Boilers rated 10 to 30 kW Unica SENSOR boilers rated 10 to 30 kW have preinstalled air supply system which consists of the following elements ref fig 3 Other parts used to connect power supply and pumps driven by the controller are located in the box attached to the boiler A Blower B Connecting cable C Tech ST 81 controller Fig 3 Air supply system the photo shows a 20 kW rated boiler Connecting power supply The boiler is connected to the power supply network by inserting one end of the power supply cord delivered with the boiler to the electric power supply receptacle 1 Fig 4 The other end terminated with the power plug must be inserted 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 pum This operation shall be performed by a person with necessary qualifications to perform electric installation works Connect th
29. s its periodical cleaning par 3 4 After the heating season the boiler shall be thoroughly cleaned Fig 13 its internal surfaces shall be protected with oil 5 Safe operation conditions The main precondition of boiler safe operation is construction of its installation and protections according to Polish standards In order to maintain safe operating conditions of the boiler it is necessary to follow the principles stated below 29 wear protective gloves and goggles do not block charging flaps and ash pan doors perform grate readjustment using the ash pan lever use portable 24V lamps maintain order and cleanness in the boiler room maintain good technical condition of the boiler and its related installation during the winter season ensure that the heating process is continuous If water freezing in the installation is suspected check whether safety piping is not blocked The water added to the water charge in the installation shall return through the overflow pipe from the pressure vessel If safety piping 1s blocked the boiler must not be ignited and if it has been operating proceed as in boiler emergency shutdown procedure see section 3 6 It is forbidden to spill water onto the grate ignite the boiler using flammable liquids After the end of the heating season April to September pay special attention when using the boiler for heating the household hot water ZN only Boiler power will be too high
30. s necessary to stop the device disconnect it from the electric installation and then proceed to repair the damage If needed you may contact the boiler manufacturer Controller panel must be kept clean and protected against water 1 Maintenance activities involve periodic checking of electrical cabling 3 2 Igniting Ignition of a cold boiler may only be started after prior checking that the slot is correctly filled with water Open ash pan doors or open the throttle on ash pan doors Ignite using dry wood for about 1 5 hours gradually reaching the temperature of 80 C We recommend to perform first ignition without using the air supply system adjusting the air supply by opening and closing ash pan doors or the throttle remembering to switch on the pump after the temperature exceeds 40 C during further operation when using 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 80 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 the whole combustion chamber for wood 50 fill rate for coal maximum 20 fill rate 3 3 Burning During normal boiler operation monitor and periodically supplement the fuel In order to maintain sta
31. s of the PN 87 B 02411 standard Here are some of the most important of them e waterproof flooring e steel or wooden doors lined with sheet metal opening outwards e 21x21 cm air supply hole in the bottom part of the boiler room at least 14x14 cm exhaust hole in the upper part of the boiler room Equipment e tap e sewage well e sing ZN Forced ventilation must not be used 2 3 Boiler Installation Boiler installation shall be performed by an engineer with appropriate qualifications and experience we advice you to seek help from representative centres whose installers have undergone training in Moderator Sp z 0 0 A faulty installation may cause premature wear of the boiler and threatens fire or may cause an explosion Moderator boilers are delivered in assembled state Boiler may be positioned directly on the floor with 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 and fan difficult Recommended distances are min 80cm for side walls and 100 cm for the front wall 2 4 Connecting to the Chimney Boiler s smoke breeching shall be seated directly in the chimney and after installation sealed along the contact line of smoke breeching sheet metal chim
32. sh Standard It is particularly recommended for boilers which are not equipped with cooling exchanger Figure 1 presents installation principle at a close distance from the boiler with special consideration for such guiding and sizing of pipes so that no pressure losses occur Installation and operating principle The 5067 thermal protection valve consists of the following elements non return valve 1 pressure reducer 2 thermally controlled filling valve 3 and ejection valve 4 pressure sensor with a capillary tube 5 The pressure reduction valve 2 is connected to the water pipe network The output of the thermally controlled filling valve 3 is connected to boiler s return line The supply line to the input of thermally controlled ejection valve 4 which output side leads to the outlet The pressure sensor is installed in the warmest part optimally in the upper part of the boiler The pressure reduction valve is firmly set to 1 2 bar thus the operating pressure in the heating device shall be by 0 2 to 0 3 bar higher This prevents opening of the safety valve in the installation It is recommended to use a safety valve with settings of at least 2 bars If the preset opening temperature of ca 90 C is exceeded the filling valve 3 starts to open In order to maintain stable pressure in the heating installation the ejection valve opens at 97 C After the ejection valve opens hot water flows out of the installation and cold water may flo
33. t 1 2 bar factory fixed 16 bar 2 3 bar of opening of closing 90 C 0 2 C 88 C 0 2 C 97 C 0 2 C 94 C 0 2 C 135 C 1300 mm standard length 1 5kg 3 Boiler operation 3 1 Controller description operation servicing 3 1 1 Boilers rated 10 to 30 kW Figure 11 describes components of the control system with Tech ST 81 controller MICROPROCESFOR TEMPERATURE CONTROLLER VA POWER MERE 1 Tech ST 81 controller panel 3 Settings buttons 2 Display 4 Power switch Fig 11 Control system with Tech ST 81 controller front view Detailed information on basic parameters key functions parameter setting etc are provided in Tech ST 81 controller operating instructions delivered with the 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 damage If needed you may contact the boiler manufacturer Controller panel must be kept clean and protected against water 2 3 1 2 Boilers rated 40 to 60 kW Boiler automatic control unit utilizes a microprocessor controlled PLUM ecoMAX 200 controller Its task is to maintain the preset
34. temperature in the heating circuit and temperature of hot water in hot household water tank STOP START HO 1 STB temperature limiter 5 Setiings buttons 2 Red control 6 Power switch 3 ecoMAX 200 controller panel 7 Fuse 4 Display 8 Thermometer Fig 12 Control system with ecoMAX 200 controller front view Figure 12 describes elements of he control system Setting buttons 6 are used for specifying controller parameters and for selecting displayed parameters describing the operating status of the boiler control system For detailed information on basic parameters 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 order to restore the boiler to normal operation it is necessary to undo the black nut of the STB temperature limiter and press the pushbutton located underneath The thermometer shows current temperature also in case of power outage 24 Periodical maintenance notes 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 i
35. 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 affect the safety or cause the equipment operating costs to raise in future All performance tests and trials of boilers have been performed using carefully selected accessories safety valves thermal protections and equipment air supply systems In order to guarantee maintenance of declared high performance of the boiler manufacturer recommended equipment must be used exclusively We would like to hereby advise against using substitute solutions which have not been checked with that boiler and which do not have required approvals Technical Supervision Office UDT and certificates declaration of conformity CE sign We also advise against any unauthorized changes in the boiler design Failure to follow these recommendations may lead to serious threats and expose the operating personnel to health or life hazard In case of doubt please consult our sales department or authorized servicing agent Safety and Warning Signs Note The washout located under the masking cover may be hot Pay special attention in the boiler room as other parts of the boiler and the installation may also be hot This sign in this manual indicates a danger Please carefully read the corresponding section
36. w in from the supply line this cools down the boiler When boiler temperature drops to 94 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 filling valve closes Build The thermal protecting device is controlled by two independent valves the filling valve and the ejection valve The body of the device is a die stamped brass element whilst other parts that contact water are made of stainless steel and temperature resistant plastic All sealing elements are made of resilient and high temperature resistant heavy duty elastomeric rubber material Springs are made of stainless spring steel The sensor and capillary tube are made of copper whereas the sleeve is additionally nickel plated Valve opening is controlled by doubled temperature sensor The fittings are self venting Elements of the valve the valve seat and seal may be removed and cleaned without any change to pre set opening temperature Compact head of the temperature sensor may be conveniently disassembled during the valve body installation The capillary tube from the sensor to actuator is protected by a special metal flexible hose Pressure reducer operating pressure Maximum water inlet pressure Minimum required inlet water pressure Temperature filling valve ejection valve Maximum operating temperature Capillary tube Weigh
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