Moderator Unica Max 80 kW User manual

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

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TABLE OF CONTENTS
Dear User,...............................................................................................................................3
1. Overview............................................................................................................................3
1.1. Safety Instructions...........................................................................................................3
1.2. Warranty Terms and Conditions .....................................................................................5
1.3. Fuel..................................................................................................................................6
1.3.1. Burning Other Fuels.....................................................................................................7
1.4. Technical Description .....................................................................................................7
1.5. Accessories:.....................................................................................................................8
2. Installation..........................................................................................................................8
2.1. General parameters..........................................................................................................8
2.2. Boiler Room..................................................................................................................10
2.3. Boiler Installation..........................................................................................................10
2.4. Connecting to the Chimney...........................................................................................10
2.5. Boiler connection to the central heating system............................................................11
2.6. Boiler connection to the electric installation.................................................................12
2.6.1 Boilers rated 80 to 160 kW .........................................................................................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 operation conditions.................................................................................................27
6. Disposal............................................................................................................................29
7. Boiler connection to "SMOK"-type Automatic Biomass Burning Feeders*...................29
8. Boiler Specifications ........................................................................................................30
Due to ongoing research & development work, the manufacturer
reserves the right to make boiler design and documentation
changes.

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Dear User,
Thank you for your purchase of our equipment and congratulations on
your good choice.
Moderator Spółka z o. o. has been manufacturing boilers utilizing
proprietary technological solutions developed in late 70’s in Hajnówka by
engineer 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 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

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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 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.

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1.2. Warranty Terms and Conditions
1. Manufacturer grants 36-month warranty for the unit, which covers all
workmanship and material faults.
2. The manufacturer guarantees correct operation of the central heating boiler,
which is confirmed by the declaration of conformity.
3. The manufacturer recommends the following guidelines to be adhered to:
4. the first start of the device shall be performed by the manufacturer's
representative 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 include faults resulting from:
failure to follow installation guidelines presented in these operating
instructions or those resulting from laws currently in force
incorrect operation or maintenance or 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 matching of the boiler's output to the heat demand of
the building.
6. All warranty complaints shall be directed to the boiler vendor. Before
submitting a claim, please make ready the following information:
photocopy of page 5 of the operating instructions, item 1.2.
(with date and legible signature of the user)
fault description
a document to prove boiler purchase
boiler rated power
serial number
7. User's statement:
I hereby declare to have acknowledged myself with the Moderator boiler operating instructions and that the
unit has been delivered according to the order, new, complete and in good technical condition. Also the specialized
installation company have acknowledged me with the unit operation and have provided me with the complete set of
documentation.
Date and name
legible signature

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Declaration of Conformity
We,
Moderator Spółka z o.o.
Ul. 11 Listopada 16a
17-200 Hajnówka
tel. [phone]
hereby declare under our own and sole responsibility that the product: MODERATOR
central-heating boiler, with serial numbers starting from 400, to which this declaration
applies, meets the following requirements and standards, as applicable:
Directives Standards
97/23/WE EN-PN- 303-5
Hajnówka, 2004.02.01
1.3. Fuel
Use only fuels recommended by the manufacturer.
The Moderator boiler is designed to burn renewable fuels, wood-based
and vegetable-based 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 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 thermal energy is wasted in the burning process for heating
up the fuel and 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). 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.

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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 if
mixed with wood. Papers and colour 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 boiler's
convection chambers and 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 (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.
Approximate data of different fuels
Fuel type Burning time cubic meter weight Moisture content
( h) (kg ) ( % )
wood pieces 4-6 300 30
chips 3-5 155 30
sawdust 2-4 145 30
bark 2-5 200 30
coal 6-8 - -
1.4. Technical Description
This manual applies to boilers rated from 80 to 160 kW manufactured in
the plate version.
Moderator boilers (Fig. 1) are boilers operating in the top-burning system.
Walls and grate are water cooled and are made of boiler-grade sheet metal
plates. Manual, top fuel charging, mechanical ash removal from the grate,

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bottom doors (ash pan doors) equipped with mechanical air supply throttle (used
in case of a power outage).
Boilers are equipped with directional air supply to the combustion
chamber with automatic primary and secondary air distribution. On its way to
the combustion chamber air is heated up. This has a significant impact on the
combustion process. Boilers are equipped with exhaust fans, installed directly on
the breeching. Breeching output (round cross-section280) up, it allows the
boiler to be connected to the chimney at an angle of 0 to 180º.
Boilers in the Uni version, i.e. with system connections can be connected
on their left or right side, also a combined variant is possible, depending on the
specific installation needs.
1.5. Accessories:
The boiler is delivered in assembled state. The standard equipment
includes the complete cleaning set, connection 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 ¾ 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.
The electric control system is installed on the boiler housing and is pre-
wired. The blower installed on the upper boiler housing is connected with the
primary and secondary air circuits and does not require the user to adjust
blowing directions (for detailed information on the air-supply system see section
7 and operating instructions enclosed 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 –180oC

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Fig. 1. MODERATOR UNICA MAX
boiler description of main parts
1. Charging flap
2. Grate doors
3. Ash-pan doors
4. Air throttle
5. Mobile grate lever
6. Air supply fan
7. Return pipe
8. Washout cover
9. Smoke breeching 180mm
10. Chimney damper lever
11. Air exhaust fan
12. Supply pipe
13. Thermal protection sensor G½ muff (80, 100kW)
14. 1” stub pipe for safety valve connection
15. * Thermostat installation G½ muff
16. Ash pan cleanout cover
17. G¾ 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

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2.2. Boiler Room
The boiler room shall meet requirements of the PN-87/B-02411 standard.
Here are some of the most important of them:
fireproof flooring
steel or wooden doors lined with sheet metal, opening outwards
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
Accessories:
tap
sewage well
sink
Forced ventilation must not be used.
2.3. Boiler Installation
Boiler installation shall be performed by an engineer with appropriate
qualifications and experience (we recommend to seek help in our representative
centres, whose installers have been trained at Moderator Sp. z o.o.). A faulty
installation may cause premature wear of the 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 access to fuel charging, grate cleaning and the
side cleanout of the boiler difficult.
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 –
chimney brick. Chimney outlet shall be located 75cm 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.

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When installing the smoke breeching in the chimney, one shall pay
attention to the chimney damper lever (it is necessary to provide a space needed
for its easy opening and closing).
Remember that combustion gases entering the chimney are hot,
therefore the chimney damper lever will heat up. To operate the
chimney damper, always wear protective gloves.
Recommended chimney cross-sections
Boiler power
[kW]
Square (cm x cm)
Round - (diameter in cm)
80160
30x30
35
2.5. Boiler connection to the central heating system
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 80OC, and that the
water on return, not less than 55OC. Such operating parameters will protect the
boiler against low-temperature material corrosion. In order to ensure 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 presented on Figure 1.
If the boiler is equipped with a thermal safety valve, install the valve
sensor on the G½ muff (item 13 on fig. 1). Install the safety valve.
Connect water supply pipe through the valve installed in the G¾ muff
(item 17, on fig. 1) using a flexible hose, which shall be disconnected after water
change is filled. 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 10n. Otherwise the water shall be pre-
treated.
Install boiler accessories (handles and bakelite knobs).

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2.6. Boiler connection to the electric installation
Electric installation and connection principles
1. Before connecting the device, it is necessary to read operating instructions
for the boiler and the regulator.
2. Before commencing with installation, repairs or maintenance and during all
connection works, it is necessary to disconnect the power supply and make
sure that terminals and electric cables are not live.
3. The boiler room shall be equipped with 230V/50Hz installation, according to
applicable regulations.
4. The electric installation (regardless of its type) shall be terminated with a
power receptacle with a protective terminal. Using a receptacle without
protected terminal may lead to electric shock!!!
5. The boiler shall be connected to independently routed power supply line
protected with an appropriately 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 receptacle used for boiler connection shall be selected in
such a way, so that the receptacle is easily accessible allowing quick boiler
disconnection in case of an emergency.
8. Cables shall be routed away from heating parts of the boiler, and in particular
away from hot smoke breeching parts.
9. The regulator may not be exposed to water splashes and to conditions
causing steam condensation, e.g. in case of rapid ambient temperature
changes.
10.The regulator may not be used if its enclosure is damaged.
11.Do not allow children to access the regulator.
12.During thunderstorms the controller shall be disconnected from the mains.

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A
B
C
D
F
2.6.1 Boilers rated 80 to 160 kW
Unica MAX boilers rated 80 to 160 kW in 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

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Fig.3.Unica MAX 100 automatic control equipment (view of the boiler's rear part).
Other parts used for 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

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3. RCA plug used to terminate the cable connecting the controller with the room
thermostat.
4. Male computer-type power connectors used to terminate cables used to supply
central heating and hot water pumps.
Fig. 5. Connection sockets - on the controller side
Fig. 5 shows the side wall of the controller containing sockets, which are
used for connecting:
1. The room thermostat
2. Hot water temperature sensor
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 supply cable (item (1) fig. 4) into a socket marked as 230V~ 50Hz on the
controller enclosure (item (5) fig. 5). The other end, terminated with a plug, shall
be connected to the mains power receptacle.
1
2
1
2
3
4
5

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If the power supply cable is damaged, it shall be replaced with a cable
of the same type, with the cross-section of at least 3x0.75mm2.
Connecting central heating circulating pump
This operation shall be performed by a person with necessary
qualifications to perform electric installation works.
The circulating pump of the central heating installation shall be connected to the
socket (item (4) fig. 5) using a cable with cross-section of at least 3x0.75mm2.
The pump cable shall be terminated with the computer-type power supply plug
(item (4) fig. 4).
Connecting the hot water pump
This operation may be performed by a person with necessary
qualifications to perform electric installation works.
The pump, which 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 performed by a person with necessary
qualifications to perform electric installation works.
The room thermostat shall be connected to the socket (item (1) fig. 5)
by terminating the cable with the RCA plug (item (3) fig. 4) included with the
boiler. Operation of the controller when fitted with the local thermostat is
described in the PLUM ecoMAX 200 regulator instructions.
Unused outputs may be left unconnected.
Permissible output loads
Output
Output symbol
Current [A]
Central heating
pump
1
Hot water pump
1

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Periodical maintenance notes
Maintenance activities involve periodic checking of electrical cabling,
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 shut off the the device, disconnect it from
the power 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.
2.7. Installation protection
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
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

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Installation requirements:
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
safety riser tube (RB) with inner diameter of:
40 mm for boilers rated up to 100 kW, inclusively
50 mm for boilers rated 120 to 160 kW
riser pipe (RW) with inner diameter of
25 mm for boilers rated up to 100 kW
32 mm for boilers rated 120 to 160 kW
overflow pipe RP
inner diameters as in the case of RW and RB
circulation pipe (RC) with inner diameter of 20 mm
venting pipe (RO) and signalling pipe (RS) with inner diameters of
15 mm
No fittings permitting complete or partial closure of flow may be
installed on RB, RW and RO pipes. The protective equipment and
pipes shall be protected against freezing.
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 110OC. The protection shall be installed by the user
performing boiler connection works.
Installation of the boiler in a closed system without the
equipment to dissipate the excess heat is unacceptable.
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) a safety valve and additional thermal
protection permitting safe discharge of excessive thermal power. Muffs welded in the
upper jacket of the boiler facilitate installation of this equipment (items 13 and 14 on
fig. 1).

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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 suitable for automated operation (only and
exclusively versions with burners), protective systems are sufficient.
Fig. 8. Protection of the installation, for boilers operated in closed central
heating systems.
KOMIN –CHIMNEY ZAWÓR BEZPIECZEŃSTWA - SAFETY VALVE
CZUJNIK ZAWORU TERMICZNEGO –THERMAL PROTECTION VALVE SENSOR
CZUJNIK TEMPERATURY - TEMPERATURE SENSOR KOCIOŁ - BOILER
STEROWNIK –CONTROLLER WENTYLATOR –BLOWER
ZAWÓR SPUSTOWY –DRAINAGE VALVE ZABEZPIECZENIE TERMICZNE –THERMAL PROTECTION
ZAWÓR MIESZAJĄCY–MIXING VALVE 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 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 activate, if water from in-house water intake is
used (e.g. if power supply outage prevents the pressure booster set to switch on),
or wherever water supply outages frequently occur.
In such cases, the boiler shall not be installed in a closed system and its
automatic version should be used instead (which can not burn solid fuels with
manual charging).

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