Moderator UNICA SENSOR 10 kW User manual

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

2
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. Equipment ....................................................................................................................... 8
2. Installation.......................................................................................................................... 8
2.1. General parameters.......................................................................................................... 8
2.2. Boiler Room .................................................................................................................. 11
2.3. Boiler Installation.......................................................................................................... 11
2.4. Connecting to the Chimney........................................................................................... 11
2.5. Boiler connection to the central heating system............................................................ 12
2.6 Connecting the boiler to electric installation.................................................................. 13
2.7. Protection of the Installation ......................................................................................... 19
2.7.1. Open systems.............................................................................................................. 19
2.7.2. Closed Systems .......................................................................................................... 20
2.7.3. Thermal protection ..................................................................................................... 22
3. Boiler operation................................................................................................................ 23
3.1. Controller – 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 Feeders “Smok” ŻL and
GC ........................................................................................................................................ 31
7.2. Boilers intended for pellets burners .............................................................................. 32
8. Boiler specifications......................................................................................................... 33
Due to on-going research & 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.

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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 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 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.

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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. 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:
•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 include faults resulting from:
•failure to follow assembly guidelines stated in these operating
instructions or resulting from regulations currently in force,
•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)
•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 claim, please make ready the following details:
•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
•serial number
7. User statement:
I 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 case of an unjustified service request to the
Moderator company under a warranty repair, I 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

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Declaration of Conformity
We,
Moderator Spółka z o.o.
Ul. 11 Listopada 16a
17-200 Hajnówka, POLAND
tel. [phone]
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
Hajnówka, on 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 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 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) 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.

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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
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
combustion temperature is not lower than 850
o
C.
Approximate data of different fuels
Fuel type Burning time 1 cubic meter weight moisture content
( h) ( kg ) ( % )
wood
pieces 4-6 404 15
chips 3-5 215 15
sawdust 2-4 238 15
bark 2-5 250 15
coal 6-8 900 -
1.4. Technical Description
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

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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 is only
available for 10-25kW models.
Additional non-fixed equipment:
-G ½ drain valve
-G ¾ safety valve (G ½ 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 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
o
C

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1. Charging flap
2. Grate doors
3. Ash-pan doors
4. Air throttle
5. Mobile grate 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 G½ muff
12. Tech ST-81 controller (10 to 30kW boilers)
13. G½ 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

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1. Charging flap
2. Grate doors
3. Ash-pan doors
4. Air throttle
5. Mobile 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. G½ 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

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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:
•waterproof 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
Equipment:
•tap
•sewage well
•sing
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 o.o.).
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 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 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 –
chimney 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

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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 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.
Required Chimney Cross-Section Dimensions
Power square chimney rectangular chimney round chimney chimney height
kW cm x cm cm x cm diameter (cm) (m)
up to 15 18 x 18 14 x 27 18 6 ÷ 8
20 ÷ 32 20 x 20 14 x 27 24 8 ÷ 10
40 ÷ 50 25 x 25 - 28 8 ÷ 10
60 ÷ 150 30 x 30 - 35 8 ÷ 10
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
O
C, and that
the water on return, not less than 55
O
C. Such operating parameters will protect
the boiler against low-temperature material corrosion.
Boilers have connections in the form of threaded G1½ stub pipes.
Connecting stub pipes with the installation shall be performed using appropriate
connectors. In order to properly connect the boiler, it is necessary to install all
accessories presented on Figures 1a and 1b.
If the boiler is fitted with a thermal safety valve, the valve’s sensor
shall be installed in the dedicated G½ muff (item 13 on fig.1a,b), then
install the safety valve.

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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)
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 G½ valve (11, fig. 1a) using a
flexible hose, which after filling is 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 connection principles.
1. Before connecting the device, it is necessary to read boiler’s and controller’s
operating instructions.

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A B C
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.
3. Boiler house shall be equipped with 230V/50Hz electric installation,
compatible with relevant regulations applicable in this scope.
4. 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!!!
5. 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.
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 the parts of the boiler that may get hot, and
in particular away from hot elements of the flue breeching.
9. 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.

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1
4
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 (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 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-section of at least 3x0.75mm
2
using
suitable socket (included).
A
C
A.
Blower
B. Connecting cable
C. Tech ST-81 controller
B

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2
3
Connecting domestic hot water pump
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
2
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 heating pump
socket
5. Fuse
1 3 4 5
2

17
A
B C
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: (see fig. 5)..
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
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 regulatorem ecoMAX 200
B

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3
4
5
6
3
2
1
4
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 (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
of the same type, with wires’ cross-section of at least 3x0.75mm
2
.
The maximum, combined loading of
outputs is 3A.
Connecting the central heating circulating pump
This operation shall be performed by a person with necessary
qualifications to perform electric installation works.
The circulating pump shall be connected to socket using a cable with
cross-section of at least 3x0.75mm
2
. 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 cable with cross-section of at least 3x0.75mm
2
. While
making 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 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.

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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
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
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:
25 mm for boilers rated up to 25 kW, inclusively

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32 mm for boilers rated 40 to 60 kW
•riser pipe (RW) with inner diameter of 25 mm
•overflow pipe RP
inner diameters as 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
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 permits 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.
a) 10 to 15kW b) 20 to 30kW c) 40 to 60kW
1. Supply muff (G1½ 10 to 30kW, G2 40 to 60kW)
2. Safety valve stub pipe (G½ 10 to 15kW, G¾ 20 to 60kW)
3. G½ thermometer stub pipe (in 40 to 60kW boilers must be plugged)
4. The G½ muff of the thermal protection (SYR type)
5. Washout cover
Fig. 8. Placement of muffs and stub pipes on the upper panel of Unica Sensor
boilers.
1
1
1
2
2
2
3
3
3
4
4
4
5
5
5