FOKOLUS
00333936 - Ed. 12/2010
INSTALLATION
AND SERVICING
INSTRUCTIONS
General informations
CONTENTS
1 GENERAL INFORMATION........................................................................................................................................................................... 3
1.1 Symbols used in this manual .............................................................................................................................................................. 3
1.2 Correct use of the appliance ................................................................................................................................................................ 3
1.3 Water treatment ..................................................................................................................................................................................... 3
1.4 Information to be handed over to the user .......................................................................................................................................... 3
1.5 Safety warnings ..................................................................................................................................................................................... 4
1.6 Data badge ............................................................................................................................................................................................ 4
1.7 General warnings .................................................................................................................................................................................. 4
2 TECHNICAL FEATURES AND DIMENSIONS ..........................................................................................................................................5
2.1 Technical features ................................................................................................................................................................................. 5
2.2 Dimensions and hydraulic connection ..................................................................................................................................................6
2.3 Main components .................................................................................................................................................................................. 7
2.4 General features ................................................................................................................................................................................ ...7
3 INSTRUCTIONS FOR THE INSTALLER ................................................................................................................................................ 9
3.1 General warnings ................................................................................................................................................................................ ..9
3.2 Standard codes for installation .......................................................................................................................................................... ..9
3.3 Packaging ............................................................................................................................................................................................ 10
3.4 Transport .............................................................................................................................................................................................. ..10
3.5 Assembly .............................................................................................................................................................................................. ..11
3.6 Connection of the boiler to the C.H. system...................................................................................................................................... .11
3.7 Connection of the safety heat exchanger to the sewage................................................................................................................. 12
3.8 Recirculation pump ............................................................................................................................................................................ 12
3.9 Assembly instructions ......................................................................................................................................................................... 13
3.10 Electrical and hydraulic connection diagrams..................................................................................................................................15
3.11 Connection to the chimney................................................................................................................................................................. 19
3.12 Filling the system............................................................................................................................................................................... 20
4 ELECTRICAL CONNECTIONS…................……………………………………………………………………………………………….21
5 BOILER STARTING .................................................................................................................................................................................. 22
5.1 First lighting ......................................................................................................................................................................................... 22
5.2 The wood ............................................................................................................................................................................................. .23
5.3 The humidity of the wood .................................................................................................................................................................... 23
5.4 Wood logs dimensions ........................................................................................................................................................................23
5.5 Checks at first lighting ......................................................................................................................................................................... 23
5.6 Starting.................................................................................................................................................................................................. 24
5.7 Combustion air adjustment .............................................................................................................................................................. 24
5.8 Checks to be carried out after the first starting ............................................................................................................................... 25
5.9 Warnings ............................................................................................................................................................................................. 25
5.10 Summer operation ……..................................................................................................................................................................... 25
5.11Burner adjustment on the eventual auxiliary boiler........................................................................................................................ 25
5.12 Problem solving…... ...........................................................................................................................................................................26
6 INSPECTION AND MAINTENANCE…………………………………………...…………………………………………………………26
2
General informations
Warning: this manual contains instructions to be used exclusively by the installer and/or a competent person in accordance with the current laws in force.
The end user MUST not make any alterations to the boiler.
Failure to follow the instructions indicated in this manual, which is supplied with the boiler, could cause injury to persons,
animals or damage to property.
UNICAL shall not be held liable for any injury and/or damage.
1
GENERAL INFORMATIONS
1.1 - SYMBOLS USED IN THIS MANUAL
When reading this manual particular care has to be given to the parts marked with the followings symbols:
DANGER!
Indicates serious danger
for your personal safety
and for your life
WARNING!
Indicates a potentially dangerous situation for the product and the environment
NOTE!
Suggestions for the user
1.2 - A CORRECT USE OF THE APPLIANCE
The FOKOLUS appliance has been designed utilizing today’s heating technology and in compliance with the
current safety regulations.
However, following an improper use, dangers could arise for the safety and life of the user or of other
people, or damage could be caused to the appliance or other objects.
The appliance is designed to be used in hot water central heating systems, both with natural or forced circulation and for the production of domestic hot water (through a separate cylinder).
Any other use of this appliance will be considered improper.
UNICAL declines any responsibility for any damages or injuries caused by an improper use; in this case the
risk is completely at the user’s responsibility.
In order to use the appliance according to the foreseen scopes it is necessary to carefully follow the
instructions indicated in this manual.
1.3 - WATER TREATMENT
In hard water areas where the main water can exceed 15°f total hardness, a scale reducing device is
recommended.
The choice of this device has to be made taking into consideration the characteristics of the water.
1.4 - INFORMATION TO BE HANDED OVER TO THE USER
The user has to be instructed on the use and operation of his heating system, in particular:
• Hand over these instructions to the end user, together with any other literature regarding this appliance placed
inside the envelope contained in the packaging. The user has to keep these documents in a safe place in
order to always have them at hand for future reference.
• Inform the user on the importance of air vents and of the flue outlet system, stressing the fact that it is absolutely
forbidden to make any alterations to the boiler.
• Explain the function of time and temperature controls, thermostats, heating controls and radiators, to ensure the
greatest possible fuel economy.
• Remind the user that, in order to comply to the standards in force, it is necessary to inspect and service the boiler
according to the current codes of practice and according to the schedule indicated in this manual by the
manufacturer.
• If the appliance is sold or transferred to another owner or if the present user moves home and leaves the
appliance installed, ensure yourself that the manual always follows the appliance so that it can be
consulted by the new owner and/or installer.
Failure to follow the instructions indicated in this guide, which is supplied with the boiler, could cause injury
to persons, animals or damage to property. The manufacturer shall not be held liable for any such injury and/
or damage.
3
General informations
1.5 - SAFETY WARNINGS
WARNING!
The installation, adjustment, and servicing of this appliance must be carried out by a competent person and
installed in accordance with the current standards and regulations. Failure to correctly install this appliance could cause injury to persons, animals or damage to property. The manufacturer shall not be held liable
for any injury and/or damage.
DANGER!
Servicing or repairs of the appliance must be carried out by UNICAL authorised service technicians; UNICAL recommends drawing up a service contract. Bad or irregular servicing could compromise the safe
operation of the appliance, and could cause injury to persons, animals or damage to property for which
UNICAL shall not be held liable.
Explosive and easily inflammable substances
Do not use or leave explosive or easily inflammable material (as for example: petrol, paint, paper) in the
room where the appliance has been installed.
1.6 - DATA BADGE
The data badge is adhesive and is inserted into the document envelop; it should be applied by the installer to one side of
the boiler shell on the outside.
The serial number is printed on a riveted plate on the front plate of the shell (front upper right corner).
1.7 - GENERAL WARNINGS
This instruction manual is an integral and indispensable
part of the product and must be retained by the user.
Please read carefully the instructions contained in this
manual as they provide important indications regarding the
safe installation, use and servicing of this appliance.
Keep this manual in a safe place for future reference.
The installation and servicing must be carried out in
accordance with the regulations in force according to the
manufacturer’s instructions and by legally competent
authorized persons.
By a competent person, we imply a person who has a
specific technical qualification in the field of components for
central heating systems for domestic use and servicing.
The person must have the qualifications foreseen by the
current laws in force.
Any repairs must be carried out solely by Unical authorized
technicians and using only original spare parts.
Non observance of the above requirement may jeopardize
the safety of the appliance.
If the boiler remains unused for long periods, ensure that
any dangerous parts are rendered innocuous.
If the appliance is sold or transferred to another owner or if
the present user moves home and leaves the appliance
installed, ensure yourself that the manual always follows
the appliance so that it can be consulted by the new owner
and/or installer.
This appliance must be used only for the purposes for
which it has been expressively designed. Any other use
shall be considered incorrect and therefore dangerous
Bad or irregular servicing could compromise the safe
operation of the appliance, and could cause injury to
persons, animals or damage to property. The manufacturer
shall not be held liable for any such injury and/or damage.
4
Technical features and dimensions
2
TECHNICAL FEATURES AND DIMENSIONS
2.1 - TECHNICAL FEATURES
The FOKOLUS is a wood fired steel boiler, with the
combustion chamber under negative pressure .
It comes in the following models:
FOKOLUS 20
FOKOLUS 30
FOKOLUS 40
COMPONENTS DESCRIPTION :
• Steel boiler with combustion chamber partially coated with
refractory
• Cast iron grate
• Horizontal smoke channels
• Front wood loading door with refractory insulation and
equipped with secondary air inlet
• Lower cleaning door with refractory insulation and
equipped with primary air adjuster
• Automatic thermostatic primary air adjuster
• Rear smoke chamber with inspection and cleaning
opening
• Safety heat exchanger
• Boiler shell insulated with mineral wool panels 60 mm
thick
• Steel plate casing painted with epoxy polyester powders
5
Technical featurtes and dimensions
2.2 - DIMENSIONS AND HYDRAULIC CONNECTIONS
1. Upper
loading door
2. Lower cleaning door
3. Thermostatic draft adjuster
4. Secondary air adjuster
5. Primary air adjuster
6. Draft adjuster chain
7. By-pass opening handle with counterweight
8. Rear smoke chamber
9. Smoke chamber inspection opening
T1. C.H. flow
T2. C.H. return
T3. Thermostat draft adjuster connection
T4. Flue connection
T5. Connections for safety heat exchanger
T6. Thermometer sensor bulb holder
T7. Bulb holder for safety heat exchanger valve
fig. 1
MODELS
NOMINAL OUTPUT
NOMINAL INPUT
DIMENSIONS
A
B
C
D
E
F
G
H
I
L
M
N
O
CONNECTIONS T1 - T2
T3
T4
T5
T6 - T7
BOILER WATER CONTENT
WATER SIDE PRESSURE DROP**
CHIMNEY DRAUGHT***
MAX. WORKING PRESSURE
WOOD STORAGE VOLUME
WOOD LOADING OPENING
WEIGHT
LENGTH OF WOOD LOGS
(kW) 20 33 42
(kW)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
UNI ISO 7/1
UNI ISO 7/1
(Øe mm)
UNI ISO 7/1
(l)
(m c.a.)
(mm c.a.)
(bar)
(l)
(mm)
(kg)
(cm)
FOKOLUS 20 FOKOLUS 30 FOKOLUS 40
30,8 50 61
510
776
1260 1260
1143
106
416
87 8787
167 167167
62 6262
168 168168
900 900900
488 858658
490 570570
Rp 2
Rp ¾
200
R ½
Rp ½ Rp ½ Rp ½UNI ISO 7/1
35
0,3
3
70
360x380
250
33 50 70
590
946
1143
106
Rp 2
Rp ¾
200
R ½
53
0,3
3
125
440x380
340
590
1146
1260
1143
106
786586
Rp 2
Rp ¾
200
R ½
67
0,4
21,61,5
3
165
440x380
402
* Power achieved with good quality wood containing 15% of humidity. ** Pressure drop corresponding to a flow rate
related to a temperature difference of 15K *** Ideal draft = Chimney draft ± 0.3 mm w.g.
CO emissions: according to EN 303-5 Class 1 Efficiency: according to EN 303-5 Class 2
6
Technical features and dimensions
2.3 - MAIN COMPONENTS
1. Thermostatic valve
2. Top cover
3. Boiler body mineral wool insulation
4. Loading upper door
5. Cleaning lower door
6. Pre-molded refractory brick
7. Smoke by-pass
8. Smoke chamber
9. Thermal exchange fin
10. Fuel supporting grate
11. Ash collecting tray
12. Safety heat exchanger
13. Plate wood containing
M C.H. flow
R C.H. return
2.4 - GENERAL FEATURES
Through the draft regulator with a thermostatic operation
mounted on a FOKOLUS it is possible to get a
continuously variable quantity of air introduced into the
boiler furnace. This regulator by a chain link, acts on the
lower door of the primary air which is distributed under the
grate.
When the prescribed temperature is reached, the controller
shall automatically reduce the opening of the air intake
door in order to slow down the combustion and to avoid
overheating. In order to optimize combustion, FOKOLUS,
through a special duct on the loading upper door, equipped
with a control, distributes the secondary air in
countercurrent with respect to the route of the combustion
products. This process, which further increases
performance, allows more efficient use of fuel.
fig. 2
Note: the cast iron grates are subject to wear and it is
therefore recommend an annual review, to avoid that
there would be a strange boiler operation.
7
Technical featurtes and dimensions
FOKOLUS BOILER STRUCTURE
The boiler is composed of two shaped elements placed
inside each other, so that a cavity of water is formed in
between (Fig. 6). The wood storage, with a large capacity,
has a special refractory casing with a high mechanical and
thermal resistance, in order to keep dry the by-pass area in
every working condition.
1. Embers zone
2. Wood storage
3. Pre-molded refractory brick
4. Heating surface
5. Safety heat exchanger
6. Boiler water
M C.H. flow
R C.H. return
HEAT EXCHANGE SURFACE (4)
Working on wood and without very high percentages of
sulfur, it is important to get very low flue gas temperatures
in order to improve the water efficiency.
Then it has been selected a type of exchange surface with
dry passages (Fig. 4), already extensively tested for oil fired
boilers operating with low water temperature, allowing low
gas temperature without danger of condensation.
In order to limit this inconvenience in the boiler, it is
necessary to maintain high the operating temperature of
the boiler.
Then, in order to adjust the boiler flow temperature it is
necessary to foresee a 3 or 4 way mixing valve.
Failure to install the mixing valve will void the warranty
Always for the purpose to reduce the consequences of the
formation of condensate (tears of tar, corrosion, etc.) it is
better to dose, each time, the fuel charge to the actual
needs, in order to avoid long stop periods with the wood
storage completely filled with wet wood.
However, all these steps do not prevent the formation of
condensate in the chimney.
We therefore recommend, in the construction of the
chimney, to use thigh structure in order to prevent that the
condensate damage the building structure.
.
The surfaces of the dry ducts are provided with cuts, in
order to avoid problems of metal expansion.
The solid residue of combustion (ashes), will become
always lighter until they are dragged by the velocity of the
combustion gases and they will be deposited in the lower
zone of the rear smoke chamber, from which they will be
removed during cleaning.
the bottom of the wood storage and will be removed from
the lower cleaning door.
The heavier residue will settle at
COMBUSTION CHAMBER (2)
The firewood, as known, normally has a moisture content
higher than other types of fuels. The first operation that
occurs within the wood storage room is, therefore, the
wood drying.
The high moisture content, then, can give rise to visible
signs of condensation within the boiler and also in the
chimney.
fig. 3
8
Installation instructions
3
3.1 - GENERAL WARNINGS
FOR THE INSTALLER
WARNING!
This boiler has to be destined for the use for
which it has been expressively designed for.
Any other use shall be considered improper
and therefore dangerous.
This boiler is designed to heat water at a temperature inferior to boiling point at an atmospheric pressure
WARNING!
These appliances are exclusively designed
to be installed inside adequate sites.
Therefore these appliances must not be installed and operated outdoors. An outdoor
installation could cause malfunctioning and
could be dangerous. For external installations, it is recommended to use appliances
which are specifically designed and predisposed for this purpose.
INSTRUCTIONS
Before installing the boiler the following
points have to be carried out by a competent
engineer:
a) The whole system should be thoroughly flushed in order
to remove any residual dirt or grime which could
compromise correct boiler operation.
b) Check that the chimney/flue pipe has an adequate
draught, does not have any constrictions, and that no other
appliance’s flue outlets have been fitted, unless the
chimney is serving more than one heating appliance,
according to the specific standards and regulations in
force. The connection between the boiler and chimney/flue
outlet can be made only after this verification has been
carried out.
The appliance must be installed by a qualified
and authorised engineer, under his own responsibility, guarantees the compliance of the
standards according to the latest regulations.
NOTE: The
boiler must be connected to a heating
system compatible to its performance and its
power.
3.2 - STANDARD CODES FOR INSTALLATION
The FOKOLUS is a boiler designed for wood burning.
It must be installed according to the installation rules in
force in each destination country.
9
Installation instructions
3.3 - PACKAGING
The FOKOLUS boiler is delivered dismantled: the boiler
body, the casing and the door handles, with cleaning
accessories, are shipped in separate boxes (Fig. 4). The
insulation of the casing is shipped rolled, into the furnace.
After removing each package, make sure the
delivery is complete and undamaged.
If in doubt do not use the appliance and
contact the supplier.
Keep the packaging material (cardboard box,
plastic bags, polyester protection, etc.) out of
the reach of children, as they can be
dangerous.
UNICAL refuses all liability for injury to
persons, animals or damage to property
deriving from not having respected the above
mentioned recommendations.
Description of packages:
1. Boiler body
2. Package containing the boiler casing
3 Package containing accessories and handles
(this package is placed inside the furnace)
In the documents envelope, placed in the furnace, are
provided in:
In the case of storage of the boiler for long
periods, it is recommended to protect every
thing in an appropriate manner.
fig. 4
- Instruction manual for the user
- This Instruction Manual for installation and Maintenance
- Adhesive Data Label
3.4 - TRASPORTATION
To facilitate the transportation, loading and unloading of the
boiler, there is, on top of it, a suitable hook “G” (Fig. 8) for
lifting.
10
3.5 - ASSEMBLYING
The FOKOLUS boiler is no different from a normal solid
fuel boiler, so there are no specific installation standards
other than the security arrangements provided for by law.
The room must be ventilated by opening with a
minimum total area of not less than 0.5 m².
To facilitate the cleaning of the smoke
circuit, in front of the boiler must be left a
clearance of not less than the length of the
boiler and it should at least check that the
doors may be opened by 90 ° without
obstruction.
The boiler may be placed directly on the
floor, because it has self-supporting frame.
However, in the case of a boiler house with
high humidity, it is preferable to provide
a concrete platform.
Once installed, the boiler must be
horizontal and be well stable to reduce
any vibration and noise.
Behind the boiler a sufficient clearance will be left
in order to allow the cleaning of the smoke chamber
with a vacuum cleaner.
Installation instructions
POSITION IN THE BOILER HOUSE
NOTE: The minimum distances shown below are only
binding for thermal units with capacity exceeding 35 kW
3.6 - CONNECTION OF THE BOILER TO THE C.H. SYSTEM
Warning!
Watch out to perform a connection of the
C.H. system pipelines without points of
mechanic tension to avoid the danger of
leakages
C.H. Flow and Return must be connected to the relevant
connecting points of the boiler as shown on page 8.
For the sizing of the pipes of the heating circuit keep into
consideration the pressure losses induced by the radiators, the possible thermostatic valves, the gate valves of the
radiators and by the configuration of the system it self
The layout of the pipes must be conceived taking every necessary precaution to avoid the air-locks and to facilitate the
continuous purging of the system.
Make sure that the pipes of the heating system are not
used as earth of the electric or telephone installations.
They absolutely are not fit to this use. It
could happen that, in a very short time, damages to the pipes, to the boiler and to the
radiators can be discovered, due to stray
currents.
fig. 5
11
Installation instructions
3.7 - CONNECTION OF THE SAFETY HEAT
EXCHANGER TO THE SEWAGE
The solid fuel fired boilers must be
installed with the safety devices foreseen
by the laws in force.
For this purpose, the FOKOLUS boilers are
equipped with a safety heat exchanger.
On this safety heat exchanger must be installed a
temperature relief valve, by the installer, whose bulb shall
be inserted in the bulb holder located on the back of the
boiler FOKOLUS.
The inlet and the outlet can be reversed each other.
However, we recommend to install the valve on the cold
water inlet
Warning!
Without this precaution, any action by the
temperature relief valve can cause harm to
people, animals and things in respect of
which the manufacturer can not be held
responsible.
fig. 6
3.8 - RECIRCULATION PUMP
If the electrical supply is available we suggest,
for a better operation of the boiler, to install,
together with the C.H. pump, a recirculation
pump between the flow and return
connections, in order to keep the return
temperature in the boiler always above 65°C.
12
3.9 - ASSEMBLY INSTRUCTIONS
Mounting of insulation and casing
A) Install the door closing handles (pos. 1) on
the upper and lower door with screws, pos. 2
B) Install the by-pass control lever (pos 3) to the
pin on the smoke chamber, fixing it with the two
self tapping screws supplied in the
accessories box
C) Install the counterweight pos. 5.
D) Install the handle (pos 6) on the
counterweight (pos. 5).
E) Install the thermostatic valve on the front
upper connection (pos 7).
Installation instructions
A) Install the boiler body insulation
(pos. 1) by performing appropriate
cuts at the upper connections
B) Hook the left hand side panel (pos
2) to the front and rear boiler plates.
C) Hook the right hand side panel
(pos 3) to the front and rear boiler
plates.
D) Fit the thermometer (pos 5) to the
top panel and insert its bulb to the
bulb holder welded on the rear plate,
upper part. Secure the top panel (pos
4) to the two sides panels previously
fitted
E) Fit the rear reinforcement profile
(pos 6) of the top panel with the self
tapping screws
F) Fix the boiler technical data plate
on the right hand side panel of the
casing after cleaning and degreasing
the area with a suitable product.
Remove the backing from the label
and apply it so that it adheres
perfectly with the aid of a plastic
spatula. Do not remove the label
because it would affect the adhesion.
fig. 7
fig. 8
13
Installation instructions
A) Attach one end of the chain to the
movable primary air inlet door (pos 1).
B) Attach the other end of the chain to
the command movable rod (pos 2)
C) Put the movable rod (pos 3) in the
seat on the thermostatic valve and
lock it in place with the screw (4).
D) Mount the secondary air intake
tube and secure it with spring pin
using a hammer
A proper adjustment of the chain’s
tension will come with the chain in
tension - primary air door closed cold boiler
fig. 9
The solid fuel boilers are installed with the safety devices
foreseen by the laws in force.
For this purpose, FOKOLUS boilers are equipped with a
safety heat exchanger. The safety heat exchanger will be
connected to one side (connections can be exchanged
between them) to the water mains and to the other to the
sewage with a thermal discharge safety valve, whose bulb
will be positioned in the connection N ° 2 (Fig. 10).
- Mount the thermal discharge safety valve (pos 1) on the
inlet of the safety heat exchanger and insert its bulb into its
bulb holder (pos 2).
It is recommended to convey the discharge to the sewage.
The thermal discharge safety valve may be mounted either
left or right.
For the correct operation of boilers FOKOLUS it is
necessary to provide a recirculation pump to prevent a
low temperature return which could compromise the life
of the boiler.
fig. 10
The UNICAL, to help its customers has therefore
developed a hydraulic kit for recirculation that enhances
the function of the circulating water in the boiler.
14
Installation instructions
3.10 - HYDRAULIC AND ELECTRICAL CONNECTION DIAGRAMS
Introduction!
The diagrams below, are diagrams of principle and are subject to customization.
For special requirements, please contact our after-sales service.
Heating system with temperature regulation via a
manually controlled mixing valve.
.
It is recommended to insert on the pump supply cable a
minimum thermostat with its bulb inserted into the bulb
holder welded to the rear plate of the boiler FOKOLUS, to
enable the operation of the C.H. pump only when the
temperature in the boiler will exceed the threshold of 65 °C
(minimum temperature).
The same thermostat will turn off the C.H. pump if the boiler
temperature falls below this limit, in order to safeguard the
life of the boiler, preventing the formation of condensate.
Please note that to avoid or at least to limit the formation of
condensate within the boiler, it is necessary to install a
recirculation pump, and, failure to install it, will void the
warranty
Key:
Pr = Recirculation pump (failure to install it will void the warranty)
VM = Zone mixing valve (failure to fit or to manage it will void the warranty)
Pi = C.H. pump
VE = Open expansion tank
IR = Central Heating System
TA = Room thermostat
.
fig. 11
Ipr = C.H. pump switch
fig. 12
15
Installation instructions
Heating system with temperature regulation via a manually controlled mixing valve.
Domestic hot water production via a coil type storage tank or plate heat exchanger with separate system and
dedicated loading pump
It is recommended to insert on the
pump supply cable a minimum
thermostat with its bulb inserted into
the bulb holder welded to the rear
plate of the boiler FOKOLUS, to
enable the operation of the C.H.
pump, only when the temperature in
the boiler will exceed the threshold of
65 ° C (minimum temperature).
The same thermostat will turn off the
C.H. pump if the boiler temperature
falls below this limit, in order to
safeguard the life of the boiler,
preventing the formation of
condensate.
The loading pump of the D.H.W.
storage tank works with priority on the
C.H. pump
fig. 13
Please note that to avoid or, at least, to
limit the formation of condensate
within the boiler, it is necessary to
install a recirculation pump, and,
failure to install it, will void the
warranty
.
Key:
Pr = Recirculation pump (failure to install it will void the warranty)
VM = Zone mixing valve ((failure to fit or to manage it will void the warranty)
Pi = C.H. pump
VE = Open expansion tank
IR = Central Heating System
PS = D.H.W. recirculation pump
PC = Loading pump of D.H.W. storage tank
TA = Room thermostat
TB = D.H.W. thermostat
Ipr = Recirculation pump switch
16
fig. 14
Installation instructions
Heating system with temperature regulation via a motorized mixing valve.
Domestic hot water production via a coil type storage tank or plate heat exchanger with separate system and
dedicated loading pump
Auxiliary boiler for alternative or summer operation
During the summer season the D.H.W. production can only be provided by the oil / gas fired boiler.
The two boilers are hydraulically connected in parallel and the diverting valve VD, of manual type, provides to “insert”
in the heating circuit the FOKOLUS boiler or the alongside oil/gas fired boiler: in this case the boiler not foreseen to
operate will not be affected by the water flow of the system and then the heat losses will be reduced
The D.H.W. storage tank must necessarily be formed by a separate group, connected as per diagram.
The management of the heating system will be carried out
by an electronic temperature controller that would control
the temperature of the system by acting on the motorized
zone mixing valve according to the preselected working
curve (If equipped with the external and flow temperature
sensors) or according to the room temperature (if the room
temperature sensor is installed).
If it is decided to operate the auxiliary boiler, the user must
disconnect the power supply line of the recirculation pump
on the FOKOLUS boiler and position the diverting valve VD
for the operation in auxiliary boiler mode.
The loading pump of the D.H.W. storage tank will work
independently from the C.H. pump and will be controlled by
the D.H.W. thermostat fitted in the storage tank.
Please note that to avoid or, at least, to limit the formation of
condensate within the boiler, it is necessary to install a
recirculation pump, and, failure to install it, will void the
warranty
During the summer season it is advisable to produce the
D.H.W. with the auxiliary boiler, or with the FOKOLUS boiler,
provided the instructions given in the chapter 5.10 on page
27 are strictly observed.
.
fig. 15
17
Installation instructions
Key:
Tc = Flow temperature sensor of the wood fired boiler
Pr = Recirculation pump (failure to install it will void the warranty)
VM = Zone mixing valve ((failure to fit or to manage it will void the warranty)
Pi = C.H. pump
VE = Open expansion tank
IR = Central Heating System
PS = D.H.W. recirculation pump (controller by the thermostat positioned on the storage tank)
PC = Loading pump of D.H.W. storage tank
Sa = Room temperature sensor (optional)
Se = Outer temperature sensor
Sm = Flow temperature sensor
TB = D.H.W. storage tank thermostat
VD = Manual diverting valve
Ipr = Recirculation pump switch
fig. 16
18
3.11 - CONNECTION TO THE CHIMNEY
For the connection of the boiler to the chimney the local and
national regulations must be complied with.
Installation instructions
The size of the chimney must be able to provide the
necessary draft required for the proper operation of the
boiler
The chimney has a fundamental importance for the good
operation of the boiler: it will be therefore necessary that the
chimney is waterproof and well insulated.
Old or new chimneys, constructed without complying with
these specifications, may be conveniently recovered “by
tubing” the chimney itself.
It will be necessary to introduce a stainless steel pipe
inside the existing chimney and fill, with suitable insulating
material, the space between the metal pipe and the
chimney.
Chimneys made of prefabricated blocks shall have the
joints fully sealed, to prevent the smoke condensate
smudge the external walls for absorption.
The insertion of the pipe connecting the boiler flue socket to
the chimney shall be plugged in at 45 °.
At the base of the chimney an inspection opening must be
present.
It is recommended to conveniently insulate this connecting
pipe in order to reduce heat losses and noise.
An insufficient draft, apart from causing a smoke leakage
from the boiler, causes a significant output reduction; on
the contrary, an excessive draft causes an abnormal output
increase, a smoke temperature raise and an excessive fuel
waste.
It is strongly recommended to install a draft
adjuster, at the base of the chimney, to avoid
problems arising from an unusual draft.
It is recommended to use only exhaust pipes suitable to
the type of fuel used.
Any contractual and non-contractual liability of the
supplier, for the damages caused by errors in installation
and use or for failure to follow instructions given by the
manufacturer is excluded.
The chimney has to be manufactured according to the
rules in force.
1. Boiler
2. Pipe connecting the boiler to the chimney
3. Ashes collection chamber
4. Chimney
5. External covering of the chimney
fig. 17
6. Prefabricated blocks
7. Insulation
8. Flue pipe
9. Chimney draft adjuster
19
Installation instructions
3.12 - FILLING THE C.H. SYSTEM
Warning!
Do not mix the CH system’s water with unsuitable antifreeze products (example: anti-freeze solutions for motor vehicles) or use
wrong concentrations of anti-corrosion solutions! This could cause damage to the
gaskets and could provoke noise during normal boiler operation.
UNICAL refuses all liability for injury to per-
sons, animals or damage to property deriving from not having respected the above mentioned recommendations.
Once all the hydraulic connections have been done, fill the
C.H. system and check for water leaks.
This operation has to be done carefully, observing the
following phases:
- open the radiator’s air vents.
- gradually open the appropriate filling cock and check that
the automatic air vents (if any) fitted onto the system are
working properly.
- as soon as the water comes out from the air vents, close
the filling cock and then bleed off the air once again through
the radiator’s air vents.
If the boiler has not been fired for a long period
the pump (if any) could be jammed. Before firing
the boiler, it is important to carry out the following
un-jamming operation:
- place a cloth underneath the pump
- remove the pump vent plug positioned in the
centre of the pump
- using a screwdriver, rotate the shaft in a
clockwise direction.
Once this operation has been concluded, screw
back the pump vent plug and check that there are
no water leaks.
fig. 18
- check all the connections for soundness.
- after having fired the boiler and the system
has reached the correct temperature, stop the
pump (if any) and repeat the air bleeding
operations.
20
Installation instructions
4
ELECTRICAL
CONNECTIONS
General warnings
The FOKOLUS boiler has not electrical devices fitted on it.
It has 2” flow and return connections, so it can work for
natural circulation, without pump.
In any case if a pump or more pumps are fitted, the
appliance’s electrical safety is guaranteed only when the
same appliance has been correctly earthed in compliance
with the regulations in force.
Ensure that the above safety electrical requirements
subsist; in case of doubt, ask for a professionally qualified
technician to check the electrical installation.
21
Installation instructions
BOILER STARTING
5
5.1 - FIRST LIGHTING
Preliminary checks
The first ignition must be carried out by a
qualified technician. Failure to do so could
cause injury to persons, animals or damage
to property. UNICAL shall not be held liable
for any injury and/or damage.
Before lighting the boiler check that:
-the C.H. system is equipped with all safety devices and
controls required in accordance to the regulations in force;
- the C.H. system has been filled with water
- any of the system’s on-off valves are open;
- the boiler thermal discharge safety valve is not blocked
and that it is connected to the sewage system;
- there are no water leaks;
Lighting and shutting down procedures
For lighting and shutting down the boiler refer to the
“USER’S INSTRUCTIONS MANUAL”.
Informations to be passed on to ther user
The user must be instructed on the use and operation of his
boiler:
- Hand over to the end user the booklet: “USER’S INSTRUCTIONS MANUAL”, as well as all the other literature concerning the appliance which are placed in the envelope contained in the packaging.
The user must retain this literature for any future reference.
- Inform the user regarding the control of the C.H. system
water level through the open expansion vessel.
- Explain and demonstrate to the user the correct function
and adjustment of the temperature, through the
thermostatic valve for the economic use of the system.
- Remind the user that in order to comply to the regulations
in force the boiler has to be inspected and serviced
regularly as per local requirements.
- If the appliance is sold or transferred to another owner or
if the present user moves home and leaves the appliance
installed, ensure that the manual always follows the
appliance so that it can be consulted by the new owner
and/or installer
22
5.2 - THE FIRE WOOD
Installation instructions
The fire wood is formed mainly by lignite and
cellulose. It also contains other substances
such as resin (silver tree - pine), tannin (oak chestnut) and of course a lot of water.
Fire woods of very good quality are the oak, the
ash, the beech, the maple and the fruit trees,
except the cherry; of medium quality the
chestnut and the birch; of sufficient quality the
lime tree, the poplar and the willow. The resinous trees are,
5.3 - THE WOOD HUMIDITY
The calorific value of different types of wood
depends on its moisture as indicated by the
table. Power and autonomy of the boiler will
decrease the moisture content increases. The
table shows the reduction factor of the power to
moisture of the wood used. The power output of
the boiler FOKOLUS is calculated with wood at
15% humidity.
As an example: a timber with 2 years of drying
the indoor humidity was 25%.
Example:
if the humidity of the wood used = 30%
effective rated= output power x 0.79
normally, medium quality fuels.
The fire wood is then a fuel extremely heterogeneous, due
to different essences (beech, oak, fruit, resinous), different
humidity, different shape and dimensions.
The operation of the boiler will be certainly affected by all
these factors. Specially by the dimensions, the humidity
and how the fire wood is loaded in the boiler.
Correction factors for the humidity of the wood
% DI
UMIDITÀ
15
20
25
30
35
40
45
50
POTERE
CALORIFICO
kcal/kg
3.490
3.250
3.010
2.780
2.540
2.300
2.060
1.820
FATTORE DI
CORREZIONE
1
0,93
0,86
0,79
0,72
0,65
0,59
0,52
5.4 - WOOD LOGS DIMENSIONS
The wood log dimensions, combined with their
humidity, contribute to determine the output of
the boiler.
Small pieces (of length, however, conforming to the notes
given below) are more easily inflammable and therefore
they have the tendency to increase the boiler output and to
reduce, therefore, its autonomy.
5.5 - CHECKS AT THE FIRST LIGHTING
GENERAL CHECKS
The first time:
- check that the system is full of water and
properly vented, the safety heat exchanger was
connected to the water supply via the thermal
discharge safety valve (fig. 6, page 14 and fig.
10 page 16),
- that the chimney has a sufficient draught,
- that the boiler pump and the recirculation
pump are not blocked (if any)
Also check that the cast iron grates are in
their places.
Besides, they fall with greater facility, in the ash tray,
reducing the risk of formation of “bridges”. The so-called
“bridge” is an empty space in the firewood store, with
formations of wood bridges not burnt.
THE BY-PASS
The by-pass is a direct passage between the combustion
chamber and the chimney. It is normally closed by a
movable disk. When opening the wood loading door it is
previously necessary to open, manually, the by-pass.
The smokes accumulated in the combustion chamber can,
then, go directly to the chimney.
The by-pass, at the end, allows the smokes to reach
directly the chimney without escaping from the upper door
during the ignition operation and loading. However, it is
necessary to open the upper loading door slowly and
gradually to obtain an effective smoke suction by the
chimney draught.
CHEKING OF THE BY-PASS
When installing and before using the boiler it is necessary
to check the bypass for leaks and for its good operation.
23
Installation instructions
5.6 - STARTING
IGNITION
Make sure that the checks listed in paragraph
5.5 have been performed.
Place, in the center of the grate, thin paper
(newspapers etc.) and a little thin and dry
wood, cross disposed; avoid large pieces in the shape of
squares
Open the rear by-pass
Light the paper and close the upper door. Wait for the fire to
start and produce the embers (5 to 10 minutes).
After that, looking through the secondary air inlet on the
upper door, the flame will be noticed .
Important: The by-pass should be used only at the start
and during subsequent loading,
by-pass should always be tightly closed
During the operation, the
1st LOADING
When the bed of embers is formed on the grate, it is
possible to proceed to the loading of the wood
Open slowly the upper door.
Spread the embers uniformly on the grate, using the poker.
Caution: After wood loading close the upper door and
remember to close the by-pass.
SUBSEQUENT LOADINGS
Before making a new loading of wood, consume, as much
as possible, the previous one.
The new loading will be done when the bed of embers, on
the grate, will be reduced to a thickness of about 5 cm.
Open slowly the upper loading door.
Use only wood logs having a length as stated in the
previous paragraph.
Place the new loading of wood as above described.
USEFUL SUGGESTIONS AND LOADING ERRORS
- Too long logs do not fall down regularly and can cause
“bridges”.
- Too short logs cause not regular air passages, with
consequent reduction of output and efficiency.
- In case the quality of the wood causes “bridges” it could
be necessary to cut the wood logs in two parts, as stated in
the paragraph FIRST LOADING.
The wood must be of the following length:
a) 33 cm (+ 1 cm - 4 cm) for the model FOKOLUS 20
b) 50 cm (+ 1 cm - 4 cm) for models FOKOLUS 30
c) 70 cm (+ 1 cm - 4 cm) for the model FOKOLUS 40
These dimensions must be strictly observed.
fig. 19
Since for a good combustion it is essential that there is an
uniform falling down of the firewood, it is necessary to
make sure that the length of the introduced wood logs, their
form and the way of loading don’t prevent the regular
descent of the fuel.
- Open the upper door always slowly, in order to avoid
blowbacks and smoke formations.
5.7 - COMBUSTION AIR ADJUSTMENT
ADJUSTMENT OF PRIMARY AND SECONDARY AIR
The boiler FOKOLUS is equipped with primary air (pos 5,
fig. 1) and secondary air adjustment (pos 4,Fig. 1). The
primary air adjustment is done automatically through the
thermostatic valve; the secondary air, however, done
through the port located on the upper loading door, must be
done by the user, tightening or loosening the adjustment
screw.
At the first start it is necessary to adjust the
primary and the secondary air and bearing in
mind that the primary air determines the boiler
output, and therefore the amount of wood that
is burned, and the secondary air completes the
combustion.
The optimal setting of the FOKOLUS operation
is obtained when boiler and chimney are in
“warm conditions”.
The wood logs must be placed longitudinally and
horizontally. No log has to be placed slanting or athwart.
We recommend not to use small wood pieces for fuel
charges, because they have an excessive inflammation
and can cause an unacceptable increase of the output and
of the smoke temperature in the chimney.
24
Once the thermostatic valve of the primary air adjustment
has been mounted according to the instructions of the
manufacturer, it is forbidden to open, manually, the primary
air adjustment door to activate the combustion after wood
loading, because it could be the cause of excessive output,
with an abnormal increase of the smoke temperature to the
chimney.
GENERAL SUGGESTIONS
Installation instructions
- Best performances are obtained after two/three days of
operation. Refractory material must be cooked.
- The flame should have a good size and fairly fill the
firebox.
- The flame should not be too red (insufficient secondary air
S).
- If the chimney is smoking too much (open all the
secondary air S).
- If it continues smoking, give maximum of secondary air.
Example No. 1
Big wet wood logs of difficult combustion:
SECONDARY AIR: Very closed (try to get the maximum size
of the flame, but not of the red color).
Example No. 2
Highly flammable wood logs
SECONDARY AIR: - Completely open.
5.8 - CHECKS TO BE CARRIED OUT AFTER
THE FIRST START
CHECKING OF THE SEALS
During the initial start-up check the tightness
of the smoke circuit and the connection to the
chimney . If there is any noticeable smoke
leaks alert the installer and / or the After Sale
Service. If there is any noticeable air suction
through the door seals, tighten the handle
with greater force.
Check for water leaks from pipe connections.
5.9 - WARNINGS
HOW TO AVOID CORROSION IN WOOD STORAGE
The use of wood with high humidity content
(above 25%) and / or charges not proportional
to the system needs (Long stops with the wood
storage full) cause considerable condensation
in the inner wall of the wood storage.
Check, once a week, the steel walls of the wood storage.
They should be covered with a thin layer of dry tar, mat color,
with bubbles that tend to break and fall down. If, on the
contrary, the tar is shiny, runny and, if removed with the
poker, it shows the liquid: it is necessary to use less wet
wood and / or reduce the amount of charged wood.
THE CORROSION OF SMOKE CIRCUIT
The smokes are reach of water steam, due to the
combustion and the use of wood very wet.
If the smokes come in contact with relatively cold surfaces
(having a temperature below about 60 - 70 °C), the water
steam condensates and in combination with other combustion products originates corrosion phenomena of the metallic parts. Inspect every day if there are signs of smoke condensation (black liquid on the floor, behind the boiler). In this
case a less humid wood shall be used; check the operation
of the recirculation pump, the smoke temperature at part load,
and increase the working temperature. To control the room
temperature it is, then, necessary to install a mixing valve.
The corrosion due to condensation of the smokes is not
covered by the guarantee, because due to the wood humidity and to the way of boiler operation.
WARNINGS DURING THE USE
After every adjustment of the air, wait 5 to 10 minutes before
proceeding for a new adjustment. Once established the
adjustment held optimal, check at the end of the day the
surfaces of the combustion chamber and the insulation of
the door that will have to be white.
Open always slowly the upper loading door.
If in despite of this prudence some blowback will occur, it
will be necessary to use thicker and a little more humid
firewood logs and to verify that the boiler does not stop
working for a long time, and check always the integrity of
the grates.
5.10 - SUMMER OPERATION
The summer operation only for the domestic
hot water production is not suggested,
unless the boiler is operated in the
meticulous respect of the following rules:
1) use very dry firewood
2) load the boiler with little firewood, effecting
small loadings, 2 or 3 per day according to
the needs.
Important
It is absolutely wrong to load completely the
boiler and, so, to get very long autonomies
(for example 24 hours). Doing so the boiler
will produce a lot of acid condensate with
corrosion of the firewood storage walls.
5.11 - BURNER ADJUSTMENT ON AN
EVENTUAL AUXILIARY BOILER
If, in spite of these interventions tar does not dry out, the
anomaly is to be reported to authorized service center.
The Condensation inside the wood storage causes
corrosion of the steel plates. Corrosion which is not
covered by the warranty, because due to an abnormal
use of the boiler (wet wood, excessive charges, etc.).
All the adjustments and maintenance service
on the burner, fitted on the auxiliary boiler, are
of exclusive competence of the authorized
personnel of the burner manufacturer.
25
Installation instructions
5.12 - FAULT REMOVAL
Symptom:
- When opening the loading door blowbacks and smoke
leaks occur.
Remedy:
- Open slowly.
- Use less dry wood logs; make sure the boiler does not
make long stops (see chap. 5.9).
- Use thicker wood logs.
- Consume the previous charge before making a new one.
Symptom:
- The boiler does not reach the temperature. The flame is
small, with air excess.
Inspected the wood storage, the formation of bridges is
observed.
Remedy:
- Check the length of the logs (see chap. 6.6).
- Check the arrangement of the logs (see chap. 6.6).
- Cut the logs in half (see chap. 6.6).
- Use the smaller-sized logs (round or squares about 5-7
cm wide).
- Mix the medium-large size logs (round or squares of 1520 cm per side) with small logs (see above).
Symptom:
- The boiler does not reach the temperature, the flame is
very small.
Remedy:
- Check the closing of the by-pass.
- Check the closing of the doors.
Not getting results, refrain from further
action and contact an authorized Unical
service center
6
To ensure the continuous, safe and efficient operation of
the boiler it is highly recommended that it is checked at
regular intervals and serviced when necessary, and that
only original spare parts are used.
Regular attention will prolong the life of the boiler.
If the boiler is not checked and serviced regularly it could
cause material and personal damages.
For this reason UNICAL recommends that a servicing
contract should be made with an authorized After Sales
Service.
The inspection and maintenance works have to be done in
the order shown on page 27.
INSPECTION AND MAINTENANCE
26
Inspection and maintenance
Maintenance on the boiler body
Danger!
Before doing any work on the boiler, ensure
that it and its components have cooled
down.
Warnings
Never discharge water from the boiler and C.H. system,
even partially, unless really necessary.
Do not clean the boiler and / or its parts with flammable
substances (eg petrol, alcohol, etc.). Do not leave
containers of flammable substances in the room where the
boiler is installed.
It is necessary at the end of each heating season, to
inspect the boiler in order to maintain the system in perfect
working condition.
A proper care is always a source of savings and safety.
USEFUL SUGGESTIONS
For cleaning, use brushes and vacuum cleaners, if wiping
clothes are used, make sure that they are all retrieved.
Keep nuts and bolts protected with grease.
CLEANING AND ORDINARY MAINTENANCE OF A WOOD FIRED BOILER
Every day
- Remove the ashes from the bottom tray
- Remove with the poker supplied with the boiler, the bed of
embers in order to let fall down, through the slots of the
grate, the ashes accumulated in the wood storage.
Every week
- Carefully remove, from every point, any residue of
combustion accumulated in the wood storage.
- Clean, with the brush supplied, the upper smoke dry
passages of the furnace
- Remove the ashes accumulated in the smoke chamber
through the rear cleaning door
- Make sure that the slots of the grate are not clogged, and
if they are, make free the slots with the poker’s help
Every month
Check the operation of the by-pass and its tightness as
described in chapter 5.5.
EXTRAORDINARY MAINTENANCE OF A WOOD FIRED
BOILER
After each heating season, make a general cleaning of
the boiler by taking care to remove all the ashes from
wood storage. During the summer , close the doors of
the boiler .
Components to be checked during the annual extraordinary maintenance
Component Solution
- Cast iron grates
- Tightness of the by-pass disc
- Integrity of the upper refractory insulation of the
furnace bottom
- Position of the refractory bent tiles
- Integrity of the refractory bent tiles
- Integrity of upper and lower door Insulation Possible reparation or replacement of the doors
- Integrity of door sealing gasket
- Smoke circuit (rear side)
Possible replacement
Possible replacement
Possible reparation with refractory cement
Possible repositioning
Possible replacement
Possible replacement of the seals
Possible cleaning
27
AG S.P.A.
46033 casteldario - mantova - italia - tel. +39 0376 57001 (r.a.) - fax +39 0376 660556
The Unical declines every responsibility for the possible inaccuracies if owed to errors of transcript or press. Also
reserves the right to bring those changes that it will hold necessary to it own products or profits, without jeopardizing its
essential characteristics.
www.unical.ag - info@unical-ag.com
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