Unical FOKOLUS Installation instructions

USER’S

INSTRUCTIONS

00333935 - Ed. 12/2010

FOKOLUS

Index

1 - SYMBOLS USED IN THIS MANUAL

When reading this manual particular care has to be given to the parts marked with the followings symbols:

NOTE!

Suggestions for the user

WARNING!

Indicates a potentially dangerous si-

tuation for the product and the envi-

ronment

DANGER!

Indicates serious dan-

ger for your personal

safety and for your life

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.

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.

CONTENTS

1 Symbols used in this manual .................................................................................................................................................... 2

2 A correct use of the appliance .................................................................................................................................................. 2

3 Water treatment ......................................................................................................................................................................... 2

4 Informations to be passed on to the user by the installer ........................................................................................................ 3

5 Safety warnings ......................................................................................................................................................................... 3

6 Istructions for the use ................................................................................................................................................................ 4

6.1 Checks to be performed before putting the boiler in operation ......................................................................................... 4

6.2 Starting ............................................................................................................................................................................... 4

6.3 Combustion air adjustment ................................................................................................................................................ 5

6.4 Checks to be carried out after the first start ...................................................................................................................... 5

6.5 Warnings ............................................................................................................................................................................. 6

6.6 Summer operation .............................................................................................................................................................. 6

6.7 Maintenance on the boiler body ......................................................................................................................................... 7

6.8 Fault removal ...................................................................................................................................................................... 8

-.- Easy replacement spare parts ........................................................................................................................................... 9

general informations

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.

4 - INFORMATION TO BE HANDED OVER TO THE USER

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 ap-

pliance could cause injury to persons, animals or damage to property. The manufacturer shall not be held

liable forany 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.

Instructions for the User

Pressure of the C.H. system

In case the C.H. system is of open expansion vessel type,

there is no need of reinstatment of the pressure, because

this is automatically done via the expansion vessel per-

manently connected to the C.H. system.

In case the C.H. system is of closed expansion vessel

type,(see the local rules to ascertain this possibility),

the system pressure will be reinstated, via the filling val-

ve, at a value, with cold system, of 1.0 /1.2 bar.

In case repeated reinstatment interventions are re-

quired, check the C.H. system for water leaks.

6 - INSTRUCTIONS FOR THE USE

6.1 - CHECKS TO BE PERFORMED BEFORE

PUTTING THE BOILER IN OPERATION

Before putting the boiler in operation it is suggested to

perform the following checks:

- Make sure that, after a service work, the flow and re-

turn gate valves are open.

- Ascertain that the discharge of the safety valve, in case

of closed expansion vessel type, is connected to the

sewage.

- Ascertain the good operation of the smoke by-pass,

by placing an electrical torch in the smoke chamber,

through the cleaning door and looking from the wood

loading door: no light shoul de seen.

WARNING !

The C.H. system can be conveniently protected from fre-

ezing by adding an antifreeze product, suitable for multi-

metal C.H. system.

Do not use antifreeze products suitable for engines,

because they can damage the sealing gaskets of the

C.H. system.

6.2 - STARTING

Make sure that all the checks listed on paragraph 6.1 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, During the operation,

the by-pass should always be tightly closed

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.

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.

to cut

Instructions for the User

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.

The wood logs must be placed longitudinally and

horizontally. No log has to be placed slanting or athwart.

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.

- Open the upper door always slowly, in order to avoid

blowbacks and smoke formations.

6.3 - 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”.

GENERAL SUGGESTIONS

- Best performances are obtained after two/three days of ope-

ration. 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.

6.4 - 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.

Instructions for the User

6.5 - 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.

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.).

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 (ha-

ving a temperature below about 60 - 70 °C), the water steam

condensates and in combination with other combustion pro-

ducts 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 recircu-

lation 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 gua-

rantee, 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.

6.6 - 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.

Instructions for the User

6.7 - 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.

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.

The grates are subject to consumption; it is, then,

advisable their annual inspection, in order to avoid

an anomalous operation of the boiler.

ORDINARY CLEANING AND MAINTENANCE OF

A POSSIBLE OIL OR GAS FIRED AUXILIARY

BOILER.

Before the beginning of each heating season

The boiler body has to be checked and cleaned by autho-

rized personnel.

Inpesction of the burner

Possible inspection on oil or gas fired burner equipping

the auxiliary boiler has to be performed by authorized per-

sonnel of the burner manufacturer.

Instructions for the User

6.8 - 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 15-20

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

Easy replacement spare parts

BOILER MODEL

FOKOLUS 20

POS. CODE DESCRIPTION

20611 Glass fibre gasket 16x16 m. 1,4

95900283 Door handle X

20611 Glass fibre gasket 16x16 m. 1,6

95900507 X

95900352

Kit of cast iron grates

95900508

30996 X

95900363

ATTENTION: For a correct and fast carrying out of the spare part order for your FOKOLUS boiler, you are kindly requested to always

mention the following data: Code No., Description, desired quantity and Boiler Model.

For the components which are not in this list, please contact our Authorized Service Center.

COMPONENT

95900056

95900057

Sealing gasket for cleaning door ø 95x3

95900058

FOKOLUS 30

m. 1,6

m. 1,7

FOKOLUS 40

m. 1,6

m. 1,7

XXX

95900622

95900852

95901020

31418

95900362

31045

MAN0020

95900862

PUC0420

32762

95900523

95900863

Kit of curved tiles

Front wood protection

Kit of cast iron grates

Kit of smoke turbulators

Kit of cast iron grates

Triangular brush

Kit of basement tiles

Ash tray

Handle

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