Unical FOKOLUS Installation guide

Brand: Unical

Model: FOKOLUS

Type: Installation guide

INSTALLATION

AND SERVICING

INSTRUCTIONS

00333936 - Ed. 12/2010

FOKOLUS

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

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:

NOTE!

Suggestions for the user

WARNING!

Indicates a potentially dangerous si-

tuation for the product and the envi-

ronment

DANGER!

Indicates serious danger

for your personal safety

and for your life

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 circula-

tion 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.

GENERAL INFORMATIONS

Warning: this manual contains instructions to be used exclusively by the installer and/or a competent person in accor-

dance 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.

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 applian-

ce 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; UNI-

CAL 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.

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.

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

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

TECHNICAL FEATURES AND DIMENSIONS

• 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

Technical featurtes and dimensions

2.2 - DIMENSIONS AND HYDRAULIC CONNECTIONS

fig. 1

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

* 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

MODELS

FOKOLUS 20 FOKOLUS 30 FOKOLUS 40

(kW) 20 33 42

NOMINAL OUTPUT

DIMENSIONS

510

776

590

946

590

1146

1260 1260

1143

106

1143

106

416

1260

1143

106

786586

(mm)

CONNECTIONS T1 - T2

UNI ISO 7/1

(Øe mm)

UNI ISO 7/1

Rp 2

200

Rp ¾

R ½

Rp 2

200

Rp ¾

R ½

Rp 2

200

Rp ¾

R ½

BOILER WATER CONTENT

WATER SIDE PRESSURE DROP**

CHIMNEY DRAUGHT***

MAX. WORKING PRESSURE

WOOD STORAGE VOLUME

WOOD LOADING OPENING

WEIGHT

LENGTH OF WOOD LOGS

(m c.a.)

(l)

0,3

0,4

21,61,5

(mm c.a.)

(bar)

(l)

(mm)

(kg)

360x380

250

125

440x380

340

165

440x380

402

(cm)

33 50 70

UNI ISO 7/1

(kW)

30,8 50 61

NOMINAL INPUT

87 8787

(mm)

167 167167

(mm)

62 6262

(mm)

168 168168

(mm)

900 900900

(mm)

488 858658

(mm)

490 570570

(mm)

T6 - T7

Rp ½ Rp ½ Rp ½UNI ISO 7/1

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

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.

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.

Technical featurtes and dimensions

fig. 3

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.

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 heavier residue will settle at

the bottom of the wood storage and will be removed from

the lower cleaning door.

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.

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.

Installation instructions

INSTRUCTIONS

FOR THE INSTALLER

3.1 - GENERAL WARNINGS

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 tem-

perature inferior to boiling point at an atmo-

spheric pressure

WARNING!

These appliances are exclusively designed

to be installed inside adequate sites.

Therefore these appliances must not be in-

stalled and operated outdoors. An outdoor

installation could cause malfunctioning and

could be dangerous. For external installa-

tions, it is recommended to use appliances

which are specifically designed and predi-

sposed for this purpose.

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.

NOTE: The

boiler must be connected to a heating

system compatible to its performance and its

power.

The appliance must be installed by a qualified

and authorised engineer, under his own re-

sponsibility, guarantees the compliance of the

standards according to the latest regulations.

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.

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:

- Instruction manual for the user

- This Instruction Manual for installation and Maintenan-

- Adhesive Data Label

fig. 4

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.

In the case of storage of the boiler for long

periods, it is recommended to protect every

thing in an appropriate manner.

Installation instructions

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.

POSITION IN THE BOILER HOUSE

NOTE: The minimum distances shown below are only

binding for thermal units with capacity exceeding 35 kW

fig. 5

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 radiato-

rs, 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 ne-

cessary 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, da-

mages to the pipes, to the boiler and to the

radiators can be discovered, due to stray

currents.

3.6 - CONNECTION OF THE BOILER TO THE C.H. SYSTEM

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.

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.

fig. 6

Installation instructions

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).

fig. 7

fig. 8

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.

Installation instructions

fig. 9

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. 10

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.

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.

Installation instructions

3.10 - HYDRAULIC AND ELECTRICAL CONNECTION DIAGRAMS

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

Ipr = C.H. pump switch

fig. 11

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

fig. 12

Installation instructions

fig. 14

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

fig. 13

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

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

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

Installation instructions

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

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.

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

Installation instructions

3.11 - CONNECTION TO THE CHIMNEY

For the connection of the boiler to the chimney the local and

national regulations must be complied with.

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.

1. Boiler

2. Pipe connecting the boiler to the chimney

3. Ashes collection chamber

4. Chimney

5. External covering of the chimney

6. Prefabricated blocks

7. Insulation

8. Flue pipe

9. Chimney draft adjuster

boiler

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.

fig. 17

The size of the chimney must be able to provide the

necessary draft required for the proper operation of the

Installation instructions

3.12 - FILLING THE C.H. SYSTEM

Warning!

Do not mix the CH system’s water with unsu-

itable antifreeze products (example: anti-fre-

eze solutions for motor vehicles) or use

wrong concentrations of anti-corrosion so-

lutions! This could cause damage to the

gaskets and could provoke noise during nor-

mal boiler operation.

UNICAL refuses all liability for injury to per-

sons, animals or damage to property deri-

ving from not having respected the above mentioned re-

commendations.

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.

- 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.

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

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Unical FOKOLUS Installation guide

Brand: Unical

Model: FOKOLUS

Type: Installation guide

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Unical FOKOLUS Installation guide

Unical FOKOLUS Installation guide

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