Unical FOKOLUS Installation instructions

USER’S
INSTRUCTIONS
00333935 - Ed. 12/2010
FOKOLUS

2
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

3
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.

4
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

5
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.

6
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.

7
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.

8
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
1
2
3
4
4
4
5
5
6
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
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
6X 95900057
Sealing gasket for cleaning door ø 95x3
6X 95900058
X
FOKOLUS 30
m. 1,6
X
m. 1,7
FOKOLUS 40
m. 1,6
X
m. 1,7
X
XX
X
X
X
X
X
X
XXX
XXX
XXX
X
X
X
7
7
7
8
8
8
9
10
11
12
12
12
95900622
95900852
95901020
31418
95900362
31045
MAN0020
95900862
PUC0420
32762
95900523
95900863
Kit of curved tiles
Kit of curved tiles
Kit of curved tiles
Front wood protection
Front wood protection
Kit of cast iron grates
Kit of smoke turbulators
Kit of smoke turbulators
Kit of smoke turbulators
Kit of cast iron grates
Triangular brush
Kit of basement tiles
Kit of basement tiles
Kit of basement tiles
Ash tray
Ash tray
Ash tray
Handle