FOKOLUS Ed. 12/2010 INSTALLATION AND SERVICING INSTRUCTIONS

Transcription

1 FOKOLUS Ed. 12/2010 INSTALLATION AND SERVICING INSTRUCTIONS

2 General informations CONTENTS 1 GENERAL INFORMATION Symbols used in this manual Correct use of the appliance Water treatment Information to be handed over to the user Safety warnings Data badge General warnings TECHNICAL FEATURES AND DIMENSIONS Technical features Dimensions and hydraulic connection Main components General features INSTRUCTIONS FOR THE INSTALLER General warnings Standard codes for installation Packaging Transport Assembly Connection of the boiler to the C.H. system Connection of the safety heat exchanger to the sewage Recirculation pump Assembly instructions Electrical and hydraulic connection diagrams Connection to the chimney Filling the system ELECTRICAL CONNECTIONS BOILER STARTING First lighting The wood The humidity of the wood Wood logs dimensions Checks at first lighting Starting Combustion air adjustment Checks to be carried out after the first starting Warnings Summer operation Burner adjustment on the eventual auxiliary boiler Problem solving INSPECTION AND MAINTENANCE

3 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 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 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 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 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

4 General informations 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; 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 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) 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

5 Technical features and dimensions 2 TECHNICAL FEATURES AND DIMENSIONS 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

6 Technical featurtes and dimensions 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 FOKOLUS 20 FOKOLUS 30 FOKOLUS 40 NOMINAL OUTPUT (kw) NOMINAL INPUT (kw) 30, DIMENSIONS A B C D E F (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 UNI ISO 7/ * 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 Class 1 Efficiency: according to EN Class G H I L M N O CONNECTIONS T1 - T2 Rp 2 Rp 2 T3 T4 T5 Rp ¾ 200 R ½ Rp ¾ 200 R ½ Rp ¾ 200 R ½ T6 - T7 Rp ½ Rp ½ Rp ½ BOILER WATER CONTENT (l) WATER SIDE PRESSURE DROP** (m c.a.) 0,3 0,3 0,4 CHIMNEY DRAUGHT*** (mm c.a.) 1,5 1,6 2 MAX. WORKING PRESSURE (bar) WOOD STORAGE VOLUME (l) WOOD LOADING OPENING (mm) 360x x x380 WEIGHT (kg) LENGTH OF WOOD LOGS (cm) Rp

7 Technical features and dimensions 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 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. 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. fig. 2 7

8 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 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. 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. fig. 3 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. 8

9 3 INSTRUCTIONS FOR THE INSTALLER Installation instructions Before installing the boiler the following points have to be carried out by a competent engineer: 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 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. 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 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

10 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. In the case of storage of the boiler for long periods, it is recommended to protect every thing in an appropriate manner. 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: fig. 4 - Instruction manual for the user - This Instruction Manual for installation and Maintenance - Adhesive Data Label 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

11 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 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. 11

12 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 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

13 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). A) Install the boiler body insulation (pos. 1) by performing appropriate cuts at the upper connections fig. 7 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. 8 13

14 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

15 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. Installation instructions 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

16 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 fig

17 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

18 fig. 16 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 18

19 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. The size of the chimney must be able to provide the necessary draft required for the proper operation of the 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 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 19

20 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 persons, animals or damage to property deriving from not having respected the above mentioned recommendations. 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. 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. fig 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

21 4 ELECTRICAL CONNECTIONS Installation instructions 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

22 FIRST LIGHTING Preliminary checks BOILER STARTING 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 INSTRUC- TIONS 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

23 5.2 - THE FIRE WOOD 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, 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 POTERE CALORIFICO kcal/kg FATTORE DI CORREZIONE 1 0,93 0,86 0,79 0,72 0,65 0,59 0, 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 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

24 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, 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. 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. 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. 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. - Open the upper door always slowly, in order to avoid blowbacks and smoke formations 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. 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. 24

25 GENERAL SUGGESTIONS - 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 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 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 (having a temperature below about 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 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 BURNER ADJUSTMENT ON AN EVENTUAL AUXILIARY BOILER 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

26 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. 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 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 cm per side) with small logs (see above). 6 INSPECTION AND MAINTENANCE 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 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 MAINTENAN- CE 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 Possible replacement - Tightness of the by-pass disc Possible replacement - Integrity of the upper refractory insulation of the Possible reparation with refractory cement furnace bottom - Position of the refractory bent tiles Possible repositioning - Integrity of the refractory bent tiles Possible replacement - Integrity of upper and lower door Insulation Possible reparation or replacement of the doors - Integrity of door sealing gasket Possible replacement of the seals - Smoke circuit (rear side) Possible cleaning 27

28 AG S.P.A casteldario - mantova - italia - tel (r.a.) - fax info@unical-ag.com 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.