Jolly Mec AERJOLLY 70 Quick guide

CAMINETTI S.P.A.
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AERJOLLY
WOOD-BURNING FIREPLACE
ASSEMBLY AND MAINTENANCE INSTRUCTIONS
keep in a safe place
PATENTED MODEL

This manual and the instructions it contains should be
thoroughly read and followed to ensure fast
installation and correct use.
Before starting to assembly your fireplace, please
read the manual thoroughly and follow the instructions
carefully, otherwise the product warranty may be
invalidated and safety may be compromised.
The assembly sheet is an important integral part of
the product and must be handed to the user.
The assembly sheet must be kept in a safe place and
consulted whenever necessary as the directions it
contains are important for safety during the installation,
use and maintenance of your fireplace.
Incorrect installation can lead to injury to people or
pets and damage to property, for which the manufacture r
cannot be held liable.
This piece of equipment must be used solely for the
purpose for which it was designed and built. Any other
use will be considered improper and therefore
dangerous.
The manufacturer cannot be held liable under
contract or otherwise for any damage caused by
errors during installation or use of the fireplace or, in
any case, by non-observance of the instructions
provided by the manufacturer himself.

Pag. 1
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Technical data .................................................................................................................................................................... Pag. 2
Flue ............................................................................................................................................................................................ Pag. 3
Components ........................................................................................................................................................................ Pag. 4
Optional accessories ...................................................................................................................................................... Pag. 5
Positioning of the air intake and electricity ..................................................................................................... Pag. 6
Positions to be followed during installation ...................................................................................................... Pag. 7
Assembly procedure ..................................................................................................................................................... Pag. 8-9
Glasses assembly procedure ................................................................................................................................... Pag. 10
Cladding .................................................................................................................................................................................. Pag. 11
Electrical connections .................................................................................................................................................... Pag. 12
Example of air ducting ................................................................................................................................................... Pag. 13
Boiler hood ......................................................................................................................................................................... Pag. 14
Assembly and maintenance instructions ........................................................................................................... Pag. 15
CONTENTS

ASSEMBLY INSTRUCTIONS
Pag. 2
AERJOLLY - A HEAT EXCHANGER SYSTEM FIREPLACE, WOOD WORKING
This fireplace is a single unit and has a shaped double-wall
steel heat exchanger, treated inside: the air, thanks to a
heater fan, passes through this, and, after been heated and
humidified, is sent to the rooms of the house.
The ventilation system can also be used in Summer to cool
the rooms.
The Aerjolly fireplace is insulated with a rock wool blanket
(5 cm) covered by zinc-plated sheet metal to minimise the
risk of heat loss and to make installation easier, without the
need for masonry work.
It is supplied with a fan (air flow capacity of 420 or 620 m
3
/h),
with an electronic control panel, three speed, that
automatically controls the amount of air supplied to suit the
temperature and a room thermostat.
It also has a manually fed humidifier to avoid health
problems, such as a dry throat, headaches, various
allergies, etc. fragrant, balsamic essences can be added
(mixed with the water).
The fireplace can become a gas-working unit also in a
second time, being arranged for the insertion of a burner.
D
C
38
52
13
42
145
A
B
DATI TECNICI
CHARACTERISTICS MOD. 70 MOD. 80 MOD. 100
Heat output 23,000 Kcal/h 25,000 Kcal/h 28,000 Kcal/h
26.7 Kw 29.0 Kw 32.5 Kw
Pre-testing heat output 18,308 Kcal/h
21.289 Kw
Whole output 74% 76%
Fumes output 68%
Heatable surfaces 100 m2130 m2150 m2
(for buildings compliant with Italian Law 10/91)
Air outlet Ø 100 mm Ø 100 mm Ø 100 mm
Fan air flow capacity 420 m3/h 420 m3/h 620 m3/h
or, on require 620 m3/h or, on require 620 m3/h
Electrical absorbing 200/170 W 200/170 W 170 W
Fumes outlet Ø 200 mm Ø 200 mm Ø 250 mm
Burner weight 117 Kg 127 Kg 173 Kg
Total weight 155 Kg 167 Kg 213 Kg
MOD. A B C Ø D
70 78 54 30 20
80 88 54 60 20
100 108 54 78 25

Pag. 3
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FLUE
The flue is a crucial element for the fireplace to work
properly. The cross-section of the flue must be as indicated
in the technical specifications for the fireplace. Every
fireplace must have its own flue, without any other
entrances (other fireplaces, boilers, stoves, etc.). The
dimensions of the flue are strictly proportional to its height
(measured from the fireplace to the base of the chimney
pot). To guarantee efficient updraught, the outlet of the
chimney pot must be twice the cross-section of the flue and
must meet the following requirements:
-it must prevent the escape of combustion products, be
impermeable and suitably insulated and lined
-it must be made from materials capable of withstanding
normal mechanical stress, heat, the action of the products
of combustion and any condensation
-it must be mainly vertical with an angle of deviation no
greater then 45°
-it must be kept at a suitable distance from any
combustible or inflammable material by means of an air
gap or suitable insulation
-it must have a circular inside cross-section, where at all
possible: square or rectangular cross-sections must have
rounded corners
-it must have a constant, free and independent inside
cross-section
-it must have rectangular sections with a max ratio of 1.5
between sides
We recommend installing a chimney pot with a shaped
cowl. If the flue is installed on the outside of the building,
this must be lined to prevent the fumes from cooling and the
consequent formation of condensation; the same goes for
the exposed section from the roof to the chimney pot.
We recommend using unlined stainless steel tubes inside
the hood for the connection between the fireplace and the
flue, whenever there are bends or deviations and to make
installation faster, easier and safer.
Elements made from non-combustible materials resistant to
the products of combustion and any condensation should
be used to fix the conduits.
The flue must not pass through areas where the installation
of combustion appliances is prohibited.
Flue sections must be installed to guarantee perfect
tightness during normal working conditions in depression.
Horizontal sections should be avoided wherever possible.
In the case of fireplaces with flue outlets in the wall or
ceiling not perfectly in line with the outlet from the fireplace,
open bends at not more than 45° must be used for any
changes in direction.
In this case the flue must be fitted with a chamber for
collecting solid materials or eventual condensations: it must
be used for flue cleaning, thanks to an inspection air-tight
window easy to be open.
The use of downwards elements is absolutely forbidden.
The flue must allow for recovery of any soot or be easy to
sweep. It is absolutely forbidden to pass other conduits (for
air or plant) inside the flue, even if oversized.
40/50 cm
45°
45°
45°
No other fireplaces, boilers or air extractors may be installed in the same room.
Fig.1 Fig.2 Fig.3 Fig.4 Fig.5
Mod. 70 Mod. 80 Mod. 100
Ø 200 Ø 200 Ø 250
-min height of flue - min height of flue
with glasses 1.5 m without glasses 1.5 m
FLUE DIMENSIONS

13
8
17
15
610
11
9
18
19
20
21
12
14
16
9
10
1
5
3
7
2
ASSEMBLY INSTRUCTIONS
Pag. 4
COMPONENTS
1-Fireplace
2-Tray holder
3-Right refractory panel
4-Left refractory panel
5-Rear refractory panel
6-Cast iron grille
7-Front sheet
8-Deflector
9-Fume register
10 -Fume register push rod
11 -Friction with screws and nogs
12 -Humidifier topping up
13 -Cap ø 1/2
14 -Steel attack
15 -Legs with 16 screws
16 -Ash tray
17 -Ventilator
18 -Control unit
19 -Pipes for air 3 MTL, ø 100
20 -Tube clamps n. 2
21 -Outlets with adjustable closure
for air, n. 2

Pag. 5
OPTIONAL ACCESSORIES
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1-Steel flue
(various measures)
2-Reduction unit for flue
(various measures)
3-Hood ventilation grille 4x10
4-External air intake grille 20x20
5-Alu outlets with adjustable
closure for air 18x10
6-Flexible alu pipe for air
(various measures)
7-“T” fitting ø 80 - 100 - 120
8-“Y” fitting ø 80 - 100 - 120
9-Reduction unit for alu flexible
pipe ø 100/80 - ø 120/100
10 -Tube clamps
11 -Glass-wool blanket
for air pipes
12 -Rock-wool blanket for flue
13 -Box with automatic closure
for external air intake
14 -Box for external air intake
holder with fitting ø 150
15 -Fitting for ventilator ø 150
16 -Door-frame and latch
17 -Glass door-frame
18 -Boiler hood with hydraulic kit
and electrical coil
19 -Fitting for boiler hood
20 -Woodburner grate
21 -Stainless steel grille with handle
(for cooking at close fireplace)
22 -Fitting and universal reduction
unit for stainless steel flue
12
3
5
7
13
11
14
15
16
17
19
20 21 22
18
12
8 9
610
4

ASSEMBLY INSTRUCTIONS
Pag. 6
POSITIONING OF THE AIR INTAKE AND ELECTRICITY
To make installation of the fireplace easier, fit all the external
air vents, the two distribution boxes with wiring beforehand
and the flexible sheath for electrical cables in the positions
shown in the diagram.
The positions shown in the diagrams are valid for the three
models (70 - 80 - 100) both when wall or corner positioned.
Leave two stretches of flexible sheath sticking out from the
wall (by about 50/70 cm) to allow for the electrical connections.
We recommend respecting the indicated measures.
If the fireplace is to have a side seat, the electrical plant
must be installed on the opposite side.
All air intakes as well as electrical connections may be
moved, provided the characteristics remain unchanged.
A-Current distribution box, connection
with B box and connection with ventilator
B-distribution box for control unit connection
C-Free air intake for ventilator and hood
ventilation ø 200 (see optional pag. 5)
D-Omnipolar circuit breaker
WALL POSITIONING
CORNER POSITIONING
fireplace centre line
fireplace centre line
line 220V
line 220V

MOD. 70
Pag. 7
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POSITIONS TO BE FOLLOWED DURING INSTALLATION
60
78
60
88
60
108
78
79
21
88
91
28
108
102
28
WALL POSITIONING
MOD. 80MOD. 100
CORNER POSITIONING

ASSEMBLY INSTRUCTIONS
Pag. 8
ASSEMBLY PROCEDURE
The fireplace is dispatched on pallets (see drawing).
Assembling and moving are easier if the fireplace is
emptied, in order to make its weight lighter.
1-Place the boiler on the ground or lift using a crane
and fix the legs using the screws provided
2-Place the fireplace in its final position (pag. 7)
3-Connect the flue (see pag. 3)
to the universal fitting
4-Connect the power cable between the fan
and the control panel (see pag. 12)
5-Apply a line of silicone to the fan, place it in its proper
seat and then secure using the screws provided
6-Assemble the tray holder bottom
7-Right refractory panel
8-Left refractory panel
9-Rear refractory panel
10 -Front sheet
11 -Cast iron grille
12 -Ash tray
13 -The deflector must be hanged with a front
inclination for a max. rendering
14 -Connect the stainless steel flexible tube to one of the
two fittings on the humidifier tank. Close the one not
used with the plug provided. The flexible tube with the
top-up fitting must run parallel with the boiler fitting.
The tank must be fixed on the inside or outside of the
hood. Extend the tube as required
15 -Register friction
16 -Fit the fume register so that the name JOLLY MEC
is horizontal when the register is closed. You must
be able to extract the register easily in order to clean
the flue by extracting the rod
17 -Fume register push rod
18 -Tubi flessibili per la distribuzione dell’aria. Bloccare i
tubi con una fascetta stringitubo, coibentarli per tutto
il percorso con lana di vetro anche all’interno della
cappa, evitare il contatto con legno (Se prevista la
canalizzazione dell’aria, vedi esempio pag. 13)
19 -Before creating the hood, make sure the two tubes
leave the boiler, securing them with mortar or silicone:
open the fins that block the grill frame as far as they
can go and then fix the grill frame with silicone
between this and the wall (make sure air cannot
pass, to avoid stains on the wall, as often happens
with radiators)
20 -Fit the adjustable air vents. Apply the grill and fix
with silicone
21 -Wire up the control panel (see page 12)
148
90
60
9
8
10
6
12
13
11
5
1
3
14
18
14
Water
level
TRADUZIONE

Pag. 9
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Fold the fins down at 45°, insert the fitting in the flue up to
the point where it is possible to fill with calcined gypsum or
rapid cement, forming a well polished funnel (see example).
Otherwise make a hole in the flue (see drawing).
16
15
17
20
19
OFF
MIN
MED
MAX
ESTATE
INVERNO
20
EXAMPLE OF FLUE WITH UNIVERSAL FITTING Flue
Hole for walling
the fitting
Steel pipe
Mix with calcined
gypsum and cement
or rapid cement
Fitting and universal
reduction unit
Seal the joint with
silicone to prevent
air from escaping
at these points

ASSEMBLY INSTRUCTIONS
Pag. 10
GLASSES ASSEMBLY PROCEDURE
The fireguards with doors and latch doors must be assem-
bled before cladding the fireplace (i.e. before installing the
sides).
Mount the fume register so that the name JOLLY MEC is
horizontal when the register is closed. You must be able to
extract the register easily in order to clean the flue.
FIREGUARD WITH GLASS DOORS (OPTIONAL)
The fireguard with glass doors is fitted by simply using the
self-threading screws provided.
Drill holes in line with those in the fireguard, apply a layer of
silicone along the base of the fireguard and to the side that
will sit against the fireplace.
If the doors don't close properly (i.e. not aligned or one
sticking out), loosen the screw responsible for the misalignment
and compensate with silicone.
FIREGUARD WITH DOORS AND LATCH DOORS
(OPTIONAL)
Apply a layer of silicone along the base of the fireguard and
to the side that will sit against the boiler.
Rest the fireguard against the boiler, making sure it's
perfectly vertical on both sides. Apply a layer of silicone to
the fireguard (the part touching the boiler).
Drill holes and fix the fireguard using the self-threading
screws provided.
Make sure that both sides are perfectly vertical (ignore the
fact that the fireplace might be uneven) otherwise loosen
the screw(s) concerned or drill the holes again.
Hermetically seal the top with silicone inside (between the
fireplace and the fireguard).
DETAIL OF DOOR REMOVAL
1- Screw to extract to remove door
2- Washer
3- Rod
1
2
3

Pag. 11
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CLADDING
Start assembling the cladding and the relative hood: put the
control unit in a suitable position.
A window must be fitted to allow for the feeding of the
humidifier. It is necessary creating an air grille in the hood
(min. 10x30 cm) without any filters, nets or other closures:
IMPORTANT
Should the installation of the fireplace be done in a basement, fit
the air intakes 20x20 (or diam.20) outside, by using flexible pipes
and creating an air intake, under the fireplace, connecting the
internal room with outside to allow the ventilator to intake air from
outside (solution A).
Otherwise, make a hole in the hood, communicating with
outside, diam. 150 (solution B), leaving the air passing through
the base of the cladding (min. meas. 10x30).
the grill must be connected to the air intake without any pipe
connection (see example).
A gap must be left between the fireplace and the cladding
to allow for the ventilator to get the air.
A
B
4
linea 220V
Hood ventilation grille10x40

ASSEMBLY INSTRUCTIONS
Pag. 12
ELECTRICAL CONNECTIONS
CONTROL UNIT
ELECTRICAL DEVICE - DETAILS
Connect the 220 - 230 V line to terminals 1 - 2 on the con-
trol panel and the earth cable to screw on the control panel
casing.
Connect the fireplace thermostat cable to terminals 5 - 6 on
the control panel.
Connect the fan to terminals 7 - 8 and to the earth screw on
the control panel casing.
Make sure you observe the relevant safety standards when
wiring up the various components.
If you need to replace the earth cable (code “Cable/GND”),
please obtain the new one from your local dealer or direct
from the manufacturer
Take great care when making all electrical connections
through its devices. Always insert properly.
The luminous led on the control panel is always on when the
fan is working. You may also find that the luminous led is on
when the control panel is switched to OFF, as this led is
directly linked to the operation of the fan, which remains on
as long as the contact thermostat provides the OK signal.
1
VENTILATORE
CENTRALINA
234 5678
TERMOSTATO CAMINO
CUSTODIA CENTRALINA
linea 220 - 230 V
terra
2
1
3
4
OFF
MIN
MED
MAX
ESTATE
INVERNO
Control unit
Control unit case
Fireplace thermostat Ventilator
Line 220/230V
earth
1 -Fireplace thermostat
2 -Insulation braid
3 -Connecting ceramic device
4 -Protection sump

Pag. 13
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EXAMPLE OF AIR DUCTING AND BOILER HOOD FOR HOT WATER PRODUCTION
The air ducts must be run to the rooms you want to heat.
Each room heated in this way must guarantee the return of air
to the room with the fireplace by means of gaps under the door
(1 cm min) or special vents.
The air is distributed by means of circular-section, flexible tubes
made from aluminium with sheet metal fittings and deviators.
These tubes must be fixed to the fittings by means of tube
clamps.
These tubes must be insulated in order to guarantee top per-
formance of the fireplace. These should thus be fully lined with
glass-wool blankets (min 3 cm thick).
Never use plastic tubes to distribute the hot air, as the high
temperature of the air could melt these.
Where it's impossible to run the tubes in the wall, you can
create a false ceiling, false beams or boxes.
Important: Always seal the joint between the outlets and the wall
(with silicone, see pag. 9) to prevent air from escaping at these
points and so darkening the surrounding surfaces due to the
heat.
For better efficiency, fit an adjustable air vents (ø 120) in the
base of fireplace to allow the ventilator to intake 50% air from the
room.

ASSEMBLY INSTRUCTIONS
Pag. 14
BOILER HOOD
The boiler hood is a 2 mm stainless steel back-boiler,
pre-tested at 4,5 ate pressure, available in two versions: 60
or 90 litres.
It produces hot water at no extra charge, as it exploits the
heat of the fumes (or using electricity).
The hood contains 60-90 litres of water, which heats up
quickly at 60 - 70° (it depends on the type of fireplace) and
easily meets a normal family's requirements.
In 40 - 60 minutes at normal fire burning, the water
temperature can reach 60 - 90°C.
The size of the back-boiler hood makes it suitable for all
fireplace models:
- Aerjolly
- Aerjolly combinati
- Universaljolly aria forzata e tradizionali
- Superjolly
The boiler hood can produce hot water in summer, working
when the fireplace is not being used thanks to an electrical
heating element: consumption levels are the same as the
ones of a normal boiler.
BOILER HOOD ASSEMBLING INSTRUCTIONS
Place the boiler hood on the fireplace flue and fix to the top
of the flue using a stainless steel tube.
Insulate the boiler hood with a layer of fibreglass.
Plumb as shown in the figure.
A door must be fitted on the left of the hood to allow for
inspection of the valves and electrical coil.
The water temperature gauge must be built into the hood
and be easily visible.
An omnipolar switch must be used for the electrical coil.
HINTS AND UPKEEP
The efficiency of the boiler hood depends on the type of
fireplace, the quality of the firewood and the aperture of the
fume register.The risk of hood overtemperature is controlled
by the vent valve that ensures the temperature of the water
doesn't exceed 95°C by discharging the hot water. If you
find water escaping from these valves, check the pressure
(this should be 2 - 2.5 bar). Adjust the pressure using the
pressure reducing valve.
Cold
water intake
Safety
valve drain
Hot water
delivery
Hood emptying
Boiler hood
Fibreglass
insulation
Ball valve to drain
system to avoid risk
of frozen pipes
Pressure reducing
valve (recommended
setting: 1.8 - 2 bar) Heat vent valve
3 bar
safety valve
Sleeve
4 bar safety valve (extra,
do not connect to drain)
JOLLY vent valve
Water temperature
gauge
Electrical resistance,
connect to omnipolar
switch (optional)
We recommend using an
expansion tank to avoid
sudden variations in pressure
(optional)
600/900
200
440

Pag. 15
ASSEMBLY AND MAINTENANCE INSTRUCTIONS
CAMINETTI S.P.A.
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When the fireplace is burning wood, the fume register must
always be open: you can adjust the actual aperture once the
fire is properly lit for better efficiency and less consumption.
The fan only starts automatically when the air has reached the
set temperature on the fireplace thermostat (roughly 60°C). It
automatically stops when the temperature drops below the set
temperature (even when the control panel is switched off).
The fireplace fan must work, at the desired speed, when the
fireplace is lit.The fireplace can be used in Summer to ventilate
the rooms (turn the fan control to Summer).
The electrical control panel has three power stages to allow
setting the desired temperature.
The humidifying water must be manually added to the humidi-
fier trays.The humidifier is full when the water reaches the level
of the two trays (2-3 l capacity).
The fireplace can work also without water. You can add
balsamic essences to the water to perfume the air.
Never use thick or closing grilles on air intakes which
could stop the air flow. It is advisable the use of a wide net.
AERJOLLY MAINTENANCE
Routine and systematic upkeep is essential to ensure top
efficiency and max heat output.
All components must be cleaned and checked once a year. We
recommend carrying out the following operations to comply
with the safety standards and ensure the validity of the warranty:
-yearly general cleaning
-yearly flue cleaning
-yearly glasses cleaning (using a wrinkling sponge and a
specific product - such as Cif, Fornet, Vim)
-Be sure that the fireplace have a good draught, trying it with
a fired-paper at the beginning of the flue.
-There must be no other fireplaces, boilers or exhaust systems
in the same room
The manufacturer cannot be held liable for any problems
arising from non observance of the directions in this manual.
CERTIFICATE OF WARRANTY
JOLLY-MEC guarantees the boiler body for 5 years,
excluding all electrical components, consumable parts
and glass.
The relevant manufacturer warranties apply for the vari-
ous complementary accessories.
This warranty is valid only if the fireplace has been
installed and used in compliance with the instructions
and recommendations in this manual.
JOLLY-MEC reserves the right to make any changes
without prior notice.

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JOLLY-MEC Caminetti s.p.a.
24060 Telgate (BG) - Italy - via Fontana, 2
Tel. [phone] - Fax [phone]
web: www.jolly-mec.it • E-mail: [email protected]
06-2003