Jolly Mec JOLLY STAR 68-80 User manual
SM053 EN REV03 2015_10
Fireplace
10 kW and 14 kW
INSTALLATION, USE AND
MAINTENANCE MANUAL
To be kept by the purchaser
Pellet operated air heating fireplace
JOLLY SYNTHESIS 68-80 JOLLY STAR 68-80
Dear Customer,
thank you for having chosen to heat and save with a Jolly Mec product. Please carefully read and keep this sheet
before using the equipment.
This sheet provides necessary information and suggestions on how to correctly install, use, clean and maintain
the product. Knowing and observing these instructions will allow you to fully and safely enjoy the potential your
equipment can offer you.
SM053 EN REV03 2015_10
3
ENGLISH
TABLE OF CONTENTS
CHAP.01 PREMISES...................................................................................................................................4
01.1 WARNINGS..................................................................................................................................................4
01.2 SYMBOLOGY...............................................................................................................................................5
01.3 APPLIED STANDARDS ...............................................................................................................................5
01.4 USE AND STORING OF THE INSTALLATION AND MAINTENANCE MANUAL........................................6
01.5 MANUFACTURER LIABILITY AND WARRANTY CONDITIONS ................................................................6
CHAP.02 ACCIDENT PREVENTION / SAFETY REGULATIONS..............................................................7
02.1 GENERAL CONSIDERATIONS...................................................................................................................7
02.2 SAFETY REGULATIONS FOR ROUTINE MAINTENANCE AND USE.......................................................7
02.3 SAFETY REGULATIONS FOR EXTRAORDINARY MAINTENANCE AND INSTALLATION......................8
02.4 EQUIPMENT FOR OPERATORS AND MAINTENANCE PERSONNEL.....................................................9
02.5 RESIDUAL RISKS........................................................................................................................................9
CHAP.03 HANDLING AND TRANSPORT................................................................................................10
03.1 RECEIVING GOODS..................................................................................................................................10
03.2 LIFTING AND TRANSPORT......................................................................................................................10
CHAP.04 ECOLOGICAL REGULATIONS................................................................................................11
04.1 WASTE MATERIALS AND THEIR DISPOSAL..........................................................................................11
04.2 DISPOSAL OF THE MACHINE..................................................................................................................11
CHAP.05 DESCRIPTION...........................................................................................................................12
05.1 PRODUCT PRESENTATION.....................................................................................................................12
05.2 PRODUCT IDENTIFICATION ....................................................................................................................14
CHAP.06 TECHNICAL DATA ...................................................................................................................15
06.1 HOMOLOGATION......................................................................................................................................15
06.2 RECOMMENDED FUELS..........................................................................................................................16
06.3 COMPONENTS..........................................................................................................................................17
06.4 OPTIONALS...............................................................................................................................................18
06.5 DIMENSIONS.............................................................................................................................................19
CHAP.07 POSITIONING AND CONNECTIONS FOR THE INSTALLER.................................................20
07.1 POSITION OF EXTERNAL AIR INTAKES AND ELECTRIC CURRENT...................................................20
07.2 ASSEMBLING AND INSTALLING THE FIREPLACE IN A PRE-EXISTING FIREPLACE.........................21
07.3 ASSEMBLING AND INSTALLING THE FIREPLACE IN A NEW FIREPLACE..........................................22
07.4 AIR CIRCULATION ....................................................................................................................................23
07.5 EXAMPLE OF AIR DUCTING IN THE VARIOUS ROOMS........................................................................23
07.6 FLUE OR FUME EXHAUST SYSTEM.......................................................................................................25
07.7 INSTALLATION ROOM VENTILATION ....................................................................................................26
07.8 ELECTRICAL CONNECTIONS..................................................................................................................27
07.9 CONTROL UNIT M10-P.............................................................................................................................27
07.10 CONTROL UNIT ELECTRICAL WIRING DIAGRAM .................................................................................28
CHAP.08 USE AND MAINTENANCE FOR THE USER............................................................................29
08.1 APPLIANCE OPERATIONS.......................................................................................................................29
08.2 DOOROPENINGANDINSETFIREPLACEEXTRACTION(onlywithreplaceoffandcold) ..................29
08.3 EMERGENCY CONSOLE..........................................................................................................................30
08.4 REMOTE CONTROL M10-P......................................................................................................................30
08.5 SAFETY THERMOSTAT PELLET TANK WITH MANUAL RESET............................................................30
08.6 RECOMMENDATIONS AND WARNINGS.................................................................................................31
08.7 ORDINARYMAINTENANCE(tobedonebythecustomer).......................................................................32
08.8
PREVENTIVEMAINTENANCEPROGRAM(tobedonebytheauthorisedJolly-MecTechnicalAssistanceCentre) .....34
CHAP.09 FAULT DIAGNOSIS AND TROUBLESHOOTING....................................................................35
09.1 PROBLEMS................................................................................................................................................35
09.2 ALARM MESSAGES..................................................................................................................................36
CHAP.10 ATTACHMENTS........................................................................................................................38
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CHAP.01 PREMISES
01.1 WARNINGS
• Familiarityandcompliancewiththeinstructionsgiveninthismanualwillensurequickinstallationandcorrectuseoftheappliance.
• Readthemanualattentivelybeforecommencinginstallation,andbecertaintofollowthedirectionsitcontains,otherwisethewar-
rantycouldbeinvalidatedandtheperformanceandsafetyoftheappliancejeopardized.
• Theinstallationmanualisanintegralpartoftheproductandmustbegiventotheuser.
• Itmustbekeptinasafeplaceandconsultedcarefully,asallofthewarningsprovideimportantinformationonsafetyduringinstal-
lation,useandmaintenance.
• Incorrectinstallationoftheappliancecouldcausedamageandinjurytopeopleoranimals,forwhichthemanufacturecannotnotbe
heldliable.
• InstallationshallbeperformedbyqualiedoperatorsinaccordancewiththeregulationsinforceintheCountryofinstallation.
• Themanufacturerdeclinesanycontractualornon-contractualliabilityfordamagescausedbyerrorsininstallationoruseofthe
applianceorfailuretofollowtheinstructionscontainedinthismanual.
• AllrightsonthereproductionofthistechnicalmanualareownedbyJollyMecCaminettiS.p.A.
• Thedescriptionsandillustrationsprovidedinthefollowingpublicationarenotbinding.
• JollyMecCaminettiS.p.Areservestherighttomakeanymodicationsthatmaybedeemedappropriate.
• ThismanualcannotbegiventothirdpartiesforperusalwithoutthewrittenpermissionofJollyMecCaminettiS.p.A
• Thetechnicaldirectionsforinstallationcontainedinthismanualshouldbeconsideredasbasicrequirements.Regulationsinsome
countriesmaybemorerestrictive;inthisinstance,complyfullywiththeregulationsprevailinginthecountryofinstallation(all laws
and local bylaws must be observed when installing and using the appliance, including those referring to national and
European standards).
• Neverusetheapplianceasanincinerator,orinwayotherthanthatforwhichitwasdesigned.Anyotheruseisdeemedimproper
andthereforedangerous.
• Donotusefuelsthatarenotrecommendedunderpenaltyofcancellationofthewarranty.
• Whentheapplianceisrunning,theglassandothervisiblepartsreachextremelyhottemperaturestothetouch;handlewithextreme
caretoavoidburns.
• Donotplacetheapplianceindirectcontactwithcombustiblematerials.
• Donotmakeanyunauthorisedmodicationtotheappliance.Anyunauthorisedmodicationwillautomaticallyinvalidatethewarranty
andreleasethemanufacturefromallliability.
• Useonlyoriginalsparepartsrecommendedbythemanufacturer.originalsparepartsareavailablethroughauthorisedretailers,
authorisedAssistanceCentres,ordirectlyfromJollyMecCaminettiS.p.A.
• Acceptanceofthemachinebytheusermustbe“total”,includingthesoundlevelofoperation,comparabletoanelectricalappliance.
Complaintsforcharacteristicsnotindicatedinthismanualshallnotbeaccepted.
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01.2 SYMBOLOGY
Inthismanual,pointsofconsiderableimportancearemarkedwiththefollowingsymbology:
INSTRUCTION: Instructionsregardingthecorrectuseoftheappliance.
WARNING: Thispointisparticularlyimportant.
DANGER: Animportantpointregardingbehaviourforpreventinginjuryanddamageto
materialsisexpressed.
01.3 APPLIED STANDARDS
AllJOLLYMECproductsareconstructedaccordingtothefollowingdirectives:
• EU 305/2011 Europeanconstructionproductsregulation.
• 2006/42/CE Machines.
• 2014/30/UE Electromagneticcompatibility(EMC).
• 2014/35/UE Lowvoltage(LVD)-electricalsafety.
• 2011/65/EU (RoHs 2) Restrictionoftheuseofcertainhazardoussubstancesinelectricalandelectronicequipment
• 2014/53/UE RadioEquipment
• 97/23/CE PressureEquipment(PED)
Andincompliancewiththestandards:
• CEI EN 61000-3-2 Electromagneticcompatibility(EMC)-Limits-Limitsforharmoniccurrentemissions(equipmentinput
current≤16Aperphase).
• CEI EN 61000-3-3 Electromagneticcompatibility(EMC)-Limits.Limitationofvoltagechanges,voltageuctuationsand
icker
inpubliclow-voltagesupplysystems,forequipmentwithratedcurrent≤16Aperphaseandnotsubject
toconditionalconnection.
• EN 55014-1 Electromagnetic compatibility. - Requirements for household appliances, electric tools and similar
apparatus-Emission
• EN 55014-2 Electromagnetic compatibility – Requirements for household appliances, electric tools and similar
apparatus-Immunity.Productfamilystandard.
• EN 60335-1 Safetyofhouseholdelectricalappliancesandsimilarproducts.-Generalsafetyregulations
• EN 60335-2-102 Safetyofhouseholdelectricalappliancesandsimilarproducts.-Specialregulationsforappliancestted
withgas,dieselorsolidfuelburnersandelectricalconnections.
• EN 62233 Measurementmethodsforelectromagneticeldsofelectricalappliancesforhomeuseandsimilargoods
regardinghumanexposure.
• EN 50581 TechnicalDocumentationForTheAssessmentOfElectricalAndElectronicProductsWithRespectTo
TheRestrictionOfHazardousSubstance
• EN 7129 Domesticandsimilargassystemspoweredbythedistributionmains.
• UNI 10412-2 Hotwaterheatingsystem-Safetyrequirements-Specicrequirementsforsystemswithdomestictype
heatingdevicespoweredbysolidfuelwithbuilt-instove,withtotalrepowernotover35kW.
• UNI 10683 Heatgeneratorsoperatingwithwoodorothersolidbiofuels-Installationrequirements
• UNI EN 303-5 Heatingboilers.-Heatingboilersforsolidfuels,manuallyandautomaticallystoked,nominal
heatoutputofupto500kW-Terminology,requirements,testingandmarking.
• UNI EN 1443 Fireplaces-Generalrequisites
• UNI EN 1856-1 Chimneys-Requirementsformetalchimneys-Systemchimneyproducts.
• UNI EN 1856-2 Chimneys.Requirementsformetalchimneys-Metaluelinersandconnectinguepipes.
• UNI EN 13229 Insertappliancesincludingopenresredbysolidfuels-Requirementsandtestmethods
• UNI EN 13240 Roomheatersredbysolidfuel-Requirementsandtestmethods
• UNI EN 13384 Fireplaces-Thermalcalculationsanddynamicuid.
• UNI EN 14785 Residentialspaceheatingappliancesredbywoodpellets-Requirementsandtestmethods
• UNI EN ISO 12100 Machinesafety.
6
01.4 USE AND STORING OF THE INSTALLATION AND MAINTENANCE MANUAL
• Recipients of the manual
Theuseandinstallationmanualisaddressedtousersresponsiblefortheinstallation,operationandmaintenanceofthestove;particular
attentionmustbegiventhepartsofthemanualconcerningsafety.
Iftheproductissubsequentlyresold,theuserisrequestedtohandoverthissheetandtoinformthemanufacturerofthenameofthe
newowner,sothatthelattermayreceiveanyupdatesissued.
• Scope of the manual
Themanualcontainsinformationonthecorrectuseoftheproductinaccordancewiththepurposesforwhichitwasdesignedandbuilt.
Italsoprovidesinformationaboutloads,commissioning,repairandmaintenanceofthestoveinconformancewiththelimitssetdown
bythemanufacturer.
• Conservation of the manual
Theinstallationandmaintenancemanualisanintegralpartoftheproductandmustbeconserveduptothetimewhenthestoveis
dismantled.Itmustbekeptinaprotected,dryplaceoutofdirectsunlightandneartheproductsothatitisalwaysreadilyavailablefor
consultation.
Shouldthemanualgetdamaged,theusermustrequestacopyfromtheManufacturer,contactingtheretailerwherehepurchasedthe
appliance.Whenrequestingassistance,alwaysmakereferencetotheMODEL,LOTandSERIALNUMBERindicatedonthelabelshown
in
CHAP.05.2 - PRODUCT IDENTIFICATION.
• Updating the manual
Theinstallationandmaintenancemanualreectsthestatusofthetechnologyatthetimetheproductwasmarketed.Themanufacturer
reservestherighttomakemodicationstotheproduct,andconsequentlytherelativemanual,withoutanyobligationtoupdateprevious
editions.
01.5 MANUFACTURER LIABILITY AND WARRANTY CONDITIONS
Uponthedeliveryofthismanual,JollyMecS.p.A.cannotbeheldliable,whethercivilorcriminal,foraccidentsduetopartialortotal
non-compliancewiththespecicationshereincontained.
Themanufacturerisespeciallyheldharmlessfromanyliabilityinthefollowingcases:
• Improperuseoftheproduct
• Usenotintendedbyspecicnationalregulations
• Incorrectinstallation
• Faultsintheelectricalconnections,theconnectionsofthefumeexhaustsystemand/orthecomburentairductingsystemeandin
plumbingconnections
• Failuretocarryoutmaintenanceasprescribedinthismanual
• Unauthorisedmodicationsoroperations
• Useofreplacementpartsthatarenon-originalornotspecictothemodel
• Totalorpartialfailuretofollowtheinstructions
• Exceptionalevents(e.g.:breakagesduetonaturaloraccidentaleventsaslightening,shortcircuitsetc.)
• Damagecausedbyelectricalpowercuts,suddenuctuationofsupplyvoltage,electromagneticelds
• Useoffuelwithcharacteristicsotherthanthoserecommendedinthismanual
Intheabovecasesthewarrantyisvoid.
PleaserefertoAnnexSM082fordetailsonthewarrantyconditionsandcompilingtherelativecerticate.
IntheeventofamalfunctionorinterventionrequestbyTechnicalAssistance,theusermustbeabletodemonstrate
theuseoffuelwiththecharacteristicsrequiredbythismanual.
TheManufacturerdisclaimsallliabilityconcerninganomaliesormalfunctionscausedbyuseofFUELwhichdoesnot
complywiththerecommendedrequirements.
NOTE
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CHAP.02 ACCIDENT PREVENTION / SAFETY REGULATIONS
02.1 GENERAL CONSIDERATIONS
• Themanualreferstoessentialaspectsofthedirectives,regulationsanddispositionsonusingthemachine,summarising
itsmostsignicantpoints.
• General legal regulations and mandatory rules regarding injury prevention and environmentalprotection must be
observed.Theseobligationsalsoincluderegulationsregardingtheuseofpersonalprotectiveequipment.
• Forallworktobedoneonthesystem,thefollowingdispositionsandregulationsinforcemustbeobservedregarding
accidentprevention,followingtheindications.
• Beforeusingthesystemthersttime,theusermusthavereadandunderstoodtheinstructionmanualperfectlyandthis
chapterinparticular.
• Theusermustalsomakesurethatthemachineisalwaysingoodconditionasregardsitssafetyrequirements.
• During maintenance and inspection activities, wear the protective garments specied in following
CHAP.02.4 -
EQUIPMENT FOR OPERATORS AND MAINTENANCE PERSONNEL.
Cleaningandmaintenanceactivities
mayonlybeperformedwiththeequipmentcoldandpreferablydisconnectedfromthepowermainsorwiththemain
switchinthe“O”position.
• Dangerwarningsandsignalsintheformofplates,labelsandmarkingsmustnotberemovedormadeunidentiable.If
theyarewornorbroken,theymustbereplaced.
• Modications, additions or transformations must not be made on the machine and its components without the
manufacturer’sauthorisation.Thisisvalidrstandforemostforinstallationandregulationoftheinstalledsafetydevices.
FailuretocomplywiththiswarningrelievestheManufacturerofallandanyresponsibility.
• Makesure,beforestartingupeverytimeandaftercarryingoutmaintenance,thatdismantledpartshavebeenrepositioned
correctlyandinparticularalltheprotectiondevicesthatimpedeaccesstothemachine.
02.2 SAFETY REGULATIONS FOR ROUTINE MAINTENANCE AND USE
• Theuserand/orowneroftheproductisrequired,inaccordancewiththelawsinforce,toassigntheinstallationand
maintenancetoqualiedandspecialisedoperators,andacknowledgetherisksandhazardsshouldtheyfailtoobserve
thisrequirement.
• Useofthisproductisnotpermittedforchildren,personswithacknowledgedreducedpsycho-physicalandsensory
abilitiesandpersonswholackexperienceinusingsuchmachines,unlesstheyaresupervisedbydesignatedpersons
responsiblefortheirsafety.
• Thesettingsandprogrammingoftheproductmustonlybeperformedbyadultswhohavereceivedsuitableandspecic
training.Errorsorincorrectsettingscancreatehazardousconditionsandtriggermalfunctionswithrelativeconsequences
forpersonsandthings.
• Beforeanycleaningand/orroutineorextraordinarymaintenanceonthemachine,disconnectitfromallenergysources;
inparticular,turntheelectricalpowerswitchto“O”.
• Priortoinstallation,theuserandinstallerareobligedtocheckthatthemainselectricalsupplytowhichthemachinewillbe
connected,correspondstothevoltageontheidentificationplate(see
CHAP.05.2 - PRODUCT IDENTIFICATION
),
andthatitisequippedwithallsuitablesafetydevicestoclassifytheelectricalsystemascompliantwithapplicablesafety
standards.Ifthisisnotthecase,contactaQualifiedTechniciantoadaptthesystemtorequiredstandards.
• Upstreamfromthemachine(attheuser’sexpense)ontheelectricalpowersupplyline,abipolarswitchmustbeinstalled
thatisabletointerceptallthecurrentphases(see
CHAP.06 - TECHNICAL DATA
).
• Theirradiationareaincludestheareabetweentheopeningofthehearthandupto1metreofspacefrontallyaswellas
laterally.Noinammableobjectmustbeleftinthisarea(suchas:inammableliquids,re-startingproductsorrewood,
drapes,woodendecorations,rugs,etc.).
• Donotusethestovetodryclothes,itcouldoverheatandcauseanoutbreakofre.
• ATTENTION - BEWARE OF BURNS,mostoftheoutersurfacesofthestoveareveryhot,doorhandle,glass,metal
sides,majolicaormetaltop,fumeexhaustpipeetc.Nevertouchthestovewithnakedhandswhenitisrunning;always
useheatprotectiongloves,suchasthosesuppliedwiththestove,whenhandlingallparts.
• Beforedoinganyinternalcleaningormaintenance,youmustwaituntilthemachinereachestheambienttemperature.
• Ifthestoveisinalarmstatusduetoamalfunction,donotattempttorestartitbeforendingoutwhathascausedtheheat
generatortoshutdown.
• Neverwashtheinternalpartsofthecombustionchamberwithwater.
• Inalarmstatusforfailedstartup,donottrytorestartthestoveuntilthereboxhasbeenthoroughlycleaned.
8
• Theappliancemustalwaysbestartedupwiththereboxempty,withoutpelletsandwithoutunburnedfuelfromprevious
use.
• Donotattempttoignitethefuelwithinammableliquidsorsolids;thestovemustigniteautomaticallyviatheelectrical
componentsinstalledonboard.
• Donotloadpelletsmanuallyintothereboxbeforeorwhilsttheapplianceisrunning.
• Keeptheventilationgridsintheareatheapplianceisinstalledincleanconditions.
• Neverloadanyfuelotherthanpelletsintothestovestoragehopper.Corn,nutsorothercombustiblematerialsmustnotbe
usedasfuelfortheappliance.
• Checkandperiodicallycleanthefumeexhaustpipe,fromtheappliancetotheue(Union).
• Itisstrictlyprohibitedtostartuptheproductwiththecombustionchamberdooropenorallowittorunwiththeglassbroken.
• TheusershouldcontactanauthorisedJOLLY-MECTechnicalAssistanceCentreifanyoperatingproblemspersist
• Nevertrytostartthedeviceusingethylalcoholorotherammableliquids..
02.3 SAFETY REGULATIONS FOR EXTRAORDINARY MAINTENANCE AND INSTALLATION
• Theuserand/orowneroftheproductisrequired,inaccordancewiththelawsinforce,toassigntheinstallationand
maintenancetoqualiedandspecialisedoperators,andacknowledgetherisksandhazardsshouldtheyfailtoobserve
thisrequirement.
• Theinstallationoftheheatgeneratorandtherelativecombustionproductexhaustionsystem,theelectricalconnections,
thecommissioningandextraordinarymaintenanceMUSTalwaysbeperformedbyQualiedand/orLicensedProfessional
TechniciansorthoseAuthorisedbytheManufacturer.
• TheproductmustbeinstalledinaccordancewiththelawsandstandardsinforceintheState,RegionorAreainwhich
themachineisinstalled.
• Installationinbedrooms,roomswithavolumebelow15m3orwithexplosiveatmospheresisstrictlyprohibited.
• ThesysteminstallerMUSTissueaDeclarationofcompliancefortheworkperformedaftercommissioningthesystem,
inaccordancewiththelawsinforcerelatedtosystemsafetystandards.
• Theinstallationtechnicianmustinformtheuseronsafeequipmentuse.
• Theinstallationoperatorisresponsiblefortheinstallationandisthereforerequiredtoperformtheworktotopworkmanship
standards.
• Theappliancemustbeconnectedtoacombustionproductexhaustionuebuiltinaccordancewithapplicable
standardsandcertiedwithadeclarationofcompliance.
• Theinstallationtechnicianisinchargeofinstallationandmustcheckemissionsfollowingrstinstallation.
• Shouldanyinstallationdefectsariseduringcommissioning,theAuthorisedJolly-MecTechniciancanrefusetoendorse
useoftheproductforsafetyreasonsandsubmitawrittenServicingReporttotheUserinforminghimthatheandthe
Installationoperatorshallbejointlyliableforanydamagetopersons,animalsorthingsifused.
• Beforeinstallingthemachine,thecustomerandinstallationoperatormustensurethattheooringonwhichitwillbe
positionedissuitablylevelledandcansupporttheweight(see
CHAP.06 - TECHNICAL DATA
).IIfthereisanydoubt
onthesolidityoftheooring,itisessentialtohaveaStructuralEngineerverifyrelativeinstallationfeasibility.
• Onlyspecialisedandqualiedpersonnelmayworkorcarryoutchecksinside the machine, complying with safety
regulations.
• Priortoinstallation,theuserandinstallerareobligedtocheckthatthemainselectricalsupplytowhichthemachinewillbe
connected,correspondstothevoltageontheidentificationplate(see
CHAP.05.2 - PRODUCT IDENTIFICATION
),
checkthatthesystemissizedsoastobearthemaximumloadrequiredoftheproduct,andalsothatitisequippedwith
9
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allsuitablesafetydevicestoclassifytheelectricalsystemasCOMPLIANTwithapplicablesafetystandards.Ifthisisnot
thecase,contactaQualiedTechniciantoadaptthesystemtorequiredstandards.
• Personnelassignedtohandlingthemachinesandequipmentmustalwayswearindustrialglovesandboots.
• TheMaintenanceOperatormustrecommendtheCustomertosignanannualmaintenancecontractfortheproduct,so
astomaintainthelevelsofsafetyandefcientperformanceoftheproduct.
• TheMaintenanceOperatormustchecktheworkinghoursoftheproductbetweenonemaintenanceinterventionand
another,toverifytheactualworkloadofthestove.TheactualhoursofoperationshallberesetattheendoftheTechnical
interventionandindicatedontheServicingReport.
02.4 EQUIPMENT FOR OPERATORS AND MAINTENANCE PERSONNEL
Everyoperatorperformingmaintenanceonthemachine,mustwearsafetygarmentsandpersonalprotectiveequipment:
1 Protectionheadphones
2 Gloveshandprotections
3 Respiratorymask
4 Facemaskorgoggles
5 Accidentpreventionboots
6 Overallsorsmock
02.5 RESIDUAL RISKS
ThoughJOLLYMECCAMINETTIS.p.A.doeseverythingwithinitspowertoproduceitssystemswiththegreatestcompetenceregarding
safetyandconsultingallthedirectives,laws,andregulationsavailable,therearestill,ifminor,someresidualrisksduringthephasesof:
• TRANSPORT AND INSTALLATION
• ELECTRICALCONNECTIONS(Whichmustbedonebyaqualiedelectrician)
• MAINTENANCE
Therefore,thetechnicianswhoperformthesetasksmusttaketheseresidualrisksintoaccount.
Removalortamperingwiththeprotectionandsafetydevicescanbeonlybedonevoluntarilyandmaycause
seriousinjurytopeople.
Replacethesafetysignalswhentheybecomeillegibleorcomeoff.
WARNING
10
CHAP.03 HANDLING AND TRANSPORT
03.1 RECEIVING GOODS
Theproductisdeliveredonpallets,packagedinacardboardboxwithacellophanewrapping.
whenreceivingmerchandise,checkthat:
• allpackagingisintact
• allofthemerchandiseindicatedonthedeliverybillhasactuallybeendelivered
• thesupplycorrespondstotheorderspecications;
• ifthepackagingisdamaged,checktheconditionofthecontentsasanybreakagesshouldbereportedimmediatelyto
thecarrierandretailer.
• checkthereisnodamagetoanysuppliedelements;ifthereisanybreakagedetected,reporttothecarrierandretailer
assoonaspossible.
Ifanymateriallistedonthebillofladingismissing,informtheretailerimmediately.
03.2 LIFTING AND TRANSPORT
Personnel in charge of handling the product must have read and thoroughly understood the safety prescriptionsin
CHAP.02 -
ACCIDENT PREVENTION / SAFETY REGULATIONS
ofthismanualandmustwearworkglovesandsafetyfootwear.
Forsafetyreasons,unauthorisedpersonsmustnotbeintheareawhiletheproductisbeingmoved.
Theproductmustbemovedonlywithatrolleyorpalletfork,andneverwithbelts,chains,overheadcranes(see
CHAP.06 - TECHNICAL
DATA
fortheweight).Allpartsofthepackagingcomingintocontactwiththecrane,beltsorstrapsmustbeprotected.
Unlessthereareobstacles,lifttheproducttoamaximumof30cmfromthegroundandmoveitslowly,avoidingjerkyorbrusque
movements.
Danger of crushing, collision and abrasions.
WARNING
Danger of suffocation
Makesurethatchildrendonotcomeintocontactwithpackagingmaterials,plasticlmorpolystyreneasthiscouldcause
suffocation.
WARNING
11
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CHAP.04 ECOLOGICAL REGULATIONS
04.1 WASTE MATERIALS AND THEIR DISPOSAL
Sparepartsreplacedduringthemachine’sproductlifearetobeconsideredwasteandmustbetakentospecialcollectioncentresor
entrustedtoauthoriseddisposalcentres.
Ashesmustbeplacedinametalcontainerwithasealedlid.Theclosedcontainermustbeplacedonanon-combustiblebaseandkept
awayfromcombustiblematerialsuntilalltheembershavebeenextinguished.
Onlywhenextinguishedcanashesbethrownintotheorganicwastecollection,naturallywithoutnailsorothernon-organicmaterials.
Onlywhenextinguishedcanashesbedisposedofaccordingtotherecyclingregulationsinyourtown.
Theashesfromnaturalwood(untreated)derivedfromstoveorreplacecombustionaremainlycomposedofcalcium,silicon,potassium
andmagnesiumoxides.
PROTECT THE ENVIRONMENT!!!!
Danger of environmental pollution
AdoptpositivecivicbehaviourandDONOTdispersethepackagingintotheenvironment,buttakeittowastedisposal
centresforrecycling.Allpackagingcanberecycled,asitconsistsofwood,polyethylenefilm,polystyreneandcardboard
WARNING
04.2 DISPOSAL OF THE MACHINE
Thestoveismainlycomposedofferrousmaterials,butitmayalsocontain:
• piping
• insulatingmaterials
• electricalpartsetc.
• refractorymaterials
Whenyounolongerintendtousethestoveeveragain,donotdisposeofitirresponsibly.Rememberto:
• emptythecircuitcompletely(ifpresent)
• removepiping(ifpresent)
• removeplasticparts
• removeelectriccablesandelectriccomponents
Thesematerialsmustbedisposedofbyspecialisedrmsoraccordingtothelawsofthecountrywhereitisinstalled.
Furthermore:
• immobilisemovingparts
• makethelocksonthedoorsinoperativ
Taketheremainingpartofthestovetothermsthatdisposeofferrousmaterials.
Themachinemustbedisposedofinamannerthatcomplieswiththelawsinforceandtheenvironment.
Whentakingittothermsthatdisposeofferrousmaterials,handlethestoveasdescribedin
CHAP.03 - HANDLING
AND TRANSPORT.
NOTE
12
CHAP.05 DESCRIPTION
05.1 PRODUCT PRESENTATION
Jolly-Mecproductsaretheresultofoverfortyyearsexperienceinthewoodenbiomasscombustionsector;theyaredesignedand
engineeredtomeettheincreasingdemandsoftoday’smarketswithhighperformancelevelsandsavingsenvelopedinamoderndesign.
ThepelletcassettereplaceisamonoblockheatingdeviceapprovedtoEN14785:2006Standardrequirementsbyathirdpartyrm
accreditedbytheECasamachinetestingandcerticationinstitute.
Itisahighperformanceproductforairheating,operatingonalternativeandrenewableenergysources:pellets.
Adesignthatisalwaysuptodate,maintainingthetraditionandirreplaceablecosinessofareplace.
Itisaheatermadewithadvancedcharacteristics;
theSYNTHESISmodelisequippedwitharobuststeelframeandnishedingalvanised
sheetmetal(optionalaccessory)forgreateraestheticinsulationandeasierinstallation.
The cassette replace features a support base with runners for easy
extractionfornormalinspections,checks,maintenanceonelectricaland
mechanicalpartsandahandyfrontdrawerforloadingpellets.
TheSTARmodelisttedwithaheight-adjustablestandandismadetobe
securedtotheooraswellasthewall,andpre-disposedforductinghot
airtootherareaswithspecialinsulatedaluminiumpipes.
Itisalsoequippedwithaconvenientchuteforloadingpelletsintothe
hopperandcanbepositionedonthesidesaswellasthefront.
TheBoileriscomposedofanexchangerinFIREFLECTORanddual
heatdevelopmentcapacitysteel,betweenwhichairisblownwitha
fanwhichonceisheated,isdistributedintheroom.
It works by recycling the air in the installation area, or by ducting it
externally.
Itoperatesonlywiththedoorclosed,insertedandlockedinitshousing.
Combustioniscontrolledbymeansofaradio-frequencyelectronic
controlunitandwirelessremotecontrolwiththefollowingfunctions:
•
Remote control display
Ample screen that
providesaninterfacewiththeproduct,tosetfunctionvalues
andreaddataonworkstatus.
•
Chronothermostat
On and off time setting function
programmedwithsettabletemperatureregulationprogram.
•
Room temperature
Functionused tosetanddisplay
theambienttemperaturereachedwithTLCorprobeupto
3m.
•
Power levels
Controlpossibilitieson5heatpowerlevels.
•
Operating status
Functionthatdisplaysproductand
connectedheatsystemoperatingstatusinrealtime.
•
Multilingual
Possibility to select one of ve different
Europeanlanguages(ITA-ENG-DEU-FRA-ESP).
Cassettereplaceforapre-existingreplace
Cassettereplaceforanewreplaceandducting
JOLLY SYNTHESIS 68-80
JOLLY STAR 68-80
13
ENGLISH
Theyarealsofittedwith:
• Pellethopperwithabout15kgcapacity
•
“Humidier”withincorporatedwatertanktohumidifytheheatingairintheenvironmentandpreventundesireddry
throatsensationscausedbyexcessivelydryair;itispossibletoaddsomedropsoffragranceoilstothewaterto
freshentheairinthehome.
• Apracticaldrawertocollecttheashes.
• Thermalsafetydeviceagainstpossibleoverheating.
• Safetydeviceagainstpossiblecloggingoftheuepipe.
• TangentialFanforhotairexchangeintheenvironment.
• Fumeexhaustfan.
• Electricalresistancetostartcombustion.
PELLETcombustionproductsmustonlybeusedwiththecombustionchamberdoorclosed.
WARNING
Thechromaticvariationsofthepaintedsurfaces,especiallythoseindifferentmaterialsandnishesandsubject
todifferenttemperatures,cannotbedeemedreasonfordisputeastheydependuponthenaturalcharacteristicsofthe
materialsandtheuseoftheproduct.
NOTE
14
05.2 PRODUCT IDENTIFICATION
Theillustratedexampleplatemaydifferingraphicsfromtheoriginalafxedtotheproduct.
NOTA
1
ProductModel
2
CEmarking
3
Yearofcommisionignandcertication
4
Referencestandard
5 PerformancedeclarationNumber*
6
ProductLOTNumber
7
Productsalescode
8
Productserialnumber
9 Productlabelcode
*Pursuant to European Regulation No.
305/2011,manufacturersarenowrequiredtohave
the DoP - Declaration of Performance for each
product of own design concerned; Jolly-Mec did
namely provide all of these documents in
downloadableelectronicformthatyoucaneasilysee
on the website of the Company at the following
address: http://www. jolly-mec.it/it/servizio-clienti/
docman.html
WARNING
ItisCOMPULSORYtoindicatetheproductMODEL,theLOTnumber
andSERIALNUMBERinallcommunicationswiththeManufacturer.
Identicationnumbersareprintedontheadhesiveplatelocatedon
therightsideofthepelletcontainerasillustrated.Stoveperformance
valuesmeasuredduringinspectiontestsaccordingtotheindicated
referenceandECmarkingsarealsoincludedontheplate.
1
2
4
5
3
6
7
9
8
Via San Giuseppe, 2 - 24060 Telgate - BG - *
Tel. +39.035.8359211 - fax +39.035.8359200
Inserto Synthesis 68
Apparecchio funzionanante a pellet -equipment with pellet feeding -betriebene Geräte Pellet -
équipement alimentés à granulés -equipo alimentado pellets
Potenza elettrica nominale
Rated electrical power
Elektr. Leistungsaufnahme
Puissance électrique nominale
Potencia eléctrica nominal
Distanza minima materiali combustibili adiacenti
Min. clearance from combustible materials
Abstand zu angrenzenden entzündlichen Stoffen
Distance matériaux combustibles adjacents
Distancia a materiales combustibles adyacentes
Utilizzare solo combustibili raccomandati
Use recommended fuels only
Verwenden Sie nur die empfohlenen Brennstoffsort*
Utiliser seulement des combustibles recommandés
Utilizar sólo los combustibles recomendados
CO emissioni
CO emissions
CO emission
Emission de CO
Emisión de CO
Tensione/Frequenza nominale
Rated voltage/frequency
Spannung/Nennfrequenz
Tension/Fréquence nominale
Tensión/Frecuencia nominal
Temperatura media fumi
Medium flue gas temperature
Abgastemperatur Mittelwert
Température moyenne des fumées
Temperatura media de los humos
Leggere e seguire le istruzioni di funzionamento
Read and follow the operating instructions.
Lesen und befolgen Sie die Betriebsanleitungen
Lire et suivre les instructions de fonctionnement
Leer y seguir las instrucciones de funcionamiento
Potenza termica nominale
Rated heat output
Nenn-Heizleistung
Puissance thermique nominale
Potencia térmica nominal
N° lotto:
230 V
Front 1000 mm
L000000
Pellet
Cod: SYNTHESIS/68/1
55
174,9 °C
Matr: 000000
P
Potenza bruciata
Burned power
Max Heizleistung
Puissance brûlée
Potencia quemada
Qtot
ta
14
Potenza termica ridotta
Reduced heat output
Teilwärmeleistung
Puissance thermique réduite
Potencia térmica reducida
50 Hz
365W
2,8 kW
10,0 kW
Dust @ 13% O
Ignition
Working
170W
n° DOP JM 00039A
the dop was drafted on the basis to the test report of accredited laboratory
the accreditation number of the laboratory is 2456 TÜV Rheinland Energie und Umwelt
Emissioni polveri
Dust emissions
Emission poussières
Staubemmissionen
Emission de polbo
24,3 mg/Nm3
Pr
Rendimento
Efficiency
Wirkungsgrad
Rendement
Rendimiento 90,75%
87,47%
3,12 kW
11,46 kW
378,6 mg/Nm
169,6 mg/Nm
CO @ 13% O
Back 150 mm
Side 300 mm
Reduced
Nominal
Nominal
Reduced
Nominal
Reduced
22
Reduced
Nominal
18,1 mg/Nm
3
3
3
1
2
4
5
3
6
7
9
8
15
ENGLISH
CHAP.06 TECHNICAL DATA
06.1 HOMOLOGATION
TechnicalspecicationsresultingfromlaboratorytestsconductedaccordingtoEN14785:2006testmethodsattheCERTIFICATION
institute.
Description mod.68 mod.80 UM
Burningoutput 11,46 15,86 kW
Nominalheatoutput 10,03 13,76 kW
Reducedburningoutput 2,84 3kW
Nominaloutputconsumption 2,37 2,69 kg/h
Reducedoutputconsumption 0,65 0,7 kg/h
Nominaloutputefciency 87,47 86,76 %
Reducedoutputefciency 90,75 - %
Ratedvoltage 230 230 V
Ratedfrequency 50 50 Hz
Electricalabsorptionmin(atfullcapacity)-max(duringstart-up) 170 - 365 190 - 370 W
Totalweight 105-120(star) 120-130(star) kg
Standardhoppercapacity 15 18 l
Minimumuedraught 10 12 Pa
Fumeexhaustdiam. 80 80 mm
AveragefumeTatnominaloutput 174,9 187 °C
AveragefumeTatreducedoutput 77,7 - °C
CO (13% O
2
)nominaloutput 0,014 0,032 %
CO (13% O
2
)reducedoutput 0,030 - %
Dusts(13%O
2
)nominaloutput 24,3 26,6 mg/Nm
3
NO
x
(13% O
2
)nominaloutput 145,4 -mg/Nm
3
OGC (13% O
2
)nominaloutput 6,20 4,81 mg/Nm
3
OGC (13% O
2
)reducedoutput 3,30 -mg/Nm
3
CO
2
nominaloutput 9,13 9,020 %
Nominalfumemassoutput 8,70 11,12 g/s
Reducedfumemassoutput 5,00 -g/s
Minimudistancefrominammablematerial(frontal-side-rear) 1000 - 300 - 150 300 mm
Percentagofoutputductibletootherrooms 40-60 40-60 %
Diameterpipeforductingair 80(star) 100(star) mm
Comburentairpipediameter 80 80 mm
Thedeclaredoutputmayvaryaccordingtofueltype.
The above technical specications were measured with certied quality PELLETS. ONLY use this type of fuel as
recommendedlaterinCHAP.06.2 - RECOMMENDED FUELS.
Allappliancetests,nalinspectionandne-tuningwasperformedusingtherecommendedcertiedpellets..Jolly
MecCaminettiS.p.A.isnotresponsibleformalfunctions,breakdownsorproblemsduetotheuseofpelletsthatarenot
recommended,ascombustionparametersvaryaccordingtothequalityofthepellets.
Toachievebestoperationalresults,itmaybenecessarytochangethedefaultfactorysettingsonthecontrolunitduringthe
“rststart-up”commissioningphase.TheseoperationsmustonlybeperformedbytherelativeTechnicalAssistanceCentre
(CAT),beingtheonlyoperatorsauthorisedtocompletetherststart-upactivities
WARNING
16
06.2 RECOMMENDED FUELS
Apelletproduct’sperformanceissignicantlylinkedandhighlyinuencedbythetypeandqualityofwoodenpelletsthatisburned.Itis
importanttochoosepelletsthathavenodebrisorimpurities.TheAssociationofPelletManufacturerswiththeItalianThermotechnical
Committeehaveestablishedstandardsforidentifyingpelletsintermsofenergy*.
AstheefcienciesofdifferentwoodenPELLETSqualitiesdiffer,likewisetheefciencyandheatcapacityemittedbytheproductrunning
onpelletswillvary.Similarly,unburnedresidueleftinthecombustionchamberisinverselyproportionatetopelletquality:thelowerthe
pelletpurity,thefasterdirtaccumulatesinthemachine.
JollyMecCaminettiS.p.Astronglyrecommendstheuseofthesametypeofpelletsusedduringrststart-up,i.e.whenthesettingsand
calibrationsweremadetosuittheloadedcombustiblematerials.Continuousswitchingoftypesandqualitiesofcombustiblematerials
willrequirecontinuousadjustmentstosettingsbytheTechnicalAssistanceCentre,whichcannotbeendorsedbytheManufacturer.
ThemainqualitycerticationsforPELLETSontheEuropeanmarketareDIN Plus,Ö-NormM7135andUNI EN ISO 17225-2(classA1
orA2),whichguaranteethefollowingqualitystandards:
Storepelletsatleast1mfromtheappliance,inadryplaceandnotoutdoors,notevenunderporchesorroongs.
Donotusepelletsthatareveryhardandwithdifferentdimensions;themechanicalpartsaresizedandtestedforusewithpelletswith
theabove-mentionedcharacteristics.
Nobreakdownormalfunctiondependingonthequalityofthepelletsusedand/orbythedosageofthequantitywillbecovered
bythewarranty.
PELLETQUALITYISVERYIMPORTANT;PLEASEREADTHISSECTIONCAREFULLY
WARNING
*CERTIFIEDPELLETCHARACTERISTICS
Powder 1%maximumthrougha3.2mmscreen
Apparent density
680Kg/m3minimum
Dimensions
6mmdiameterfrom25to30mmofmaximumlength
Ash content
1%maximum
Humidity
8%maximum
Heating power
4,9kWh/Kg
Packaging ineco-compatibleorbiodegradablematerialsacks
WHATYOUSHOULDKNOWABOUTPELLETS:
pelletsareobtainedbyadrawingprocessusingsawdustdiscardedbyvirginwoodprocessingsystemsandtherefore
havenochemicaladditives.Theconsistency,compactnessandstrengthwithwhichthepiecesremainintactisduetoa
substancecontainedinwoodcalledlignin;thisactsasabinderduringthecompressionphase.
Thevariousqualitiesofcombustiblematerialscanalsodependonthesawdustmixusedtoproducethepellets,which
generallyhaveastandardlengthofbetween5and30mm,adiameterofbetween5and6mm,aweightoffrom600to
700Kg/m3andahumidityofnomorethan8%ofitsweight.
Oneadvantageoverwoodisitsgreaterheatingpower;infact,whenusinggoodqualitywood,itispossibletoachieve
about4.3kWh/Kgwithahumidityrateofupto15%,whilstwithpelletsthiscanclimbto4.9kWh/Kgandawatercontent
ofamaximumof8%.
Thesacksofpelletsmustbestoredinaclean,dryplace.
NOTE
17
ENGLISH
06.3 COMPONENTS
Theinsetreplaceissuppliedwithanassembledandtestedpellethopper,packedinacardboardcontainerinawoodbox,with
polystyreneprotectionandcellophanehoodwiththefollowingcomponents:
• Usage,maintenanceandinstallationsheet
• Controlpanelwithelectroniccontrolunitmod.M10-P
Componentslist:
1.
Airdiffusiongrid(Itcanbeopenedtoextractthepellet
loadingdraweroradjusttheairdamper)
2.
Electroniccontrolunit
3.
Pellet hopper (With front extractable drawer for lling
(model Jolly Synthesis); With overhead lateral lling
(modelJollyStar)
4.
Pressostat
5.
Supportbasewithrunners
6.
Emergencyconsole
7.
Combustionfanandfumedischarge
8.
Runnersforinsetreplaceextraction
9.
HumidierAccessiblebyopeningthedoor)
10.
Airdamperregulatinglever(Accessiblebyopeningtheair
diffusiongrid;onlyJollyStarmod.)
11.
Handleforopeningdoor
12.
Door
13.
Combustionbasket
14.
Ashgrid
15.
Lockingscrewslidinginsert(Accessiblebyopeningthe
door)
16.
Pelletloadingaugergearmotor
17.
Electricalheatingelementforlighting
18.
Heatingfan
19.
Safetymicroswitch
20.
Safetythermostatwithmanualreset
21.
Mainswitch
22.
Electricalsocketwithfuse
23.
Chuteforloadingpelletsinthehopper
24.
Supportframeforducting
25.
Supportframeandcassettereplacefastening
1234
5
7
8
9
10 10
11
12
13
14
15
23
24
25
6
17 18 19
20
22
21
16
18
06.4 OPTIONALS
Automaticclosingboxforexternal
airpassageway:
Installed on the external air
passageway, it only allows for air
intake when actually necessary,
closing the cold air passage when
thegeneratorisnotrunningtothus
avoidcoolingtheinstallationroom
Insect- proof grate 230 x 230
mm:
Installed on the exterior of the
comburentairintake,itprevents
insectentrancewithinthehome.
The mesh must be periodically
cleaned since dust, pollen or
humiditycanobstructairpassage
throughthegrateovertime.
FumeconnectionpipeØ80mm:
Metallicpipeusedtoconnectthe
generatortotheue.
JointforpipeconnectionØ80
T union for fume exhaust with
condensate drain cap:
Tobeinstalledatgeneratoroutput.
Aluminiumpipeforairducting
Ø80
Adjustableairgrillsforducting
YdeviationpipeØ80
Support for internal suction grille
(onlymod.Synthesis)
19
ENGLISH
06.5 DIMENSIONS
Allmeasurementsareinmm.
-Insetreplaceforpre-existingreplaceJOLLYSYNTHESIS68-(80)
-InsetreplaceforanewreplaceandductingJOLLYSTAR68-(80)
Thepelletchuteforloadingthehoppercanbeassembled,accordingtothecladdingthathasbeenchosenon
theright,leftorfront.
NOTE
403 580
983
580
565 403
430min.
680(800)
53 53
680(800)
580
580
60
20
CHAP.07 POSITIONING AND CONNECTIONS FOR THE INSTALLER
07.1 POSITION OF EXTERNAL AIR INTAKES AND ELECTRIC CURRENT
Themachinemustonlybeinstalledonsurfacesthatcansupporttheload.If
theexistingconstructiondoesnotmeetthisrequirement,itwillbenecessary
totakeappropriatemeasures(e.g.installingaloaddistributionplate).The
machinemustbeinstalledinanareawherethemachine,gasexhaustpipes
anduecanbeeasilyaccessedforcleaning.
Theexternalairintakesmustbemadesothattheycannotgetaccidentallycovered.
WARNING
INSTALLATION IN A NEW FIREPLACE
Allmeasurementsareinmm.
1. Werecommendtomounttheboxwithauthomaticaclosurefor
theexternalfreshairentry.
2. OutdoorcombustionairoutletØ80
3. TakenoutsideairexchangeØ120
4. Electricalsocket
INSTALLATION IN A PRE-EXISTING FIREPLACE
Allmeasurementsareinmm.
1. Werecommendtomounttheboxwithauthomaticaclosurefor
theexternalfreshairentry.
2. TakenoutsideairexchangeØ120
3. Create the room with the measurements shown, starting
65mmfromthewireglassfront
4. InternalairintakeØ80foraircirculationinsideenvironmentor
tolevycombustionair
5. Electricalsocket
6. Raceway
1. Therearefourairintakepositionsfromwhichtheinstallermay
choose:
A - An air intake connecting outdoors of with a
Ø150mmexiblepipewithoutadirectconnectionto
thesupportplate.
B - An air intake connecting outdoors with a Ø120
mmexiblepipe(exchangedair)andaØ80mmpipe
(comburent air) to the support plate by its special
collars.
C- An air intake connecting outdoors with a Ø120
mmexiblepipe(exchangedair)tothesupportplate
andtheinternalairintakeinthereplaceskirtingfor
connectingaØ80exiblepipe(comburentair)once
more to the support plate (illustrated in the above
leftgure).Inthiscase, another air intake must be
createdwhichconnectstheinstallationroomwiththe
outdoors).
D- Usethegridtosupportinternalaspiration(Optional)
seepar.06.4.Inthiscase,however,isnecessaryto
createanairintakethatconnectsthelocalinstallation
withtheoutside.
1
2
3
4
6
5
260
450
400
123
4
110min.
110min.
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