I-Dea Idro Manual

I-DEA IDRO

INSTALLATION, USE AND

MAINTENANCE MANUAL

To be kept by the purchaser

QUADRA FRONTALE ANGOLO

Pellet fired stove with boiler

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.

TABLE OF CONTENTS

CHAP.01 PREMISES...................................................................................................................................4

01.1

01.2

01.3

01.4

01.5

WARNINGS .................................................................................................................................................. 4

SYMBOLOGY ............................................................................................................................................... 5

APPLIED STANDARDS ............................................................................................................................... 5

USE AND STORING OF THE INSTALLATION AND MAINTENANCE MANUAL ........................................ 6

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

04.2

WASTE MATERIALS AND THEIR DISPOSAL .......................................................................................... 11

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

06.2

06.3

06.4

06.5

HOMOLOGATION ...................................................................................................................................... 15

RECOMMENDED FUELS .......................................................................................................................... 16

COMPONENTS .......................................................................................................................................... 17

OPTIONALS ............................................................................................................................................... 18

DIMENSIONS ............................................................................................................................................. 20

CHAP.07 POSITIONING AND CONNECTIONS FOR THE INSTALLER .................................................21

07.1

07.2

07.3

07.4

07.5

07.6

07.7

07.8

HYDRAULIC CONNECTION AND EXTERNAL AIR INTAKE SETTINGS ................................................ 21

FLUE OR FUME EXHAUST SYSTEM ...................................................................................................... 22

INSTALLATION ROOM VENTILATION ..................................................................................................... 23

ELECTRIC CONNECTIONS ...................................................................................................................... 24

CONTROL UNIT ELECTRICAL WIRING DIAGRAM ................................................................................. 25

HYDRAULIC KIT ........................................................................................................................................ 28

EXTERNAL PROBE SOCKET UNIT .......................................................................................................... 30

SYSTEM CONFIGURATIONS .................................................................................................................. 31

CHAP.08 USE AND MAINTENANCE FOR THE USER ............................................................................34

08.1

08.2

08.3

08.4

08.5

08.6

08.7

APPLIANCE FUNCTIONS .......................................................................................................................... 34

CONTROL UNIT ......................................................................................................................................... 34

APPLIANCE START AND USE .................................................................................................................. 35

SAFETY THERMOSTAT WITH MANUAL RESET .................................................................................... 36

TIPS FOR THE USER ............................................................................................................................... 37

ORDINARY MAINTENANCE (by the costumer) ......................................................................................... 38

SCHEDULED PREVENTIVE MAINTENANCE ........................................................................................... 44

CHAP.09 FAULT DIAGNOSIS AND TROUBLESHOOTING ....................................................................46

09.1

09.2

PROBLEMS ................................................................................................................................................ 46

ALARM MESSAGES ................................................................................................................................. 47

SM094 EN REV04 2015_10 3

CHAP.01 PREMISES

01.1 WARNINGS

• Familiarity and compliance with the instructions given in this manual will ensure quick installation and correct use of the appliance.

• Read the manual attentively before commencing installation, and be certain to follow the directions it contains, otherwise the warranty could be invalidated and the performance and safety of the appliance jeopardized.

• The installation manual is an integral part of the product and must be given to the user.

• It must be kept in a safe place and consulted carefully, as all of the warnings provide important information on safety during installation, use and maintenance.

• Incorrect installation of the appliance could cause damage and injury to people or animals, for which the manufacture cannot not be held liable.

• Installation shall be performed by qualified operators in accordance with the regulations in force in the Country of installation.

• The manufacturer declines any contractual or non-contractual liability for damages caused by errors in installation or use of the appliance or failure to follow the instructions contained in this manual.

• All rights on the reproduction of this technical manual are owned by Jolly Mec Caminetti S.p.A.

The descriptions and illustrations provided in the following publication are not binding.

• Jolly Mec Caminetti S.p.A

reserves the right to make any modifications that may be deemed appropriate.

This manual cannot be given to third parties for perusal without the written permission of

Jolly Mec Caminetti S.p.A

• The technical directions for installation contained in this manual should be considered as basic requirements. Regulations in some countries may be more restrictive; in this instance, comply fully with the regulations prevailing in the country of installation (

all laws and local bylaws must be observed when installing and using the appliance, including those referring to national and

European standards).

• Never use the appliance as an incinerator, or in way other than that for which it was designed. Any other use is deemed improper and therefore dangerous.

• Do not use fuels that are not recommended under penalty of cancellation of the warranty.

• When the appliance is running, the glass and other visible parts reach extremely hot temperatures to the touch; handle with extreme care to avoid burns.

• Do not place the appliance in direct contact with combustible materials.

• Do not make any unauthorised modification to the appliance. Any unauthorised modification will automatically invalidate the warranty and release the manufacture from all liability.

• Use only original spare parts recommended by the manufacturer. original spare parts are available through authorised retailers, authorised Assistance Centres, or directly from Jolly Mec Caminetti S.p.A.

• Acceptance of the machine by the user must be “total”, including the sound level of operation, comparable to an electrical appliance.

Complaints for characteristics not indicated in this manual shall not be accepted.

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01.2 SYMBOLOGY

In this manual, points of considerable importance are marked with the following symbology:

INSTRUCTION:

Instructions regarding the correct use of the appliance.

WARNING:

DANGER:

This point is particularly important.

An important point regarding behaviour for preventing injury and damage to materials is expressed.

01.3 APPLIED STANDARDS

All JOLLY MEC products are constructed according to the following directives:

EU 305/2011

2006/42/CE

2014/30/UE

2014/35/UE

European construction products regulation.

Machines.

Electromagnetic compatibility (EMC).

Low voltage (LVD) - electrical safety.

• 2011/65/EU (RoHs2)

Restriction of the use of certain hazardous substances in electrical and electronic equipment

• 2014/53/UE

Radio Equipment

• 97/23/CE

Pressure Equipment (PED)

And in compliance with the standards:

• CEI EN 61000-3-2

Electromagnetic compatibility (EMC) - Limits - Limits for harmonic current emissions (equipment input current ≤ 16 A per phase).

• CEI EN 61000-3-3

Electromagnetic compatibility (EMC) - Limits. Limitation of voltage changes, voltage fluctuations and flicker in public low-voltage supply systems, for equipment with rated current ≤ 16 A per phase and not subject to conditional connection.

EN 55014-1

EN 55014-2

EN 60335-1

EN 60335-2-102

EN 62233

EN50581

EN 7129

Electromagnetic compatibility. - Requirements for household appliances, electric tools and similar apparatus - Emission

Electromagnetic compatibility – Requirements for household appliances, electric tools and similar apparatus - Immunity. Product family standard.

Safety of household electrical appliances and similar products. - General safety regulations

Safety of household electrical appliances and similar products. - Special regulations for appliances fitted with gas, diesel or solid fuel burners and electrical connections.

Measurement methods for electromagnetic fields of electrical appliances for home use and similar goods regarding human exposure.

Technical Documentation For The Assessment Of Electrical Products With Respect To The Restriction

Of Hazardous Substance.

Domestic and similar gas systems powered by the distribution mains.

5

UNI 10412-2

UNI 10683

UNI EN 303-5

UNI EN 1443

Hot water heating system - Safety requirements - Specific requirements for systems with domestic type heating devices powered by solid fuel with built-in stove, with total fire power not over 35 kW.

Heat generators operating with wood or other solid bio fuels - Installation requirements

Heating boilers. - Heating boilers for solid fuels, manually and automatically stoked, nominal heat output of up to 500 kW - Terminology, requirements, testing and marking.

Fireplaces - General requisites

UNI EN 1856-1

UNI EN 1856-2

UNI EN 13229

UNI EN 13240

Chimneys - Requirements for metal chimneys - System chimney products.

Chimneys. Requirements for metal chimneys - Metal flue liners and connecting flue pipes.

Insert appliances including open fires fired by solid fuels - Requirements and test methods

Roomheaters fired by solid fuel - Requirements and test methods

UNI EN 13384

UNI EN 14785

Fireplaces - Thermal calculations and dynamic fluid.

Residential space heating appliances fired by wood pellets - Requirements and test methods

• UNI EN ISO 12100

Machine safety.

In the UK, the product must be installed, operated and maintained complying with the following regulations and legislations:

BS 7671

EN 806

BS 8558

BS EN 14961

Requirements for electrical installations

Specifications for installations inside buildings conveying water for human consumption

Part 1 General

Part 2 Design

Part 3 Pipe sizing. Simplified method

Part 4 Installation

Part 5 Operation and maintenance

Guide to the design, installation, testing and maintenance of services supplying water for domestic use within buildings and their curtilages. Complimentary guidance to BS EN 806

Solid biofuels. Fuel specifications and classes

Part 1 General requirements

Part 2 Wood pellets for non-industrial use

Part 5 Firewood for non-industrial use

UK Planning Regulations (for further details see https://www.planningportal.gov.uk)

UK Building Regulations Approved Documents (for further details see https://www.planningportal.gov.uk)

CIBSE (for further details see https://www.cibse.org)

Microgeneration Certification Scheme (for further details see http://www.microgenerationcertification.org)

Microgeneration Installation Standards (for further details see http://www.microgenerationcertification.org)

Pressure Systems Directive (for further details see http://www.hse.gov.uk)

Health and Safety at Work Act (for further details see http://www.hse.gov.uk)

Clean Air Act 1993 (for further details see http://smokecontrol.defra.gov.uk)

The installer must check and ensure, by contacting his local Council Planning Office, that the installation does or does not require

Planning Permission and that the installation is not being installed in a Smoke Control Area (for further details see http://smokecontrol.

defra.gov.uk).

The Building Regulation Notification has to be completed prior to handing over the installation. Self-certification, in lieu of building control approval, is only permitted where installation and commissioning is undertaken by a person deemed competent and registered with a

Competent Persons Scheme (CPS) approved by the Department for Communities and Local Government (DCLG) for the scope of work being undertaken (for further details see http://www.competentperson.co.uk).

6

01.4 USE AND STORING OF THE INSTALLATION AND MAINTENANCE MANUAL

• Recipients of the manual

The use and installation manual is addressed to users responsible for the installation, operation and maintenance of the stove; particular attention must be given the parts of the manual concerning safety.

If the product is subsequently resold, the user is requested to hand over this sheet and to inform the manufacturer of the name of the new owner, so that the latter may receive any updates issued.

• Scope of the manual

The manual contains information on the correct use of the product in accordance with the purposes for which it was designed and built.

It also provides information about loads, commissioning, repair and maintenance of the stove in conformance with the limits set down by the manufacturer.

• Conservation of the manual

The installation and maintenance manual is an integral part of the product and must be conserved up to the time when the stove is dismantled. It must be kept in a protected, dry place out of direct sunlight and near the product so that it is always readily available for consultation.

Should the manual get damaged, the user must request a copy from the Manufacturer, contacting the retailer where he purchased the appliance. When requesting assistance, always make reference to the MODEL, LOT and SERIAL NUMBER indicated on the label shown in

CHAP.05.2 - PRODUCT IDENTIFICATION

.

• Updating the manual

The installation and maintenance manual reflects the status of the technology at the time the product was marketed. The manufacturer reserves the right to make modifications to the product, and consequently the relative manual, without any obligation to update previous editions.

01.5 MANUFACTURER LIABILITY AND WARRANTY CONDITIONS

Warranty terms are indicated in the enclosed card

SM081.

Upon the delivery of this manual, Jolly Mec S.p.A. cannot be held liable, whether civil or criminal, for accidents due to partial or total non-compliance with the specifications herein contained.

The manufacturer is especially held harmless from any liability in the following cases:

• Improper use of the product

• Use not intended by specific national regulations

• Incorrect installation

• Faults in the electrical connections, the connections of the fume exhaust system and/or the comburent air ducting system e and in plumbing connections

• Failure to carry out maintenance as prescribed in this manual

• Unauthorised modifications or operations

• Use of replacement parts that are non-original or not specific to the model

• Total or partial failure to follow the instructions

• Exceptional events (e.g.: breakages due to natural or accidental events as lightening, short circuits etc.)

• Damage caused by electrical power cuts, sudden fluctuation of supply voltage, electromagnetic fields

• Use of fuel with characteristics other than those recommended in this manual

In the above cases the warranty is void.

NOTE

In the event of a malfunction or intervention request by Technical Assistance, the user must be able to demonstrate the use of fuel with the characteristics required by this manual.

The Manufacturer disclaims all liability concerning anomalies or malfunctions caused by use of FUEL which does not comply with the recommended requirements.

7

CHAP.02 ACCIDENT PREVENTION / SAFETY REGULATIONS

02.1 GENERAL CONSIDERATIONS

• The manual refers to essential aspects of the directives, regulations and dispositions on using the machine, summarising its most significant points.

• General legal regulations and mandatory rules regarding injury prevention and environmental protection must be observed. These obligations also include regulations regarding the use of personal protective equipment.

• For all work to be done on the system, the following dispositions and regulations in force must be observed regarding accident prevention, following the indications.

• Before using the system the first time, the user must have read and understood the instruction manual perfectly and this chapter in particular.

• The user must also make sure that the machine is always in good condition as regards its safety requirements.

• During maintenance and inspection activities, wear the protective garments specified in following

CHAP.02.4 -

EQUIPMENT FOR OPERATORS AND MAINTENANCE PERSONNEL. Cleaning and maintenance activities

may only be performed with the equipment cold and preferably disconnected from the power mains or with the main switch in the “O” position.

• Danger warnings and signals in the form of plates, labels and markings must not be removed or made unidentifiable. If they are worn or broken, they must be replaced.

• Modifications, additions or transformations must not be made on the machine and its components without the manufacturer’s authorisation. This is valid first and foremost for installation and regulation of the installed safety devices.

Failure to comply with this warning relieves the Manufacturer of all and any responsibility.

• Make sure, before starting up every time and after carrying out maintenance, that dismantled parts have been repositioned correctly and in particular all the protection devices that impede access to the machine.

02.2 SAFETY REGULATIONS FOR ROUTINE MAINTENANCE AND USE

• The user and/or owner of the product is required, in accordance with the laws in force, to assign the installation and maintenance to qualified and specialised operators, and acknowledge the risks and hazards should they fail to observe this requirement.

• Use of this product is not permitted for children, persons with acknowledged reduced psycho-physical and sensory abilities and persons who lack experience in using such machines, unless they are supervised by designated persons responsible for their safety.

• The settings and programming of the product must only be performed by adults who have received suitable and specific training. Errors or incorrect settings can create hazardous conditions and trigger malfunctions with relative consequences for persons and things.

• Before any cleaning and/or routine or extraordinary maintenance on the machine, disconnect it from all energy sources; in particular, turn the electrical power switch to “O”.

• Prior to installation, the user and installer are obliged to check that the mains electrical supply to which the machine will be connected, corresponds to the voltage on the identification plate (see

CHAP.05.2 - PRODUCT IDENTIFICATION),

and that it is equipped with all suitable safety devices to classify the electrical system as compliant with applicable safety standards. If this is not the case, contact a Qualified Technician to adapt the system to required standards.

• Upstream from the machine (at the user’s expense) on the electrical power supply line, a bipolar switch must be installed that is able to intercept all the current phases (see

CHAP.06 - TECHNICAL DATA).

• The irradiation area includes the area between the opening of the hearth and up to 1 metre of space frontally as well as laterally. No inflammable object must be left in this area (such as: inflammable liquids, fire-starting products or firewood, drapes, wooden decorations, rugs, etc.).

• Do not use the stove to dry clothes, it could overheat and cause an outbreak of fire.

ATTENTION - BEWARE OF BURNS, most of the outer surfaces of the stove are very hot, door handle, glass, metal sides, majolica or metal top, fume exhaust pipe etc. Never touch the stove with naked hands when it is running; always use heat protection gloves, such as those supplied with the stove, when handling all parts.

• Before doing any internal cleaning or maintenance, you must wait until the machine reaches the ambient temperature.

• If the stove is in alarm status due to a malfunction, do not attempt to restart it before finding out what has caused the heat generator to shut down.

• Never wash the internal parts of the combustion chamber with water.

• In alarm status for failed start up, do not try to restart the stove until the firebox has been thoroughly cleaned.

8

• The appliance must always be started up with the firebox empty, without pellets and without unburned fuel from previous use.

• Do not attempt to ignite the fuel with inflammable liquids or solids; the stove must ignite automatically via the electrical components installed onboard.

• Do not load pellets manually into the firebox before or whilst the appliance is running.

• Keep the ventilation grids in the area the appliance is installed in clean conditions.

• Never load any fuel other than pellets into the stove storage hopper. Corn, nuts or other combustible materials must not be used as fuel for the appliance.

• Check and periodically clean the fume exhaust pipe, from the appliance to the flue (Union).

• It is strictly prohibited to start up the product with the combustion chamber door open or allow it to run with the glass broken.

• The user should contact an authorised JOLLY-MEC Technical Assistance Centre if any operating problems persist.

• Never try to start the device using ethyl alcohol or other flammable liquids.

02.3 SAFETY REGULATIONS FOR EXTRAORDINARY MAINTENANCE AND INSTALLATION

• The user and/or owner of the product is required, in accordance with the laws in force, to assign the installation and maintenance to qualified and specialised operators, and acknowledge the risks and hazards should they fail to observe this requirement.

• The installation of the heat generator and the relative combustion product exhaustion system, the electrical connections, the commissioning and extraordinary maintenance MUST always be performed by Qualified and/or Licensed Professional

Technicians or those Authorised by the Manufacturer.

• The product must be installed in accordance with the laws and standards in force in the State, Region or Area in which the machine is installed.

• Installation in bedrooms, rooms with a volume below 15 m

3

or with explosive atmospheres is strictly prohibited.

• The system installer MUST issue a Declaration of compliance for the work performed after commissioning the system, in accordance with the laws in force related to system safety standards.

• The installation technician must inform the user on safe equipment use.

• The installation operator is responsible for the installation and is therefore required to perform the work to top workmanship standards.

• The appliance must be connected to a combustion product exhaustion flue built in accordance with applicable standards and certified with a declaration of compliance.

• The installation technician is in charge of installation and must check emissions following first installation.

• Should any installation defects arise during commissioning, the Authorised Jolly-Mec Technician can refuse to endorse use of the product for safety reasons and submit a written Servicing Report to the User informing him that he and the

Installation operator shall be jointly liable for any damage to persons, animals or things if used.

• Before installing the machine, the customer and installation operator must ensure that the flooring on which it will be positioned is suitably levelled and can support the weight (see

CHAP.06 - TECHNICAL DATA). IIf there is any doubt

on the solidity of the flooring, it is essential to have a Structural Engineer verify relative installation feasibility.

• Only specialised and qualified personnel may work or carry out checks inside the machine, complying with safety regulations.

• Prior to installation, the user and installer are obliged to check that the mains electrical supply to which the machine will be connected, corresponds to the voltage on the identification plate (see

CHAP.05.2 - PRODUCT IDENTIFICATION),

check that the system is sized so as to bear the maximum load required of the product, and also that it is equipped with

9

all suitable safety devices to classify the electrical system as COMPLIANT with applicable safety standards. If this is not the case, contact a Qualified Technician to adapt the system to required standards.

• Personnel assigned to handling the machines and equipment must always wear industrial gloves and boots.

• The Maintenance Operator must recommend the Customer to sign an annual maintenance contract for the product, so as to maintain the levels of safety and efficient performance of the product.

• The Maintenance Operator must check the working hours of the product between one maintenance intervention and another, to verify the actual work load of the stove. The actual hours of operation shall be reset at the end of the Technical intervention and indicated on the Servicing Report.

02.4 EQUIPMENT FOR OPERATORS AND MAINTENANCE PERSONNEL

Every operator performing maintenance on the machine, must wear safety garments and personal protective equipment:

1 Protection headphones

2 Gloves hand protections

3 Respiratory mask

4 Face mask or goggles

5 Accident prevention boots

6 Overalls or smock

02.5 RESIDUAL RISKS

Though JOLLY MEC CAMINETTI S.p.A. does everything within its power to produce its systems with the greatest competence regarding safety and consulting all the directives, laws, and regulations available, there are still, if minor, some residual risks during the phases of:

• TRANSPORT AND INSTALLATION

• ELECTRICAL CONNECTIONS (Which must be done by a qualified electrician)

• MAINTENANCE

Therefore, the technicians who perform these tasks must take these residual risks into account.

WARNING

Removal or tampering with the protection and safety devices can be only be done voluntarily and may cause serious injury to people.

Replace the safety signals when they become illegible or come off.

10

CHAP.03 HANDLING AND TRANSPORT

03.1 RECEIVING GOODS

The machine is delivered on a pallet, packed in a wooden cage with a cellophane hood.

when receiving merchandise, check that:

• all packaging is intact

• all of the merchandise indicated on the delivery bill has actually been delivered

• the supply corresponds to the order specifications;

• if the packaging is damaged, check the condition of the contents as any breakages should be reported immediately to the carrier and retailer.

• check there is no damage to any supplied elements; if there is any breakage detected, report to the carrier and retailer as soon as possible.

If any material listed on the bill of lading is missing, inform the retailer immediately.

WARNING

Danger of suffocation

Make sure that children do not come into contact with packaging materials, plastic film or polystyrene as this could cause suffocation.

03.2 LIFTING AND TRANSPORT

Personnel in charge of handling the product must have read and thoroughly understood the safety prescriptions in

CHAP.02 -

ACCIDENT PREVENTION / SAFETY REGULATIONS of this manual and must wear work gloves and safety footwear.

For safety reasons, unauthorised persons must not be in the area while the product is being moved.

The product must be moved only with a trolley or pallet fork, and never with belts, chains, overhead cranes (see

CHAP.06 - TECHNICAL

DATA for the weight). All parts of the packaging coming into contact with the crane, belts or straps must be protected.

Unless there are obstacles, lift the product to a maximum of 30 cm from the ground and move it slowly, avoiding jerky or brusque movements.

WARNING

Danger of crushing, collision and abrasions.

11

CHAP.04 ECOLOGICAL REGULATIONS

04.1 WASTE MATERIALS AND THEIR DISPOSAL

Spare parts replaced during the machine’s product life are to be considered waste and must be taken to special collection centres or entrusted to authorised disposal centres.

Ashes must be placed in a metal container with a sealed lid. The closed container must be placed on a non-combustible base and kept away from combustible materials until all the embers have been extinguished.

Only when extinguished can ashes be thrown into the organic waste collection, naturally without nails or other non-organic materials.

Only when extinguished can ashes be disposed of according to the recycling regulations in your town.

The ashes from natural wood (untreated) derived from stove or fireplace combustion are mainly composed of calcium, silicon, potassium and magnesium oxides.

WARNING

Danger of environmental pollution

Adopt positive civic behaviour and DO NOT disperse the packaging into the environment, but take it to waste disposal centres for recycling. All packaging can be recycled, as it consists of wood, polyethylene film, polystyrene and cardboard

PROTECT THE ENVIRONMENT!!!!

04.2 DISPOSAL OF THE MACHINE

The stove is mainly composed of ferrous materials, but it may also contain:

• piping

• insulating materials

• electrical parts etc.

• refractory materials

When you no longer intend to use the stove ever again, do not dispose of it irresponsibly. Remember to:

• empty the circuit completely (if present)

• remove piping (if present)

• remove plastic parts

• remove electric cables and electric components

These materials must be disposed of by specialised firms or according to the laws of the country where it is installed.

Furthermore:

• immobilise moving parts

• make the locks on the doors inoperativ

Take the remaining part of the stove to the firms that dispose of ferrous materials.

NOTE

The machine must be disposed of in a manner that complies with the laws in force and the environment.

When taking it to the firms that dispose of ferrous materials, handle the stove as described in

CHAP.03 - HANDLING

AND TRANSPORT.

12

CHAP.05 DESCRIPTION

05.1

Frontale

Quadra

PRODUCT PRESENTATION

Jolly-Mec products are the result of over forty years experience in the wooden biomass combustion sector; they are designed and engineered to meet the increasing demands of today’s markets with high performance levels and savings enveloped in a modern design.

The I-DEA IDRO Heating stove, available in the 9 or 17 kW versions and approved according to European EN 14785:2006 standards at a third party authority accredited by the European

Commission as a machine inspection and certification institute, is a high performance electronic controlled closed circuit water heating machine without hot water production, powered with an ECOLOGIC AND ECONOMIC energy source: wooden pellets.

The I-DEA IDRO Heating stove is a single-body heater with a heat exchanger in special steel, with a particular flue gas pass and whose special structure allows it to make maximum use of the heat produced by combustion to achieve high performance that places it at the top of its category for efficiency and emissions. High yield, over 90%, and reduced polluting emissions are the characteristics that allow this device to be included in the most advanced product range on the market, permitting high energy savings and fast returns on initial investments thanks to the excellent ratio between heating power and costs provided by an innovative fuel such as pellets.

It works with forced draught, with a combustion fan for pellets and an 80 mm diameter exhaust pipe located on the rear of the stove. The pellets are fed by an auger driven by a gear motor that picks the pellets from the hopper and channels them to the firebox via a chute.

The I-DEA IDRO heating stove can be connected to a radiator or floor heating system. The heating stove comes with a previously tested standard closed tank hydraulic kit.

Combustion is controlled by means of a radio-frequency electronic control unit with the following main functions and features:

Display

Room temperature

Power levels

Operating status

Chronothermostat

Multilingual

LCD screen that provides an interface with the product to set function values and read data on work status.

On and off time setting function programmed with settable temperature regulation program.

Actual room temperature settings and display function

Control possibilities on 5 heat power levels.

Function that displays product and connected heat system operating status in real time.

Possibility to select one of five different European languages (ITA - ENG - DEU - FRA - ESP).

They are also fitted with:

• Pellet container with about 30 kg capacity and minimum level sensor*

• A practical drawer to collect the ashes.

• Heat safety device against any structural or water overheating

• Safety device against possible clogging of the flue pipe

• Fume exhaust fan

• Electrical resistance to ignite combustion and pellets

• Water circulator for the heating system

Angolo

WARNING

* Fully empty net container capacity is about 30 kg. The pellet level probe will signal when fuel supplies go into reserve. When minimum pellet level is signalled operators have about 30 minutes to refuel (the level must be covered by pellets) before the minimum level alarm is triggered.

13

Standard I-DEA IDRO Heat stove cladding includes the following components with the relevant variations for the three available models:

• Painted steel top

• Painted front grid

• Painted steel sides

• Right side opening to access the main switch, the current socket and reset the safety thermostats (pellet hopper safety and water safety)

• Painted steel pellet container cover

• Vertical exhaustion of fumes by removing the screw cap to make room for the fumes tube

• Combustion chamber door with silkscreen printed ceramic glass, resistant to a temperature of 700 °C

• Steel door open/close handle

The various elements of the cladding must be handled carefully, as being satin-finished, polished or painted, they could be scratched or dented during the handling or assembly phases.

14

05.2 PRODUCT IDENTIFICATION

6

7

8

9

1

2

3

4

5

1

It is COMPULSORY to indicate the product MODEL, the LOT number and SERIAL NUMBER in all communications with the

Manufacturer.

Identification numbers are printed on the adhesive plate located on the back of the device as illustrated on the right.

Stove performance values measured during inspection tests according to the indicated reference and EC markings are also included on the plate.

2

3

I-DEA Idro Angolo 17S

Via San Giuseppe, 2 - 24060 Telgate - BG - *

Tel. +39.035.8359211 - fax +39.035.8359200

www.jolly-mec.it - [email protected]

EN 14785:2006

14 n° DOP JM 00054 the dop was drafted on the basis to the test report of accredited laboratory the accreditation number of the laboratory is 1881 IMQ Primacontrol

Rated heat output

Nenn-Heizleistung

17,0 kW

5,0 kW

P

Reduced

Rendimento

Efficiency

Wirkungsgrad

Rendement

Rendimiento

Potenza ceduta al fluido

Power given to fluid

Potencia cedida al fluido

Massima pressione di esercizio

Max. operating pressure

Max. Betriebsdruck

Pw

14,5 kW

Nominal

3,5 kW

Reduced

3 bar

Space heating output

Heizleistung an den Raum

CO emissions

CO emission

Emission de CO

Emisión de CO

93,0 %

Nominal

94,5 %

Reduced

2,5 kW

1,5 kW

Psh

Nominal

Reduced

CO @ 13% O

130 mg/m

311 mg/m

3

Nominal

Reduced

2

Medium flue gas temperature

Abgastemperatur Mittelwert ta

126 °C

Rated electrical power

Elektr. Leistungsaufnahme

345W

110W

Ignition

Potencia eléctrica nominal

Working

Distanza minima materiali combustibili adiacenti

Min. clearance from combustible materials

Abstand zu angrenzenden entzündlichen Stoffen

Dust emissions

Emission poussières

Dust @ 13% O

11,0mg/m

3

2

11,0mg/m

3

Nominal

Reduced

Tensione/Frequenza nominale

Rated voltage/frequency

230 V

50 Hz

F = 150 cm

B = 200 mm

S = 400 mm

Leggere e seguire le istruzioni di funzionamento

Read and follow the operating instructions.

Lire et suivre les instructions de fonctionnement

Leer y seguir las instrucciones de funcionamiento

N° lotto: L000000

Cod: IDEA/A/AC

Matr: 000000

Use recommended fuels only

Verwenden Sie nur die empfohlenen Brennstoffsort*

Utiliser seulement des combustibles recommandés

Utilizar sólo los combustibles recomendados

Pellet

74

I-DEA Idro Frontale 17S

I-DEA Idro Quadra 17S

Via San Giuseppe, 2 - 24060 Telgate - BG - *

Tel. +39.035.8359211 - fax +39.035.8359200

www.jolly-mec.it - [email protected]

EN 14785:2006

Apparecchio funzionante a pellet -equipment with pellet feeding -betriebene Geräte Pellet -

équipement alimentés à granulés -equipo alimentado pellets

14 the dop was drafted on the basis to the test report of accredited laboratory the accreditation number of the laboratory is 1881 IMQ Primacontrol

Potenza termica nominale

Rated heat output

Power given to fluid

Heizleistung ans Fluid

Puissance cédée au fluide

Potencia cedida al fluido

Max. operating pressure

Max. Betriebsdruck

17,0 kW

5,0 kW

14,5 kW

3,5 kW

Nominal

Reduced

Pw

Nominal

Reduced

3 bar

Rendimento

Wirkungsgrad

Rendimiento

Potenza termica resa all'ambiente

Space heating output

Heizleistung an den Raum

2,5 kW

CO emissions

CO emission

Emission de CO

Emisión de CO

93,0 %

94,5 %

1,5 kW

3

Nominal

Reduced

Psh

Nominal

3

Reduced

CO @ 13% O

130 mg/m

311 mg/m

Nominal

Reduced

2

Medium flue gas temperature

Abgastemperatur Mittelwert ta

126 °C

Dust emissions

Emission poussières

Dust @ 13% O

11,0mg/m

3

2

11,0mg/m

3

Nominal

Reduced

Potenza elettrica nominale

Rated electrical power

345W

Ignition

Potencia eléctrica nominal

110W

Working

Distanza minima materiali combustibili adiacenti

Min. clearance from combustible materials

Abstand zu angrenzenden entzündlichen Stoffen

Rated voltage/frequency

Spannung/Nennfrequenz

Tension/Fréquence nominale

Tensión/Frecuencia nominal

230 V

50 Hz

F = 150 cm

B = 200 mm

S = 400 mm

Leggere e seguire le istruzioni di funzionamento

Read and follow the operating instructions.

Utilizzare solo combustibili raccomandati

Use recommended fuels only

N° lotto: L000000

Cod: IDEA/F/AC

Matr: 000000

Pellet 74

4

5

6

7

8

9

3

4

5

6

7

1

2

8

9

Product model

CE marking

Year of commissioning and certification

Reference standard

Performance declaration No.*

Product LOT N°

Product sales code

Product label code

Product serial number

WARNING

*Pursuant to European Regulation No. 305/2011, manufacturers are now required to have the DoP - Declaration of

Performance for each product of own design concerned; Jolly-Mec did namely provide all of these documents in downloadable electronic form that you can easily see on the website of the Company at the following address: http://www.jolly-mec.it/it/servizio-clienti/ docman.html

NOTE

The illustrated example plate may differ in graphics from the original affixed to the product.

15

CHAP.06 TECHNICAL DATA

06.1 HOMOLOGATION

Technical specifications resulting from laboratory tests conducted according to EN 14785:2006 test methods at the CERTIFICATION institute.

Description 9 kW 17 kW UM

Burnt heat output

Nominal heat power

Reduced heat output

Fluid power efficiency

Space heating output

Consumption at nominal heat output

Consumption at reduced heat output

Efficiency at nominal output

Rated voltage

Rated frequency

Electrical absorption min(at full capacity) - max(during start-up)

Device weight

Standard hopper capacity

Minimum flue draught at nominal heat output

Fume exhaust diameter

Average fume T at nominal heat output

CO (13% O

2

) at nominal heat output

Dusts (13% O

2

)

)

OGC (13% O

2

NO

X

(13% O

2

)

Mass fume flow at nominal output

Minimum air distance from inflammable side wall

Minimum air distance from inflammable rear wall

Frontal air distance from inflammable material

Testing pressure

Maximum water working pressure

Water content

Heat pump head (@ 1m3/h)

Heating pump maximum capacity (@ 0,5 m.c.l.)

Comburent air pipe diameter

6

5

60

6

2,5

17

400

200

150

10,0 [0,10]

80

88,0

168

15,0

11,0

178,0

8,2

9,1

8,5

5,0

7,5

1,0

2,0

1,0

93,5

230

50

110 - 345

165

27,0

6

5

60

6

2,5

17

400

200

150

11,0 [0,11]

80

126,0

130

11

8

125

10,7

18,3

17,0

5,0

14,5

2,5

3,8

1,0

93,0

230

50

110 - 345

165

27,0

W kg kg

%

V kg/h kg/h

Hz kW kW kW kW kW

Pa [mbar] mm

°C mg/Nm

3 mg/Nm

3 mg/Nm

3 mg/Nm

3 g/s mm mm cm l bar bar m m

3

/h mm

The declared output may vary according to fuel type

The above technical specifications were measured with certified quality PELLETS. ONLY use this type of fuel as recommended later in

CHAP.06.2 - RECOMMENDED FUELS.

WARNING

All appliance tests, final inspection and fine-tuning was performed using the recommended certified pellets.. Jolly

Mec Caminetti S.p.A. is not responsible for malfunctions, breakdowns or problems due to the use of pellets that are not recommended, as combustion parameters vary according to the quality of the pellets.

To achieve best operational results, it may be necessary to change the default factory settings on the control unit during the

“first start-up” commissioning phase. These operations must only be performed by the relative Technical Assistance Centre

(CAT), being the only operators authorised to complete the first start-up activities

16

06.2

WARNING

RECOMMENDED FUELS

PELLET QUALITY IS VERY IMPORTANT; PLEASE READ THIS SECTION CAREFULLY

A pellet product’s performance is significantly linked and highly influenced by the type and quality of wooden pellets that is burned. It is important to choose pellets that have no debris or impurities. The Association of Pellet Manufacturers with the Italian Thermotechnical

Committee have established standards for identifying pellets in terms of energy*.

As the efficiencies of different wooden PELLETS qualities differ, likewise the efficiency and heat capacity emitted by the product running on pellets will vary. Similarly, unburned residue left in the combustion chamber is inversely proportionate to pellet quality: the lower the pellet purity, the faster dirt accumulates in the machine.

Jolly Mec Caminetti S.p.A strongly recommends the use of the same type of pellets used during first start-up, i.e. when the settings and calibrations were made to suit the loaded combustible materials. Continuous switching of types and qualities of combustible materials will require continuous adjustments to settings by the Technical Assistance Centre, which can not be endorsed by the Manufacturer.

The main quality certifications for PELLETS on the European market are DIN Plus, Ö-Norm M7135 and UNI EN ISO 17225-2 (class A1 or A2), which guarantee the following quality standards:

*CERTIFIED PELLET CHARACTERISTICS

Powder

Apparent density

Dimensions

Ash content

Humidity

Heating power

Packaging

1% maximum through a 3.2 mm screen

680 Kg/m

3

minimum

6 mm diameter from 25 to 30 mm of maximum length

1% maximum

8% maximum

4,9 kWh/Kg in eco-compatible or biodegradable material sacks

Store pellets at least 1 m from the appliance, in a dry place and not outdoors, not even under porches or roofings.

Do not use pellets that are very hard and with different dimensions; the mechanical parts are sized and tested for use with pellets with the above-mentioned characteristics.

No breakdown or malfunction depending on the quality of the pellets used and/or by the dosage of the quantity will be covered by the warranty.

NOTE

WHAT YOU SHOULD KNOW ABOUT PELLETS: pellets are obtained by a drawing process using sawdust discarded by virgin wood processing systems and therefore have no chemical additives. The consistency, compactness and strength with which the pieces remain intact is due to a substance contained in wood called lignin; this acts as a binder during the compression phase.

The various qualities of combustible materials can also depend on the sawdust mix used to produce the pellets, which generally have a standard length of between 5 and 30 mm, a diameter of between 5 and 6 mm, a weight of from 600 to

700 Kg/m

3

and a humidity of no more than 8% of its weight.

One advantage over wood is its greater heating power; in fact, when using good quality wood, it is possible to achieve about 4.3kWh/Kg with a humidity rate of up to 15%, whilst with pellets this can climb to 4.9kWh/Kg and a water content of a maximum of 8%.

The sacks of pellets must be stored in a clean, dry place.

17

06.3 COMPONENTS

The device is supplied with the following components:

• Installation, use and maintenance manual

• Use and maintenance accessories (see

CHAP.08.6 - ORDINARY MAINTENANCE).

• Power cord to connect the stove to the mains.

• Cladding.

• IR Remote control (1)

• Handle for opening the door and using the scraper (2)

2

1

17

16

1

3

15

2

19

20

21

22

18

23

24

5

6

4

7

14

8

9

13

10

11

12

Part List:

1.

Tube bundle scraper

2.

Automatic air breather float valve

3.

Combustion chamber door

4.

Firebox

5.

Ash pan

6.

Combustion chamber door safety microswitch

7.

Fume inspection flap

8.

Pellet hopper

9.

Heat circulation pump

10.

Pellet loading auger gear motor

11.

Pellet loading auger

12.

Electronic control unit (accessible on removing the relative support)

13.

Safety thermostat with manual reset

14.

Socket group panel

15.

LCD display

16.

Pellet loading chute

17.

3 bar safety valve

18.

Pellet loading lid

19.

Pressure switch

20.

Expansion tank

21.

Comburent air intake tube Ø 60 mm

22.

Hydraulic connections

23.

Fume exhaust pipe Ø80 mm

24.

Combustion and fume exhaust fan

18

06.4 OPTIONALS

Automatic closing box for external air passageway:

Installed on the external air passageway, it only allows for air intake when actually necessary, closing the cold air passage when the generator is not running to thus avoid cooling the installation room

Insect- proof grate 230 x 230 mm:

Installed on the exterior of the comburent air intake, it prevents insect entrance within the home. The mesh must be periodically cleaned since dust, pollen or humidity can obstruct air passage through the grate over time.

Zone module:

Essential device for correct zone control with the pellet stove.

The module can separately manage systems with zone valves or systems with zone circulators and a secondary Puffer intake circulator.

Remote thermostat module:

Installed in the home, it is used to easily control stove operations and adjust necessary temperatures from within the home.

Temperature time settings or personalised heating profiles can be set.

Receiver:

This device receives the signal via radio from the ambient thermostat.

Radio digital thermostat:

This device is a radio thermostat display to control the room temperature and use in conjunction with the receiver

Room temperature probe:

This device reads the room temperature.

Aluminium foil pipe Ø60mm:

Pipe for external connection of the comburent air pipe.

19

Fume exhaust kit rear outlet

Fume connection pipe L300/L250mm Ø80mm:

Metallic pipe used to connect the generator to the flue.

T union for fume exhaust with condensate drain cap:

To be installed at generator output. Ø80mm for union connection and Ø100mm for flue connection.

Fume exhaust pipe Ø100mm:

Metallic pipe used to connect the generator to the flue.

Fume exhaust kit vertical outlet

Connection band:

Band to fasten the fume exhaust pipe to the stove.

20

Fume exhaust pipe Ø80mm:

Metallic pipe used to connect the generator to the flue

(the pipe serves the first outlet section of the device, to be used as a flue union)

06.5 DIMENSIONS

All measurements are in mm.

A

B

C

Frontale

1134

346

852

Quadra

1134

346

852

Angolo

1134

346

862

A

Frontale

B

C

A

Quadra

B

A

C

B

Angolo

C

21

B

CHAP.07 POSITIONING AND CONNECTIONS FOR THE INSTALLER

07.1

F ig

.1

400

HYDRAULIC CONNECTION AND EXTERNAL AIR INTAKE SETTINGS

max 1250

The device must only be installed indoors and on surfaces that can support the load. If the existing construction does not meet this requirement, it will be necessary to take appropriate measures (e.g. installing a load distribution plate). The appliance must be installed in an area where the appliance itself, gas exhaust pipes and flue can be easily accessed for maintenance.

F ig

. 1 and 2 illustrate pipe functions and minimum distances that must be observed. All measurements are in mm.

102,6

425

30,9

40

291,5

The lateral distance from the adjacent wall, according to installation, is to be maintained on both sides.

1.

2.

3.

Fume exhaust Ø80 F

Air intake Ø60

System flow ¾”M

4.

5.

6.

7.

Safety valve discharge ½”M

System return ¾”M

System feed* ½” M

System discharge ¾”M

F ig

.2

400

1

2

NOTE

As indicated in the national reference standard UNI

10683:2012, the product cannot be installed in rooms with a volume of under 15 m

3

.

3

4

5

NOTE

Bear in mind that the minimum distances from inflammable materials are:

6

Minimum air distance from inflammable side wall: 400 mm

Minimum air distance from inflammable rear wall: 200 mm

Frontal air distance from inflammable material: 150 cm

7

As indicated in

CHAP.06.1 - OMOLOGAZIONE

NOTE

The external air intakes must be made so that they cannot get accidentally covered and if they have an insect protection mesh they must be cleaned periodically to prevent clogging with dust and dirt, especially in periods with intense pollen concentrations.

NOTE

The hydraulic kit does not include cut-off valves. Therefore, we recommend these valves are installed on each stove hydraulic connection during installation.

Use outlet type valves leaving the pulley towards the stove (see

CHAP.07.6 - HYDRAULIC KIT).

*FOR THE SYSTEM FEED THE COLD WATER MUST BE CONNECTED TO THE APPLIANCE.

WARNING

At the end of installation, accurately clean the heating system to eliminate all work residue. Dirt deposits can cause hydraulic components installed on the device such as the water circulator, anti-condensation valve, automatic air breather valve and safety valve to malfunction.

Maintenance for problems due to these faults is not covered by the Jolly Mec warranty.

22

C

07.2 FLUE OR FUME EXHAUST SYSTEM

The flue or fume exhaust system is a fundamental element for the proper functioning of the stove and must comply with the requirements of The Building Regulations Part J and with the following general standards:

EN1856-1

EN1856-2

UNI 10683

Chimneys. Requirements for metal chimneys - Part 1: System chimney products

Chimneys. Requirements for metal chimneys - Part 2: Metal flue liners and connecting flue pipes

Heat generators operating with wood or other solid bio fuels - Installation requirements

The diameter of the flue must be sized according to the technical specifications of the appliance and type and place of installation. Each appliance must have its own chimney flue without any inlets from other appliances.

The exhaust duct of the combustion products generated by the forced draught equipment must respond to the following requirements:

• it is necessary to use union joints and pipes with pressure resistant seals, as the union of the flue could be slightly pressurised while the appliance running

• all changes in direction must be open to inspection to facilitate maintenance

• correct draught to maintain depression in the combustion chamber, as per the technical specifications, must be guaranteed

• it must be watertight, waterproof and suitably isolated and insulated

• must be made of suitable materials that resist normal mechanical stress, heat, the action of the combustion products and acid condensations

• must be prevailingly vertical structures with deviations from the axis not greater that 45°

• must be adequately distanced from combustible or inflammable materials via an air space or suitable insulation (as indicated in

The Building Regulations Part J - Diagram 13).

• must have an internal section which is preferably circular: square or rectangular sections must have rounded corners with a radius of no less than 20 mm

• must have an internal section that is constant, free and independent

If the flue is installed externally it must be insulated to prevent the cooling of fumes and formation of condensation. The same is valid for the tract from the roof to the chimney cap (Torrino). For the union between the stove and the flue, or if there are deviations or curves, for easier, quicker and safer installation, we recommend using double-walled stainless steel pipes.

The use of pipes in fibre cement for connecting the equipment to the flue is forbidden.

Exhaust pipes must not run through rooms where the installation of combustion equipment is forbidden.

The union must be connected to the flue in such a way as to ensure they remain airtight when the appliance is operating in pressurised

F ig

. 1

conditions and to avoid the formation of condensation and its conveyance to the appliance.

1

It has to be avoid, as much as possible, the assembly of horizontal sections. In any case, the horizontal segment (or its horizontal projection) do not have to be longer than two meters with minimum slope not less than 5%. The horizontal section does not have to be connected directly to the smoke fan output but after the first vertical segment (6) F

ig

.1.

2

3

The chimney system for the smoke exhaust MUST be dimensioned and projected by a Qualified Engineer. He will determine the proper smoke exhaust system taking into consideration the product technical data, kind of installation, installation location and mostly the installation technical regulation in force. The Engineer will give indications to the installer about the materials to use, smoke path section, insulation thickness, corrosion resistance and all requirements needed for the correct working of the system product-chimney.

2

4

5

6

1

2

3

4

6

. Airtight steel sheet metal

. 45° Curves

. Fume exhaust

. External insulated flue

5

. Insulated T union for condensation

. Non-insulated pipe

The correct dimension of the air intake for ventilation and aeration of the installation location MUST be verified in conformity with the technical regulation in force.

Malfunctioning of the product caused by a smoke exhaust not properly projected and dimensioned WILL NOT be object of objections to Jolly Mec and interventions at Jolly

Mec charge.

For appliance that must reach ceiling or wall exhaust outlets that are not coaxial with regard to the issue of the fumes from the machine, changes in direction must be made using an open elbow of 45° (see F

ig

.1).

The outlet from a flue should be above the roof of the building in a position where the products of combustion can discharges freely and will not present a fire hazard, whatever the wind conditions. Flue outlet positions which can meet the requirements in common circumstances are shown in F

ig

. 2 (The Building

Regulations Part J - Diagram 17) while F

ig

. 3 (The Building

Regulations Part J - Diagram 18) shows flue outlet positions

23

F ig

. 2

Datum for horizontal measurments

A

B

C

D

150 mm max.

Datum for vertical measurments

Regulated building Adjacent building

The datum for vertical measurments is the point of discharge of the flue, or 150 mm above the insulation, whichever is the lower

Point Where flue passes through weather surface (Notes 1, 2)

Clearances to flue outlet

A

B

At or within 600 mm of the ridge At least 600 mm above the ridge

Elsewhere on a roof (whether pitched or flat)

At least 2300 mm horizontally from the nearest point on the weather surface and: a) at least 1000 mm above the highest point of intersection of the chimney and the weather surface; or b) at least as high as the ridge

At least 1000 mm above the top of the opening

C

Below (on a pitched roof) or within

2300 mm horizontally to an openable rooflight, dormer window or other opening (Note 3)

D

Within 2300 mm of an adjoining or adjacent building wether or not beyond the boundary (Note 4)

At least 600 mm above any part of the adjacent building within 2300 mm.

Notes

1. The weather surface is the building external surface, such as its roof, tiles or external walls.

2. A flat roofs has a pitch less than 10°

3. The clearances given for A or B, as appropriate, will also apply.

4. A vertical flue fixed to an outside wall should be treated as equivalent to an inside flue emerging at the nearest edge of the roof.

F ig

. 3

east mm

Area Location of flue outlet

A

At least 1800 mm vertically above the weather surface and at least 600 mm above the ridge.

B

At least 1800 mm vertically above the weather surface and at least 2300 mm horizontally from the weather surface.

Outlet should be above the shaded areas where flue discharges in proximity to roofs with surfaces readily ignitable, such as where roofs are covered in thatch or shingles.

The use of counter slope elements is forbidden. The flue union must have a constant section and allow soot to be collected and swept away. Changes in cross-section are only allowed at the outlet of the heat generator: the use of adaptors on the coupling with the chimney flue is prohibited.

Running other air ducts and installation pipes inside the exhaust pipes, even if oversized, is forbidden.

In the event of a black-out, suitable sizing of the fume exhaust system guarantees sufficient draught to exhaust the fumes generated by combustion without the use of the electric exhaust fan.

If the performance of the fume exhaust system is not excellent, it is possible to adjust the operating settings of the stove to overcome draught defects by a maximum of 15% of the fume exhaust device; this adjustment is however the exclusive competence of the Technical

Assistance Centre CAT.

One airtight reading point is recommended on the flue to check emissions after installation and measure draught.

24

Supporting the weight of the flue with the appliance union is strictly forbidden. Use specific stands or independent supports for this purpose.

To install other combustion devices in the same room where the pellet appliance is installed, refer to UNI 10683 and UNI 7129 installation regulations.

The minimum flue height must be over 3,0 m.

Blocking of wall exhaust terminals at any height and any distance from openings, doors and/or windows is not permitted and a very important rule to follow.

Installation of external fireplaces must be performed using insulated double-walled pipes, to prevent the formation of condensate; it must also be possible to inspect the base of the fireplace for routine maintenance which must be done at least once a year.

A windproof chimney cap must be installed; in the presence of adverse weather conditions, especially high winds, this accessory allows the stove flue draught system to operate much easier.

A minimum flue draught between 10 and 14 Pa must be guaranteed. This value must be measured using specific and controlled instruments each time the appliance and flue undergo maintenance. With strong winds and the chimney cap installed in the reflux area

(see F

ig

.4, zone bordered by the dotted line A for roofs with ß>10° slant) of the roof or without complying with the distances foreseen by UNI 10683 situations may arise where the stove does not work which will trigger the no depression alarm. It is not possible to make corrections or reset the stove operating values to override the alarm.

F ig

. 4

A

ß>10°

.

.

90°

130 cm

07.3 INSTALLATION ROOM VENTILATION

According to reference regulation UNI10683, 4 Pa depression must be verified between the installation room interior and exterior.

Prepare adequate ventilation openings in the room where the product is installed to permit at least 50 m³/h clean comburent air flow not taken from polluted rooms. The ventilation openings, if fitted with insect-proof mesh, must be easily removable and undergo periodic cleaning to ensure clear air flow passage.

If the comburent air inlet is directly connected to the stove, it may be necessary to make adjustments to the control unit, especially during the start-up phase, as the temperature and humidity of outdoor air not only varies during the period of use of the product, but also come into direct contact with the pellets and the ignition element, generating different fuel burning times.

Jolly Mec allows the ducting system at the input of the combustion air within and not over the following limits: the length can’t be longer that 1000 mm, the diameter has to have at least the same section of the stove/boiler connection, it is possible only one 90° change of direction, the center-to-center distance of the combustion air input pipe can be ± 300 mm.

WARNING

As for the fuel product exhaust system, air vents are also extremely important and must be given the appropriate consideration and respect.

The installer is directly liable for all electrical system parts, generation hook-up to the system, ventilation and the fume exhaust system and MUST, at the end of installation work, issue a declaration of conformity as per Ministerial Decree 37/08.

On the other hand, the purchaser MUST assign all work to a qualified professional technician.

The device must be installed and used in accordance with all local and national laws and EC Regulations

NOTE

It is only recommended to connect the comburent air ducting system to the stove if absolutely necessary. Very cold air and humidity may cause difficulties during the stove ignition phase.

WARNING

It is not allowed to install coaxial systems for the smoke output.

25

07.4 ELECTRIC CONNECTIONS

Connect the 230Vac 50Hz line with the proper cable with plug, supplied with the appliance, which powers up the control unit and all the appliance’s electrical components.

The device is equipped with a power socket and fuse, a spare fuse in the pan and a bipolar switch. In the event that the control unit does not switch on, even after turning the switch to “

I” (ONE), check that the fuse has not blown.

1.

Control unit manual

2.

Earth

3.

Power socket with cord included

4.

Switch

5.

Fuse Ø5X20 F4A 250V IEC 127-II

1

2

5

N

F

3

4

N

F

5

WARNING

Electrical connections must be carried out by skilled personnel according to the regulations in force (2014/30/UE and 2014/35/UE).

26

07.5 CONTROL UNIT ELECTRICAL WIRING DIAGRAM

WARNING

Electrical connections must be carried out by skilled personnel according to the regulations in force (2014/30/UE and 2014/35/UE).

Following is a list of electrical components illustrated in the layout on the next page:

TABLE OF COMPONENTS

POSITION CODE DESCRIPTION

4

25

34

35

38

39

26

28

29

40

41

42

18

19

23

24

11

12

15

16

5

6

DEVIATRICE/1

RESISTENZA/6

CIRCOLATORE/1

VENT/1

MOTOR/17

TERMOSTATO/13

TERMOSTATO/4

PRESSOSTATO/2

MICRO/1

SONDA/3

SONDA/3

SONDA/3

SONDA/1

TRASDUTTORE

SENS/1

DISPLAY/11

DEBIMETRO/1

QUA/PELLET/4

CONNETTORE/4

CONNETTORE/4

CONNETTORE/2

FILTRO/1

Deviator value for household boiler, installation with layout 6 and 7, terminal 02.

Connection to terminal board B

Electrical resistance to start pellet burning, terminal 04

High-efficiency stove water circulator, terminal 05

Fume exhaust fan, terminal T3

Load pellet auger gearmotor, terminal T2

Stove water safety thermostat with manual reset, terminal AC2

Pellet hopper safety thermostat with manual reset, terminal AC3

Fume exhaust fan safety depressimeter, terminal AC5

Door contact safety microswitch, terminal IN9

Stove water temperature probe electrical connection, terminal IN2

Room probe electrical connection, terminal IN3. Connection also to terminal A for external probe or thermostat connections.

Safety probe electrical connection for internal temperature inside the stove cladding, terminal IN4

Fume temperature probe electrical connection, terminal -TC+

Stove water pressure transducer, terminal IN5

Pellet level probe, terminal IN6

Command display, DISPLAY terminal CN14

Comburent air flow probe, FLOWMETER terminal CN16

Motherboard

12-way union for probes and external devices

12-way union for probes and external devices

12-way union for ambient probes

RC filter for 3 way valve

27

28

BLACK

YELLOW

BLUE

BLACK

WHITE

14

15

16

18

17

H2O Safety Ther.

Safety Therm.

Pressure Safety

13

31

30

29

28

21

20

19

26

25

24

23

22

33

32

-TC+

Smoke Probe

IN4

IN3

Safety Probe

ROOM Probe

Terminal A

IN2

IN1

Water Probe

DHW Hi Probe

Terminal A

Red - Blue

Orange

Violet

White

Red

IN11

DHW Lo Probe

Terminal A

IN10

External Cont.

Terminal A

IN9

Door Microsw.

Brown

Grey

Black

IN8

IN7

Buffer Hi Probe

Terminal A

Buffer Lo Probe

Terminal A

IN6

Pellet Level

IN5

Pressure Probe

OC

27

Zone Module

Terminal A

Yellow

Green

Black - Blue - Brown

Green - Violet - Yellow

Black - Red

OC

Therm-. Module

Terminal B

Black - Red

Violet - Red - Orange - White

FLOWMETER

Debimeter

35

Flat Cable

36 37

Black - Red - Blue

Black - Red - Blue

34

Orange

White

Blue

Yellow - Green

Violet

Red

Yellow

White

Grey

Pink

Yellow

Blue

Blue

Brown

Blue

Black

CN1 - C

CN1 - NC

CN1 - NO

CN2 - N

CN3 - F

CN2 - O2

CN2 - O7

CN2 - N

CN12 - +

CN12 - -

Black - Red - Blue

11

Blue

Yellow - Green

Smoke Fan

Pellet Auger

10

9

12

230V ac

Filtro/1

3 way Valve DHW

Terminal B

Elect. Heat Element

Stove Pump

Aux/Buffer Pump

Terminal B

GAS Exchange

Terminal B

1

38

8

4

5

3

42

6

7

2

39

TERMINAL "A"

21

31

20

22

30

33

CN9 - IN10

CN9 - IN10

CN10 - IN1

CN10 - IN1

CN9 - IN11

CN9 - IN11

CN11 - IN8

CN11 - IN8

CN11 - IN7

CN11 - IN7

CN13 - +

CN13 - -

Brown

Yellow

Yellow

Green

Green

Red

Black

Grey

Grey

Red

Red

Brown

CONTATTO

ESTERNO

SONDA

BOILER Hi

SONDA

BOILER Lo

SONDA

PUFFER Hi

SONDA

PUFFER Lo

ONDE

CONVOGLIATE

40

TERMINAL "B"

2

4

7

CN1 - C

CN1 - NC

CN1 - NO

CN2 - N

CN3 - F

CN2 - O2

CN2 - O7

CN2 - N

Pink

White

Grey

Blue

Brown

Black

Yellow

Blue

32

CN12 - +

CN12 - -

Red

Black

41

SONDA AMBIENTE

CALDAIA

GAS

TRE VIE

ACS

POMPA

AUX/PUFFER

ONDE

CONVOGLIATE

CN10 - IN3 Violet

24

CN10 - IN3 Violet

NOTE

The representation of the components is approximate, but they can change in terms of shape.

29

07.6 HYDRAULIC KIT

The water heating stove comes with a standard pre-installed hydraulic kit without domestic hot water production (DHW)

In F

ig

. 1 e 3 illustrate hydraulic kit component. Following is an itemised list of these components:

F ig

. 1

1.

2.

3.

4.

3 litre expansion tank (pre-load 1,5 bar)

Heat circulation pump

Anti-condensation valve

Safety valve discharge ½”M

8

1

2

5.

6.

7.

8.

9.

10.

11.

12.

System discharge ¾”M

System feed* ½” M

System return ¾”M

System flow ¾”M

Outlet (pulley), to be installed facing the stove

Cut-off valve (not included, supplied by the customer)

Pressure transducer

Hydrometer

9

10

6

5

7

4

3

F ig

. 2 illustrates the air breather unit:

A.

B.

C.

Air breather valve

Stove water temperature probe and water safety thermostat probe well

Safety valve 3 bar

F ig

. 2

A

F ig

. 3

B

D

C

11

12

WARNING

The installation operator is obliged to check that the closed expansion tank, supplied with the stove, has a capacity which is suitable for the system it will be connected to. For medium/large systems, a heat technician should inspect and calculate the needs of the rooms to be heated according to current regulations.

WARNING

1-1.2 bar cold pressurised water must always be in the stove. Topping up pressure is manual. After topping up, make sure the valve is closed.

30

• High Efficiency circulator

The heating stove is fitted with a high-efficiency circulator that generates low energy consumptions with an energy saving of about 60% compared to a traditional circulator.

The heater system engineer can choose from two operating modes:

• Constant pressure mode

• Variable pressure mode

Conforming to EU energy saving regulations ErP-2015.

The figure below represents a detail of the high efficiency circulator.

Variable ∆p

Venting Cycle

RKA

Constant ∆p

Red Knob to adjust the position of Variable ∆p,

Venting cycle and the Constant ∆p

Pump led colour key:

Off

LED DESCRIPTION OF FUNCTIONS

Circulator not connected to the mains.

Flashing green With the vertical knob in air position, for ten minutes the pump performs high speed operating cycles alternating with stand-bys to bleed the air from the system.

Green - Red

Flashing

Electrically powered pump at a standstill.

It may be under powered T<160V or over powered T>253V.

The engine thermal protection may have tripped due to overheating.

Flashing red

Green

Blocked Pump.

Switch off and then switch the pump back on, if the problem persists check the cause of the blocking or replace the pump.

Standard operations.

31

07.7

F ig

. 1

EXTERNAL PROBE SOCKET UNIT

A B

A

B

E

F

C

D

H

I

J

K

G

External probe socket unit (F

ig

. 1):

A

Connection for any external contact to turn the device on and off

B

Terminal for high Boiler temperature probe connection

C

Terminal for low Boiler temperature probe connection

D

Terminal for high Puffer temperature probe connection

E

Terminal for low Puffer temperature probe connection

F

Terminal for conveyed wave connection between device electronic board and any zone module.

G

Terminal for remote room probe connection. In this case the internal probe must be disconnected, or the probe on-board the device can remain connected if a room thermostat is connected.

H

Terminal for gas stove connection and for electric by-pass

I

Terminal for external three-way diverter valve connection for domestic hot water boiler

J

Terminal for connection to the auxiliary pump in layouts 1 and 3 and connection to the pump puffer in layouts 5 and 7.

K

Terminal for conveyed wave connection between device electronic board and any thermostat module.

32

07.8 SYSTEM CONFIGURATIONS

Different hydraulic system configurations are possible with the device to allow for better operations based on the system solution adopted in the installation phase.

Factory settings are set in CONFIGURATION 1 in MENU 9 – TECHNIC SETTINGS, in the SETTINGS RUNNING page, accessible to the user in the stove status page in MENU 8.

These settings must be set by the Installation technician or Service Technician (CAT) during first ignition inspection. Available system configurations are numbered up to 7 and itemised below:

NOTE

A

Use the C N

C

N

O

B

connector to enable or disable a parallel heat source based on pellet stove operations: with the pellet stove OFF,

ALARM ON and ALARM MEMORY, a parallel source can be enabled. In all other conditions, stove operations takes precedence.

CONFIGURATION 1 – Heating -

Device configuration for heating only, without the possibility of managing a zone system, an external Boiler for Domestic Hot Water

(hereinafter DHW) or Puffer for inert heat accumulation.

Summer operating mode cannot be set. Instead, the CRONO timer function or STAND-BY.

The appliance, once the ROOM TEMPERATURE and BOILER

WATER are set, runs at the set power until one of the two temperatures is reached, then switching to ECONOMY. When the appliance is running in ECONOMY mode to reach ROOM

TEMPERATURE, the water circulation pump turns off and only turns back on to run the discharge function when the stove temperature is 80°C, to then stop at 75°C, or at a new request by the room probe. It must be checked whether there are hydraulic interceptions between the device and system that could slow water flow and thus cause stove water overtemperature alarms (Alarm AL19 THERMIC

WATER).

For the room probe type, a thermostat or chronothermostat can be used, connecting it to the device side terminal boards, inside the right side panel, in line with the terminal board, in the AMB PROBE connector, as illustrated.

To use the external thermostat (or Jolly Mec thermostat module), which must have a CLEAN CONTACT, set the THERMOSTAT as

ROOM PROBE in MENU 4 – SET PROBE. A remote temperature probe can also be used as a room probe, always connecting it to the same terminal board but in this case, the temperature probed secured on the device back panel must be electrically disconnected from the electronic board by the Installation technician or Service technician (CAT).

We recommend using the Jolly Mec thermostat module as the room temperature probe, connecting it to the device back panel. With the thermostat module, all appliance functions can be fully controlled including setting operating times, selecting one of the 5 adjustable heat profiles, adjusting working temperatures, being alerted when pellets end.

33

34

A B

A B

CONFIGURATION 3 – Zone heating -

Configuration identical to CONFIGURATION 1, with the addition of a zone module to manage a system with up to four zones per module, with zone valves or zone circulators. If the module is used, parameter Pr90 must be activated in the TECHNIC SETTINGS in the

SETTINGS GENERAL page, setting the value to ON. The module allows all thermostats to be received in input (CLEAN CONTACT) and to activate the relevant outputs (CLEAN CONTACTS) that can be used for zone valves or circulators. Connection between the stove and expansion module must include the terminal from the module

OC connector to the stove back panel OC terminal. Zone module electrical power must be protected by the same circuit breaker that powers the stove.

WARNING

For stove maintenance, if the zone module is powered by a different mains than the stove, also cut off module power. Electrical connections between the two electronic parts could power the stove board even if unplugged and vice versa.

CONFIGURATION 5 – Puffer-

The appliance is connected to a Puffer (inert heat tank) and not directly to the heating system. PUFFER TEMPERATURE must be set. Room temperature control is not considered. However, make sure the room probe type is set to THERMOSTAT in MENU 4 and that the connection to the AMB PROBE terminal on the back of the appliance is always electrically open.

In CONFIGURATION 5, the appliance only ensures that the temperature probe connected to the PUFF Hi terminal meets set temperature settings.

When the puffer temperature is met, the appliance switches to

ECONOMY mode, turning off the pump. When puffer temperature drops 5°C (default value that can be adjusted in MENU 9 – TECHNIC

SETTINGS) under the set value, the appliance resumes operations at the set power, turning the circulation pump back on when stove water temperature is higher than PUFFER TEMPERATURE.

In this configuration, the STAND-BY function is automatically activated and turns the appliance off when in ECONOMY mode for a period of time longer than that set in MENU 5 – SET STAND-BY, at the DELAY OFF value.

When the appliance is in Stand-by, thus waiting to turn back on, the only input that can turn the appliance on is the PUFF Lo probe value which, at PUFFER SET TEMPERATURE -10 °C, permits restart.

The differential restart value can be set in MENU 9, password protected for the service technician.

The zone module can be used with CONFIGURATION 5. In addition to the room thermostats and zone valves or circulators, a secondary circuit circulator can also be connected to the zone module and activated by a specific parameters in the TECHNIC SETTINGS menu.

For further information on zone module use, see the specific user manual.

If the heat accumulator is equipped with an internal coil for DHW production, summer mode can be set. In this mode the appliance only considers Puffer temperature settings and ignores any zone module and/or room requests.

A B

CONFIGURATION 6 – Boiler -

The boiler is connected to the heating system and in parallel with an accumulation tank for DHW production. In this configuration, the heating part is identical to the functions described in

CONFIGURATION 1 while the boiler takes precedence over the heating system request. The boiler probe, connected to the boiler back terminal board, works with a 5°C temperature differential from the set BOILER TEMPERATURE, to activate the three-way diverter valve. The stand-by function can also be set in this conditions and, if all utilities are met, the boiler will await restart.

LO boiler probe request (low boiler probe) takes precedence with a -10°C set differential to the set BOILER TEMPERATURE (this differential can be modified by the service technician in the technical menu).

To use the zone module with CONFIGURATION 6, refer to the specific user manual.

If SUMMER mode is set, the three-way valve will be set towards the boiler and the STAND-BY function is automatically activated.

When boiler temperature is met, the boiler awaits restart and, when shutting down, if heat dissipation is required, heat is dissipated to the heating system.

CONFIGURATION 7 – Puffer + Boiler -

CONFIGURATION 7 is a mix between CONFIGURATION 5 and

CONFIGURATION 6, Puffer and Boiler are connected in parallel to the boiler. The functions described in the relevant configurations also apply to CONFIGURATION 7, with the domestic hot water boiler taking precedence.

WARNING

At the end of installation, accurately clean the heating system to eliminate all work residue. Dirt deposits can cause hydraulic components installed on the device such as the water circulator, anti-condensation valve, automatic air breather valve and safety valve to malfunction.

Maintenance for problems due to these faults are not covered by the Jolly Mec warranty.

35

CHAP.08 USE AND MAINTENANCE FOR THE USER

08.1 APPLIANCE FUNCTIONS

The appliance electronically controls pellet combustion and water distribution to utilities.

Pellets are taken from the storage tank by the gear motor driven auger and transported directly to the burn pot. The tank is filled through the lid, at the top of the cladding to permit access to the container chute. Pellets must be placed in the tank with a shovel and not directly poured from the bag (see vedi

CHAP.08.6 - ORDINARY MAINTENANCE (by the costumer))

Ignition is through air aspirated into the burn pot by the centrifuge fan and brought to high temperature by heating an electrical resistance.

The fireplace is made up of a special steel heat exchanger, closed at the front by a ceramic glass door. The exchanger has a gas pass that allows it to be defined as a flue stove, whose constructions fully exploits the heat produced by combustion.

The quantity of fuel, the feeding of comburent air and the extraction of fumes are regulated with an electronic card in order to obtain a highly efficient combustion.

All the operations for managing machine functions are handled by the supplied control unit installed on the device (see manual SM096

EN attached).

08.2 CONTROL UNIT

The electronic control unit controls all appliance functions and is controlled via a control display.

The electronic control unit features a timer function with customisable programmes and a user-friendly operating settings. Operations are controlled by the ROOM PROBE standard installed, that can be prolonged to the installation room in a more appropriate position to correctly measure room temperature. The Jolly Mec thermostat module can also be used as a room probe.

The electric/electronic elements also include certain systems that have a safety and also regulating function:

FUME TEMPERATURE PROBE

PRESSURE SWITCH

SAFETY THERMOSTAT

WATER SAFETY THERMOSTAT

Fitted inside the fume exhaust fan

Connected to the fume exhaust fan

Triggers when temperature in the appliance is too high

Triggers when water temperature is above the maximum permissible value

The control display lets you use the following main functions:

• Device start and stop

• 5 heating output level adjustment

• Regulate the desired ambient temperature.

• Optimise combustion.

• Manage the timed thermostat with several daily start ups.

• Report any function irregularities.

• Indicate the heating stove’s operating mode.

• Regulating the boiler, stove and puffer water temperatures.

NOTE

For a full and detailed description of the content in this section, see the enclosed manual SM096 EN

36

08.3 APPLIANCE START AND USE

After professionally installing the room ventilation system, the fume exhaust system, the hydraulic system and electrical system according to the relevant regulations, the CAT can commission the first start up.

After passing the Service Technician’s inspection, the tank can be filled with pellets of the recommended quality, desired temperature and power set (we recommend setting level 3) and the device turned on with Button

3. The stove will run until the room probe, thermostat or

accumulation tank probe temperature values are reached, according to the set configuration. When the set temperatures are reached, the stove switches to ECONOMY mode until a new request is sent by the probes.

When running in ECONOMY mode, the water circulation pump is off and only turns back on to dissipate heat when stove water reaches

80°C, turning back off at 75°C. For this reason, any system zone valves must be adequately controlled to permit water circulation with room temperature. For this purpose, the Jolly Mec ZONE MODULE (available separately) resolves the problem of alarms due to stove water overheating when zone valves are closed.

Activate STAND-BY mode in MENU 5 to turn off the stove when all probe temperatures are reached for a time over that set in MENU 5

(DELAY OFF). The stove is not actually off but is waiting to turn back on at a new probe request.

The STAND-BY function in system configurations 5 and 7, summer and winter mode, and configuration 6, summer mode, is automatically activated. When the Puffer and/or Boiler tank has reached the set temperature, the boiler will turn off and turn back on when the temperature measured by the Puffer Lo probe or Boiler probe is 10°C lower than the set temperature. The differential value can be modified by the CAT.

Set SET CHRONO – MENU 2 to time operation start and stop. The crono can be quickly started by pressing Button 1 and 2 on the main display screen. CHRONO and STAND-BY modes cannot be activated simultaneously. The CHRONO function should be considered as a timer function, while STAND-BY is a temperature function. It is possible to set the desired temperature level for each time band.

The message ORDINARY SERVICE is periodically displayed, every 100 hours of operation, to remind the user to clean the stove thoroughly CHAP.08.6 - ROUTINE MAINTENANCE (By the Customer). Press Button

3 in the main screen to cancel the message.

In the event of alarms and/or manual pellet load from MENU 7, message CLEAN BRAZIER is a warning to be sure not to turn on the stove with excessive pellets in the brazier. To cancel the message, clean the brazier and press and hold down Button

3 for three

seconds. Cleaning the firebox obviously involves opening the combustion chamber door, an important step to reset the CLEAN FIREBOX message, as it is not possible to restart the device without opening and closing the door. This restriction is managed by a door probe, installed on the bottom front part of the stove, which also checks that the door is opened during operations. If the user wishes to voluntarily open the door, the problem will cause the device to shut down immediately.

The stove also has ANTIFREEZE AND ANTI-JAM functions. The first turns on when stove water temperature is 5°C, starting the water circulator until temperature increases 1°C. If a THERMOSTAT MODULE is used, this function turns on when room temperature reaches the anti-freeze temperature set in the module so that the stove runs a start cycle and runs until room temperatures increases 2°C. The

ANTI-JAM function starts the water circulator after 24 hours of disuse for 30”. In addition to the water circulator, if the stove is installed in configurations 6 or 7, the hot water boiler 3-way diverter valve is also started. If the ZONE MODULE is installed, all actuators connected to outputs are run for 30”.

The shutdown phase takes about 20 minutes and the circulator is activated in this interval to perform a heat dissipation cycle.

WARNING

The installation technician must attend appliance inspection since system components may require adjustments not pertinent to the CAT at this time.

Any additional work by the CAT due to the failure to complete the above adjustments during initial inspection is at the user’s expense.

NOTE

We recommend activating STAND-BY mode when permitted by factory and/or use conditions. Frequent starts and stops may cause appliance malfunctions, possible no start alarms and waste energy and fuel.

37

08.4 SAFETY THERMOSTAT WITH MANUAL RESET

Two safety thermostats are installed on the appliance to read pellet hopper and circulating water temperature respectively and trigger the shutdown of the appliance when the temperature in the vicinity of the respective probes detect values above the limits set for safety devices.

The safety thermostats can shutdown the appliance when, for example, the pellet hopper overheats, triggering the pellet thermostat, or when there is no water circulation in the stove, triggering the water temperature thermostat.

To restore normal appliance operations following forced shutdown by a thermostat, proceed as follows:

F ig

. 1

B

C

1.

Wait until the appliance is completely cold (on average 20 minutes);

2.

Unscrew the thermostat reset button lid on the right side of the device, below the side panel (see F

ig

. 1, positions

A or B)

A

TERMOSTATO

ACQUA

TERMOSTATO

PELLET

A B

H

3.

Press the button (A or B) until you hear a CLICK;

4.

Refit the hood;

5.

Reset the alarm from the device on board display by pressing Button 3 and waiting for the OFF message;

F

E

D

6.

Start up again the appliance.

If the alarm persists, contact the Technical Assistance Centre

(CAT).

PELLET thermostat, to reset alarm AL07 SAFETY THERMOST

WATER thermostat, to reset alarm AL19 THERMIC WATER

I

G

Socket unit (F

ig

. 1):

A. Water safety thermostat with manual reset

B. Pellet safety thermostat with manual reset

C. Thermal hydrometer

D. Probe input and actuator output terminal boards

E. 2-way connector for use with external ambient probe where installed

F. Board/PC programming connector

G. Main electrical socket with bipolar switch

H. Room temperature probe

I. Motherboard support

38

08.5 TIPS FOR THE USER

• If condensation appears inside the stove, the causes could be:

- The heat pump is set too low (recommended minimum threshold 60°- 65°)

- Poor draught by the flue (clean the flue)

- Insufficient comburent air (check comburent air conduit)

• If the glass becomes very dirty (with visible blackening) while operating, the causes could be:

- Low draught by the flue (clean the flue or check its characteristics)

- Insufficient comburent air (add more air with the combustion fan, clean the air intake)

• Check for obstructions in the flue and in the external air intake before starting the machine after a prolonged period of disuse.

• When the stove is not used for a long period of time (spring-summer period) it is necessary to completely empty the tank, the auger and the basket using a vacuum cleaner, then carefully clean to prevent the residual pellets from clogging and subsequently damaging the components.

• Every 300 kg of pellets loaded into the container, check that there are no deposits of sawdust on the bottom, and remove any sawdust there. Sawdust reduces the auger’s capacity and creates functional problems for the appliance.

• The pellets must be fed into the hopper using a scoop. Do not empty the sack directly into the hopper.

• The pellet hatch must be closed while the machine is running, and opened only when refuelling is necessary.

• Prompt and systematic maintenance is a fundamental component for perfect functioning and continuous maximum heat efficiency.

• Once a year, have the CAT clean the appliance (Technical Assistance Centre , see

CHAP.08.7 - SCHEDULED PREVENTIVE

MAINTENANCE).

MORE CLEANING = HIGHER PERFORMANCE

WARNING

The device MUST only be used with the combustion chamber door closed. NEVER open it during operations.

The safety microswitch installed on-board the machine, the alarm will be triggered if the door is opened and the device will shutdown in 3 seconds.

39

08.6 ORDINARY MAINTENANCE (by the costumer)

WARNING

Before starting any type of cleaning, switch off the main switch and make sure that the appliance is cold. Never restart the stove before completing these operations and correctly reassembling all components.

A B C

Cleaning tools supplied

A)

Cleaning brush

B)

Flue cleaning brush

C)

Heat proof glove

To facilitate and improve stove cleaning, use an ash vacuum

(not supplied with the stove but available separately at Jolly Mec dealers and/or service centres).

• ORDINARY CLEANING

TO BE PERFORMED AT INTERVALS INDICATED TO THE SIDE OF EACH ILLUSTRATION.

A ROUTINE MAINTENANCE MESSAGE IS DISPLAYED EVER 100 OPERATING HOURS. THIS MESSAGE IS NOT THE

MINIMUM INTERVAL BETWEEN ONE MAINTENANCE OPERATION AND ANOTHER, BUT ACTS AS A REMINDER FOR THE

USER TO ENSURE THE STOVE UNDERGOES PERIODIC CLEANING.

F ig

. 1 F ig

. 2

1.

Opening the stove door

To open the stove combustion chamber door, turn the handle to unlock and pull to fully open (F

ig

. 1-2). Close the door making sure it is correctly locked. Periodically check seam sealing integrity inside the door (F

ig

. 3).

F ig

. 3

NOTE

Time between one cleaning and the next is strictly tied to fuel quality. The most suitable cleaning frequency can also be established a few days after use according to the actual amount of deposited residue and may vary from recommended Jolly Mec intervals.

40

F ig

. 4

F ig

. 10

F ig

. 12

F ig

. 14

F ig

. 6

F ig

. 8

F ig

. 15

F ig

. 17

F ig

. 5

F ig

. 7

F ig

. 9

F ig

. 11

F ig

. 13

F ig

. 16

2.

Burn pot removal for cleaning (daily)

Let open the combustion chamber door and remove both the pellet chute slide (F

ig

. 4) and the burn pot by lifting upright (F

ig

. 5).

A careful cleaning of the burning pot is required so that all holes are duly swept.

Remove the residual ashes stacked in the burning pot overturning them and knock off the fouling eventually formed against the internal sides by means of a suited tool and by shaking the pot.

For an easier cleaning, it is advised to pull out the burning pot from its casing. Clean carefully all air through holes in the pot by means of a sharp tool.

Check that the support casing is cleaned out and the burning pot lies in the proper casing and taking care to replace suitably the sealing seam.

Before replacing the firebox, check there is no ash or dirt in the firebox housing. Vacuum this area thoroughly too (F

ig

. 6).

After cleaning the burning pot make sure to replace it properly

(F

ig

. 7).

The ignition resistance has to be properly centred in the burning pot casing and the support seat must be standing level with the casing compartment (F

ig

. 8).

Check that the gasket located under the burning pot is correctly placed and embedded in the apposite slot. (F

ig

.9)

Replace also the pellet loading slide (F

ig

.10).

Insert both strips of the pellet slide into the apposite slots, the one located on the burning pot support surface (F

ig

.11-12) and the other one next to the pellet outlet conduct (F

ig

.13-14).

Once embedded, the pellet slide right side must be juxtaposed with the right side of the combustion chamber.

3. Ash tray removal and cleaning (daily)

Let open the combustion chamber door and pull out the tray located under. (F

ig

vacuum cleaner. (F

. 15-16). Once removed and emptied the tray, clear the residual ashes in its support base by means of a

ig

. 17).

Use a “drum type” vacuum cleaner equipped with a fine mesh filter, which will simplify cleaning as it prevents the vacuumed ash from returning to the environment. When finished, make sure the pan is correctly reassembled.

41

F ig

. 18

F ig

. 19

F ig

.20

4. Exchanger scraping and cleaning (daily on cold device)

Pull up the cladding cover flap (F

ig

. 18) and grapple the scraper lifting hook through the lower part of the opening door handle

(F

ig

. 19).

Move the scraper vertically (F

ig

. 20) at least 5 times to ensure thorough cleaning and removal of all ash and soot from inside the exchanger.

F ig

. 21

F ig

. 23

F ig

. 25

F ig

. 27

F ig

. 22

F ig

. 24

F ig

. 26

F ig

. 28

5. Fume inspection cleaning (weekly)

Open the fume inspection flap (F

ig

. 21 e 22).

Loosen the locking knobs (F

ig

. 23) of the fume inspection door and remove the cap (F

ig

. 24). Use the brush supplied to clean the ash pan (F

ig

. 25-26) and use the ash vacuum spout to suction all the residual ash left at the bottom of the exchanger

(F

ig

. 27) entering the inspection hatch with the ash vacuum handle.

Check that the silicone seal is fitted correctly (F

ig

. 28) when closing the inspection cap.

Put on the tap again and strengthen tight the locking knocks.

42

F ig

.29

F ig

.31

F ig

.33

F ig

.35

F ig

.37

F ig

. 38

F ig

.30

F ig

.32

F ig

.34

F ig

.36

6. Fume deflector cleaning and removal (weekly)

Clean the fume deflector at least once a week (F

ig

. 29). After opening the combustion chamber door, grasp the tab at the back of the part and pull horizontally forward to free it from its rear rests (F

ig

. 30). Accompany deflector rotation until vertical (F

ig

.

31-32). Shake the part in this position and vacuum dust residue.

Furthermore, fully remove the deflector at least once every two weeks to fully clean the upper part of the combustion chamber.

To remove, starting from the vertical position indicated for cleaning, tilt the deflector back and, once at a 30° angle, lift and push inward to unhook it from the front supports (F

ig

. 33).

Lower the deflector vertically and slightly rotate it to remove (F

ig

.

34-35).

Use the brush supplied to remove any ash content from the fume deflector seat and the flue deflector itself (F

ig

. 36-37).

Repeat the steps in reverse order to reassemble the deflector, making sure it is correctly fitting on its supports in the horizontal position.

7. Stove body cleaning (1 - 3 days)

Remove the burn pot and deflector (as described in points

2.

Burn pot removal for cleaning and 6. Fume deflector cleaning

and removal), Use the supplied swap and brush to clean the

exchanger, letting dust drop into the tray (F

ig

. 38). Remove the ash tray, empty it and accurately clean (as described in point

3.

Ash tray removal and cleaning).

43

F ig

. 39

F ig

. 41

F ig

. 40

8. Cleaning the glass (daily)

Clean the glass every day with a damp sponge or paper towel

(F

ig

. 39-40). If the glass becomes dirty with black fume, the burn pot is probably dirty or the combustion air must be increased.

Be careful not to use overly aggressive products to avoid ruining the paint. Never spray detergents directly onto the parts to be cleaned (F

ig

. 41).

If the stove requires more frequent and deeper cleaning, check the flue draught performance and the chimney cap. A windproof chimney cap is strongly recommended.

F ig

. 42 F ig

. 43

F ig

. 44

9. Cleaning the cladding (as necessary)

Only use neutral water-based detergents to clean the cladding with a damp cloth (F

ig

. 42-43). Never spray detergents directly on painted cladding parts (F

ig

. 44).

Use of abrasive and/or corrosive chemical products can damage the painted parts and are reason for invalidation of the warranty on these parts.

No claims can arise concerning the colour variations of the painted surfaces, especially if the different materials and finishes are subject to different temperatures, as they depend on the natural characteristics of the materials and relative use of the product.

F ig

.45

F ig

.46

10. Pellet tank opening and cleaning

Apply light pressure to lift the pellet hopper cover, pulling upwards, to release the magnet closure (F

ig

. 45 - 46).

Once burned 20 bags of pellets (300 kg), it is advised to empty out the pellet tank and check there is no residual sawdust stacked at the bottom.

Clean carefully the bottom of the tank by means of a vacuum cleaner.

In case of a long period of disuse, eg in summer, empty out the pellet tank as well as the screw conveyor.

Remember that the use of quality fuel is essential to ensure the best operating conditions for the product, preventing the mechanical action of the load auger from turning them into sawdust.

44

F ig

. 47 F ig

. 48

11. Resetting the safety thermostat (see CHAP.08.4)

Loosen the red tap located under the side panel on the right.

(F

ig

. 47).

Press the white button (F

ig

. 48), cusing a pointed instrument, until you hear the safety switch reset “CLICK”.

Refit the black hood.

F ig

. 49

F ig

. 50

F ig

. 51

12. Connecting the power socket

Before connecting the plug on the cord supplied with the stove to the domestic electrical system, plug it into the socket fitted on the back of the right side panel (F

ig

. 49-50) ) threading it through the groove on the back of the stove, making sure the switch is in the “O” position.

After inserting the plug into the power socket, press the switch

O – I on pos. “I” (F

ig

. 51).

F ig

. 52 F ig

. 53

13. Loading the pellet hopper

Located on the rear part of the device, the hopper is filled through an openable lid. The hopper must be filled with pellets using a shovel (not supplied) (F

ig

. 52-53) and not poured in directly from the bag.

45

08.7 SCHEDULED PREVENTIVE MAINTENANCE

We wish to remind you that the Extraordinary Maintenance to be carried out on this type of product must be done obligatorily every year by qualified maintenance personnel, in order to maintain its functionality, efficiency and comfort.

For any further queries you may have, we invite you to contact the authorised Jolly Mec Technical Assistance Centre through your retailer.

Scheduled maintenance must include:

• Cleaning of the flue (with special focus on horizontal segments and the chimney pot)

• Stove fume pass cleaning

• Cleaning of any deposits in the stove

• Cleaning of fans

• Check safety valves

• Checking good water circulator operations

• Check air breather valves

• Check expansion tank pressure

• Check good ignition resistance operations

• Check electric/electronic system integrity

• Check safety device, thermostat and pressure switch status and efficiency

• Check real water pressure measurements using the gauge and electronic pressure transmitter

WARNING

To carry out these operations, the appliance must be disconnected from the mains; wait until the appliance is cold and comply rigorously with the safety regulations in force.

46

Device cleaning and maintenance schedule chart.

Description

Burn pot removal for cleaning

Ash tray removal and cleaning

Exchanger scraping and cleaning

Fume inspection cleaning

Fume deflector cleaning and removal

Stove body cleaning

Cleaning the glass

Cleaning the cladding

Pellet tank cleaning

Cleaning of the flue

Stove fume pass cleaning

Cleaning of any deposits in the stove

Cleaning of fans

Check air breather valves

Checking good water circulator operations

Check air breather valves

Check expansion tank pressure

Check good ignition resistance operations

Check electric/electronic system integrity

Check safety device, thermostat and pressure switch status and efficiency

Check real water pressure measurements using the gauge and electronic pressure transmitter

Daily

U

U

U

U

From 1 to 3 day

U

Weekly

U

U

Monthly Annually As necessary

U

T

T

T

T

T

T

T

T

T

T

T

T

U

KEY: U: routine maintenance by the customer user

T: extraordinary maintenance by an authorised Jolly Mec Technical Assistance Centre

47

CHAP.09 FAULT DIAGNOSIS AND TROUBLESHOOTING

09.1 PROBLEMS

WARNING

In accordance with the laws in force on safety for electrical appliances, a Jolly Mec Technical Assistance Centre or qualified personnel must obligatorily be contacted for all installation, maintenance or interventions that require access to electrical parts.

PROBLEM MAIN CHECKS TO BE PERFORMED

The pellets are not moving to the firebox

The appliance does not start automatically

• The pellets have run out, refill the hopper.

• The gear motor is not running, check the reason:

- Not connected to the mains.

- Mechanically disconnected from the auger.

- Gear motor broken.

• The auger is blocked by a foreign body which has fallen into the hopper.

• The auger is blocked by very hard pellets; use the recommended pellet types (see

CHAP.06.2 -

RECOMMENDED FUELS).

• The basket is dirty. Clean carefully and reposition it correctly.

• The basket is positioned incorrectly, replace it.

• The resistance is faulty, replace it.

• Stove started with correct pellet pre-load.

incorrectly and unburnt elements gather in the basket, the door glass quickly dirties

• The amount of pellets loaded in the basket for the various output modes does not correspond to the amounts indicated in the Technical Specifications (see CHAP.06 - TECHNICAL DATA), check and correct the parameters.

• Low flue draught, do not use the fireplace, it could be dangerous; carefully clean the flue, the appliance and the fume extractor.

• Firebox is very dirty. Switch off the appliance and clean it.

• Humid pellets. Replace the fuel.

• The comburent air is scarce; make sure that the pellet drawer is well closed, that it is not full of ash.

• Insufficient comburent air settings, change the comburent air flow value.

• Check air inlet in the burner.

The appliance switches off when running at minimum power.

• The combustion fan speed is very high and the pellets are burning too quickly.

• The pellet supply is running out.

• The flue draught rate is too high.

• The pellet load is too high, it does not all burn within the set time and fresh pellets accumulate inside the firebox.

Adjust the load level, or correct the combustion fan speed.

• Pellet size is very small, adjust loading time

The flame is very inconsistent

• Check the bottom of the pellet container; there may be large deposits of sawdust.

• The gear motor may have broken gearings, running empty.

A lot of condensation is created in the stove

• The pump start temperature limit is too low. Raise temperature to minimum 65°C.

• The anti-condensation valve may require replacement.

The electric components are running when the appliance is switched off

• The electronic circuit board is broken. Replace it.

The circuit breaker trips

The radiators do not get hot even if the water in the boiler is hot and the pump is running

• At first start up or after prolonged disuse, condensation may form on resistances. Repeat start up until the resistance expels all humidity.

• Air in the system: Vent all radiators, pump and boiler.

• Check whether any intercepts (zone vales) are closed.

48

09.2 ALARM MESSAGES

Following is an overview on appliance alarms linked to the probable causes and some potential solutions. If an alarm occurs with a certain frequency, contact the Jolly Mec Technical Assistance Centre .

Alarm code Alarm text

AL01

POWER

OUTAGE

Alarm causes Main solutions

• No power supply.

• A black out occurred during normal operations for an interval longer than the BLACK-OUT parameter.

• Make sure the electrical connection between the socket on the appliance and power cord is correct.

• Make sure the fuse in the socket is integral.

• Make sure appliance wiring terminals are tight.

AL02

AL03

AL04

AL05

AL06

AL07

AL08

AL09

SMOKE

PROBE

HOT

SMOKE

BROKEN

FAN EXT-

IGNITION

FAILED

NO MORE

PELLET

SAFETY

THERMOST

LOWPRESS

FAILURE

H2OPROBE

FAILURE

• Fume probe fault or not electrically connected correctly to the electronic board.

• Make sure the following are correctly connected:

Red wire to terminal + and J type thermocouple probe.

• Fume temperature over 260°C limit.

• Contact the Technical Assistance Centre .

• An incorrect value was set in MAX RUN THRESH-

• Fume fan speed does not match the set point • Contact CAT, fume fan settings may required adjustments based on draught.

• Visually and manually ensure the fan freely rotates.

• Fume exhaust fan could be broken.

• Check fan wiring and ENCODER terminal wiring to the unit.

• Minimum fume temperature not reached within maximum ignition time

• The Pr17 has not been reached within the maximum Pr1 time

• Check pellet content in the tank.

• Make sure the pellet load auger works correct

(start the component from menu PELLET LOAD,

MENU 7).

• Check brazier cleanliness

• Check correct brazier position.

• Make sure the electrical resistance works (start the component from menu TEST OUTPUTS).

• The fumes temperature drops below the Pr47 value.

• Pellet tank empty, top up.

• Adjust pellet flow and fume exhaust fan speed to keep minimum flame.

• Before restarting, pellet load may be required from

MENU 7. Fully emptying the tank generally also requires the load auger to be empties and causes ignition with scarce pellets and thus the chance of IGNITION FAILED alarm. After completing the

Load Pellet sequence in Menu 7, the brazier must be emptied, i.e. the stove must be started up with a clean firebox.

• Tripped pallet hopper housing safety thermostat. • Check that the thermostat is in block position.

• Check the amount of pellets in the firebox, there may be too much.

• Check the aeration grid on the back of the device, it may be dirty and not allow enough cooling air to flow.

• Safety pressure switch triggered on fume exhaust fan delivery.

• Check flue cleanliness

• Make sure flue passage is not especially winding

(see

CHAP.07.2 - FLUE OR FUME EXHAUST

SYSTEM).

• Check fume fan cleanliness

• Make sure the door is closed.

• Water probe broken or incorrectly wired.

• Make sure the two probe wires are correctly inserted in the terminal. There are no mandatory connection directions for IN2 terminals

• Replace the water probe.

49

AL17

AL18

AL19

Alarm code

AL10

AL11

AL12

AL13

AL14

AL15

AL16

AL21

AL22

Alarm text

STOVEH2O

OVERHEAT

H2O MAX

PRESSURE

LOW AIR

DRAFT

NON-STOP

PEL LOAD

ANORMAL

FLAME

M-BOARD

SECURITY

SAFETY

SENSOR

HI-PROBE

BUFFER

DHW HI

FAILURE

THERMIC

WATER

ROOMPROB

FAILURE

LO PROBE

BUFFER

Alarm causes Main solutions

• Water temperature in the stove exceeded 85°C.

• Make sure the pump outlet to the system heating circuit is open in the event of dissipation, that there are not passageway obstructions due to zone solenoid valve triggered by external components.

• Make sure that the pump and device are working properly.

• Make sure that the system and device air venting has been completed.

• Make sure any device isolating valves are open.

• Water pressure reached maximum 2.7 bar value. • Check circuit pressure adjusting cold system pressure to 1.0 bar.

• In some cases, an expansion tank may be required for the large amount of water in the system.

• Make sure the safety valve is connected to the drain.

• Make sure air was correctly released from the heating system.

• Check the pressure probe connection, it may have disconnected.

• If a flow sensor is installed on the model, it indicates that comburent air flow is not sufficient for combustion.

• Make sure the comburent air intake tube is not obstructed or dirty.

• Check that the sensor is perfectly clean.

• Check that the fume deflector inside the combustion chamber is perfectly clean.

• Check that all the firebox air flow holes are perfectly clean.

• Check that the fume inspection cap is firmly closed.

• Make sure the door is closed.

• Pellet load is continuous and thus incorrect.

• Make sure load start parameters are correct.

• Make sure the board has not overheated. Contact the CAT.

• Fume temperature during flame stabilisation does not correctly increase.

• Make sure functional settings are correct.

• Check for any auger jams or clogs.

• Electronic board temperature has exceeded the safety threshold.

• Make sure room aeration is correct.

• Check appliance operating settings, they could generate excessive overheating in the machine body.

• Check the aeration grid on the back of the device, it may be dirty and not allow enough cooling air to flow.

• If the temperature sensor is installed on the model, it signals that the temperature in the appliance cladding has exceeded the maximum admitted value.

• Make sure room aeration is correct.

• Check appliance operating settings, they could generate excessive overheating in the machine body.

• Check the aeration grid on the back of the device, it may be dirty and not allow enough cooling air to flow.

• The Puffer Hi probe is disconnected or broken.

• Check probe wiring. If correct, replace the probe.

• The boiler probe is disconnected or broken.

• Check probe wiring. If correct, replace the probe.

• Stove water manual reset safety thermostat triggered.

• Make sure functional settings are correct.

• Make sure hydraulic connections are correct and that there are no intercepts between the boiler and system.

• If PROBE is set as room probe, the measured value is not correct read.

• Check probe wiring. If correct, replace the probe.

• The Puffer Lo probe is disconnected or broken.

• Check probe wiring. If correct, replace the probe.

50

Alarm code

AL23

AL24

AL26

AL27

AL28

Alarm text Alarm causes Main solutions

PELLET

LEVEL

• If the level sensor is installed on the model, it signals that the pellet level in the container is lower than the sensor.

• Fill the container with fuel.

h2O min pressURE

• System pressure is under 0.5 bar, read only set.

• Check system water load.

DOOR

OPEN

• The combustion chamber door was left open during operations.

• Check the microswitch electrical connections.

• The device must only be used with the combustion chamber door closed.

• The boiler Lo probe is disconnected or broken.

• Check probe wiring. If correct, replace the probe.

DHW LO

FAILURE

SERVICE 24H

• The device continuously remained on for over 24 hours.

• Thoroughly clean all the parts, firebox, ash pan, inspection cap, exchanger, glass, firebox holder and then turn the device back on.

Each safety alarm shuts down the stove.

To resume normal operating conditions, press Button

3 ESC and wait until the FINAL CLEANING procedure terminates and the message

OFF disappears from the screen.

Fix the problem that generated the alarm before turning the stove back on.

WARNING

By-passing or ignoring alarms and continuing to use the product could damage people and/or property for which the manufacturer cannot be held liable.

All alarms are saved and logged. Continuous product use in incorrect conditions could null and void the warranty.

51

Via S.Giuseppe 2 - 24060 Telgate (Bg) Italy

Tel. +39 035.83.59.211 Fax +39 035.83.59.203

www.jolly-mec.it - [email protected]

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