Jolly Mec AERJOLLY 100 Assembly And Maintenance Instructions

Brand: Jolly Mec

Model: AERJOLLY 100

Category: Fireplaces

Type: Assembly And Maintenance Instructions

Jolly Mec AERJOLLY 100 is a wood-burning fireplace with a heat exchanger system that can heat up to 150 square meters of living space. It features a double-wall steel heat exchanger, a fan with electronic control panel and three speed settings, a humidifier, and a boiler hood with hydraulic connections. The fireplace can be used for both heating and cooling, and can be converted to gas operation at a later date.

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AERJOLLY

WOOD-BURNING FIREPLACE

ASSEMBLY AND MAINTENANCE INSTRUCTIONS

keep in a safe place

PATENTED MODEL

This manual and the instructions it contains should be

thoroughly read and followed to ensure fast

installation and correct use.

Before starting to assembly your fireplace, please

read the manual thoroughly and follow the instructions

carefully, otherwise the product warranty may be

invalidated and safety may be compromised.

The assembly sheet is an important integral part of

the product and must be handed to the user.

The assembly sheet must be kept in a safe place and

consulted whenever necessary as the directions it

contains are important for safety during the installation,

use and maintenance of your fireplace.

Incorrect installation can lead to injury to people or

pets and damage to property, for which the manufacture

cannot be held liable.

This piece of equipment must be used solely for the

purpose for which it was designed and built. Any other

use will be considered improper and therefore

dangerous.

The manufacturer cannot be held liable under

contract or otherwise for any damage caused by

errors during installation or use of the fireplace or, in

any case, by non-observance of the instructions

provided by the manufacturer himself.

Pag.

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Technical data .................................................................................................................................................................... Pag. 2

Flue ............................................................................................................................................................................................ Pag. 3

Components ........................................................................................................................................................................ Pag. 4

Optional accessories ...................................................................................................................................................... Pag. 5

Positioning of the air intake and electricity ..................................................................................................... Pag. 6

Positions to be followed during installation ...................................................................................................... Pag. 7

Assembly procedure ..................................................................................................................................................... Pag. 8-9

Glasses assembly procedure ................................................................................................................................... Pag. 10

Cladding .................................................................................................................................................................................. Pag. 11

Electrical connections .................................................................................................................................................... Pag. 12

Example of air ducting ................................................................................................................................................... Pag. 13

Boiler hood ......................................................................................................................................................................... Pag. 14

Assembly and maintenance instructions ........................................................................................................... Pag. 15

CONTENTS

ASSEMBLY INSTRUCTIONS

Pag.

AERJOLLY - A HEAT EXCHANGER SYSTEM FIREPLACE, WOOD WORKING

This fireplace is a single unit and has a shaped double-wall

steel heat exchanger, treated inside: the air, thanks to a

heater fan, passes through this, and, after been heated and

humidified, is sent to the rooms of the house.

The ventilation system can also be used in Summer to cool

the rooms.

The Aerjolly fireplace is insulated with a rock wool blanket

(5 cm) covered by zinc-plated sheet metal to minimise the

risk of heat loss and to make installation easier, without the

need for masonry work.

It is supplied with a fan (air flow capacity of 420 or 620 m

/h),

with an electronic control panel, three speed, that

automatically controls the amount of air supplied to suit the

temperature and a room thermostat.

It also has a manually fed humidifier to avoid health

problems, such as a dry throat, headaches, various

allergies, etc. fragrant, balsamic essences can be added

(mixed with the water).

The fireplace can become a gas-working unit also in a

second time, being arranged for the insertion of a burner.

145

DATI TECNICI

CHARACTERISTICS MOD. 70 MOD. 80 MOD. 100

Heat output 23,000 Kcal/h 25,000 Kcal/h 28,000 Kcal/h

26.7 Kw 29.0 Kw 32.5 Kw

Pre-testing heat output 18,308 Kcal/h

21.289 Kw

Whole output 74% 76%

Fumes output 68%

Heatable surfaces 100 m2130 m2150 m2

(for buildings compliant with Italian Law 10/91)

Air outlet Ø 100 mm Ø 100 mm Ø 100 mm

Fan air flow capacity 420 m3/h 420 m3/h 620 m3/h

or, on require 620 m3/h or, on require 620 m3/h

Electrical absorbing 200/170 W 200/170 W 170 W

Fumes outlet Ø 200 mm Ø 200 mm Ø 250 mm

Burner weight 117 Kg 127 Kg 173 Kg

Total weight 155 Kg 167 Kg 213 Kg

MOD. A B C Ø D

70 78 54 30 20

80 88 54 60 20

100 108 54 78 25

Pag.

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FLUE

The flue is a crucial element for the fireplace to work

properly. The cross-section of the flue must be as indicated

in the technical specifications for the fireplace. Every

fireplace must have its own flue, without any other

entrances (other fireplaces, boilers, stoves, etc.). The

dimensions of the flue are strictly proportional to its height

(measured from the fireplace to the base of the chimney

pot). To guarantee efficient updraught, the outlet of the

chimney pot must be twice the cross-section of the flue and

must meet the following requirements:

-it must prevent the escape of combustion products, be

impermeable and suitably insulated and lined

-it must be made from materials capable of withstanding

normal mechanical stress, heat, the action of the products

of combustion and any condensation

-it must be mainly vertical with an angle of deviation no

greater then 45°

-it must be kept at a suitable distance from any

combustible or inflammable material by means of an air

gap or suitable insulation

-it must have a circular inside cross-section, where at all

possible: square or rectangular cross-sections must have

rounded corners

-it must have a constant, free and independent inside

cross-section

-it must have rectangular sections with a max ratio of 1.5

between sides

We recommend installing a chimney pot with a shaped

cowl. If the flue is installed on the outside of the building,

this must be lined to prevent the fumes from cooling and the

consequent formation of condensation; the same goes for

the exposed section from the roof to the chimney pot.

We recommend using unlined stainless steel tubes inside

the hood for the connection between the fireplace and the

flue, whenever there are bends or deviations and to make

installation faster, easier and safer.

Elements made from non-combustible materials resistant to

the products of combustion and any condensation should

be used to fix the conduits.

The flue must not pass through areas where the installation

of combustion appliances is prohibited.

Flue sections must be installed to guarantee perfect

tightness during normal working conditions in depression.

Horizontal sections should be avoided wherever possible.

In the case of fireplaces with flue outlets in the wall or

ceiling not perfectly in line with the outlet from the fireplace,

open bends at not more than 45° must be used for any

changes in direction.

In this case the flue must be fitted with a chamber for

collecting solid materials or eventual condensations: it must

be used for flue cleaning, thanks to an inspection air-tight

window easy to be open.

The use of downwards elements is absolutely forbidden.

The flue must allow for recovery of any soot or be easy to

sweep. It is absolutely forbidden to pass other conduits (for

air or plant) inside the flue, even if oversized.

40/50 cm

45°

No other fireplaces, boilers or air extractors may be installed in the same room.

Fig.1 Fig.2 Fig.3 Fig.4 Fig.5

Mod. 70 Mod. 80 Mod. 100

Ø 200 Ø 200 Ø 250

-min height of flue - min height of flue

with glasses 1.5 m without glasses 1.5 m

FLUE DIMENSIONS

610

ASSEMBLY INSTRUCTIONS

Pag.

COMPONENTS

1-Fireplace

2-Tray holder

3-Right refractory panel

4-Left refractory panel

5-Rear refractory panel

6-Cast iron grille

7-Front sheet

8-Deflector

9-Fume register

10 -Fume register push rod

11 -Friction with screws and nogs

12 -Humidifier topping up

13 -Cap ø 1/2

14 -Steel attack

15 -Legs with 16 screws

16 -Ash tray

17 -Ventilator

18 -Control unit

19 -Pipes for air 3 MTL, ø 100

20 -Tube clamps n. 2

21 -Outlets with adjustable closure

for air, n. 2

Pag.

OPTIONAL ACCESSORIES

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1-Steel flue

(various measures)

2-Reduction unit for flue

(various measures)

3-Hood ventilation grille 4x10

4-External air intake grille 20x20

5-Alu outlets with adjustable

closure for air 18x10

6-Flexible alu pipe for air

(various measures)

7-“T” fitting ø 80 - 100 - 120

8-“Y” fitting ø 80 - 100 - 120

9-Reduction unit for alu flexible

pipe ø 100/80 - ø 120/100

10 -Tube clamps

11 -Glass-wool blanket

for air pipes

12 -Rock-wool blanket for flue

13 -Box with automatic closure

for external air intake

14 -Box for external air intake

holder with fitting ø 150

15 -Fitting for ventilator ø 150

16 -Door-frame and latch

17 -Glass door-frame

18 -Boiler hood with hydraulic kit

and electrical coil

19 -Fitting for boiler hood

20 -Woodburner grate

21 -Stainless steel grille with handle

(for cooking at close fireplace)

22 -Fitting and universal reduction

unit for stainless steel flue

20 21 22

8 9

610

ASSEMBLY INSTRUCTIONS

Pag.

POSITIONING OF THE AIR INTAKE AND ELECTRICITY

To make installation of the fireplace easier, fit all the external

air vents, the two distribution boxes with wiring beforehand

and the flexible sheath for electrical cables in the positions

shown in the diagram.

The positions shown in the diagrams are valid for the three

models (70 - 80 - 100) both when wall or corner positioned.

Leave two stretches of flexible sheath sticking out from the

wall (by about 50/70 cm) to allow for the electrical connections.

We recommend respecting the indicated measures.

If the fireplace is to have a side seat, the electrical plant

must be installed on the opposite side.

All air intakes as well as electrical connections may be

moved, provided the characteristics remain unchanged.

A-Current distribution box, connection

with B box and connection with ventilator

B-distribution box for control unit connection

C-Free air intake for ventilator and hood

ventilation ø 200 (see optional pag. 5)

D-Omnipolar circuit breaker

WALL POSITIONING

CORNER POSITIONING

fireplace centre line

line 220V

MOD. 70

Pag.

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POSITIONS TO BE FOLLOWED DURING INSTALLATION

108

102

WALL POSITIONING

MOD. 80MOD. 100

CORNER POSITIONING

ASSEMBLY INSTRUCTIONS

Pag.

ASSEMBLY PROCEDURE

The fireplace is dispatched on pallets (see drawing).

Assembling and moving are easier if the fireplace is

emptied, in order to make its weight lighter.

1-Place the boiler on the ground or lift using a crane

and fix the legs using the screws provided

2-Place the fireplace in its final position (pag. 7)

3-Connect the flue (see pag. 3)

to the universal fitting

4-Connect the power cable between the fan

and the control panel (see pag. 12)

5-Apply a line of silicone to the fan, place it in its proper

seat and then secure using the screws provided

6-Assemble the tray holder bottom

7-Right refractory panel

8-Left refractory panel

9-Rear refractory panel

10 -Front sheet

11 -Cast iron grille

12 -Ash tray

13 -The deflector must be hanged with a front

inclination for a max. rendering

14 -Connect the stainless steel flexible tube to one of the

two fittings on the humidifier tank. Close the one not

used with the plug provided. The flexible tube with the

top-up fitting must run parallel with the boiler fitting.

The tank must be fixed on the inside or outside of the

hood. Extend the tube as required

15 -Register friction

16 -Fit the fume register so that the name JOLLY MEC

is horizontal when the register is closed. You must

be able to extract the register easily in order to clean

the flue by extracting the rod

17 -Fume register push rod

18 -Tubi flessibili per la distribuzione dell’aria. Bloccare i

tubi con una fascetta stringitubo, coibentarli per tutto

il percorso con lana di vetro anche all’interno della

cappa, evitare il contatto con legno (Se prevista la

canalizzazione dell’aria, vedi esempio pag. 13)

19 -Before creating the hood, make sure the two tubes

leave the boiler, securing them with mortar or silicone:

open the fins that block the grill frame as far as they

can go and then fix the grill frame with silicone

between this and the wall (make sure air cannot

pass, to avoid stains on the wall, as often happens

with radiators)

20 -Fit the adjustable air vents. Apply the grill and fix

with silicone

21 -Wire up the control panel (see page 12)

148

Water

level

TRADUZIONE

Pag.

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Fold the fins down at 45°, insert the fitting in the flue up to

the point where it is possible to fill with calcined gypsum or

rapid cement, forming a well polished funnel (see example).

Otherwise make a hole in the flue (see drawing).

OFF

MIN

MED

MAX

ESTATE

INVERNO

EXAMPLE OF FLUE WITH UNIVERSAL FITTING Flue

Hole for walling

the fitting

Steel pipe

Mix with calcined

gypsum and cement

or rapid cement

Fitting and universal

reduction unit

Seal the joint with

silicone to prevent

air from escaping

at these points

ASSEMBLY INSTRUCTIONS

Pag.

GLASSES ASSEMBLY PROCEDURE

The fireguards with doors and latch doors must be assem-

bled before cladding the fireplace (i.e. before installing the

sides).

Mount the fume register so that the name JOLLY MEC is

horizontal when the register is closed. You must be able to

extract the register easily in order to clean the flue.

FIREGUARD WITH GLASS DOORS (OPTIONAL)

The fireguard with glass doors is fitted by simply using the

self-threading screws provided.

Drill holes in line with those in the fireguard, apply a layer of

silicone along the base of the fireguard and to the side that

will sit against the fireplace.

If the doors don't close properly (i.e. not aligned or one

sticking out), loosen the screw responsible for the misalignment

and compensate with silicone.

FIREGUARD WITH DOORS AND LATCH DOORS

(OPTIONAL)

Apply a layer of silicone along the base of the fireguard and

to the side that will sit against the boiler.

Rest the fireguard against the boiler, making sure it's

perfectly vertical on both sides. Apply a layer of silicone to

the fireguard (the part touching the boiler).

Drill holes and fix the fireguard using the self-threading

screws provided.

Make sure that both sides are perfectly vertical (ignore the

fact that the fireplace might be uneven) otherwise loosen

the screw(s) concerned or drill the holes again.

Hermetically seal the top with silicone inside (between the

fireplace and the fireguard).

DETAIL OF DOOR REMOVAL

1- Screw to extract to remove door

2- Washer

3- Rod

Pag.

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CLADDING

Start assembling the cladding and the relative hood: put the

control unit in a suitable position.

A window must be fitted to allow for the feeding of the

humidifier. It is necessary creating an air grille in the hood

(min. 10x30 cm) without any filters, nets or other closures:

IMPORTANT

Should the installation of the fireplace be done in a basement, fit

the air intakes 20x20 (or diam.20) outside, by using flexible pipes

and creating an air intake, under the fireplace, connecting the

internal room with outside to allow the ventilator to intake air from

outside (solution A).

Otherwise, make a hole in the hood, communicating with

outside, diam. 150 (solution B), leaving the air passing through

the base of the cladding (min. meas. 10x30).

the grill must be connected to the air intake without any pipe

connection (see example).

A gap must be left between the fireplace and the cladding

to allow for the ventilator to get the air.

linea 220V

Hood ventilation grille10x40

ASSEMBLY INSTRUCTIONS

Pag.

ELECTRICAL CONNECTIONS

CONTROL UNIT

ELECTRICAL DEVICE - DETAILS

Connect the 220 - 230 V line to terminals 1 - 2 on the con-

trol panel and the earth cable to screw on the control panel

casing.

Connect the fireplace thermostat cable to terminals 5 - 6 on

the control panel.

Connect the fan to terminals 7 - 8 and to the earth screw on

the control panel casing.

Make sure you observe the relevant safety standards when

wiring up the various components.

If you need to replace the earth cable (code “Cable/GND”),

please obtain the new one from your local dealer or direct

from the manufacturer

Take great care when making all electrical connections

through its devices. Always insert properly.

The luminous led on the control panel is always on when the

fan is working. You may also find that the luminous led is on

when the control panel is switched to OFF, as this led is

directly linked to the operation of the fan, which remains on

as long as the contact thermostat provides the OK signal.

VENTILATORE

CENTRALINA

234 5678

TERMOSTATO CAMINO

CUSTODIA CENTRALINA

linea 220 - 230 V

terra

OFF

MIN

MED

MAX

ESTATE

INVERNO

Control unit

Control unit case

Fireplace thermostat Ventilator

Line 220/230V

earth

1 -Fireplace thermostat

2 -Insulation braid

3 -Connecting ceramic device

4 -Protection sump

Pag.

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EXAMPLE OF AIR DUCTING AND BOILER HOOD FOR HOT WATER PRODUCTION

The air ducts must be run to the rooms you want to heat.

Each room heated in this way must guarantee the return of air

to the room with the fireplace by means of gaps under the door

(1 cm min) or special vents.

The air is distributed by means of circular-section, flexible tubes

made from aluminium with sheet metal fittings and deviators.

These tubes must be fixed to the fittings by means of tube

clamps.

These tubes must be insulated in order to guarantee top per-

formance of the fireplace. These should thus be fully lined with

glass-wool blankets (min 3 cm thick).

Never use plastic tubes to distribute the hot air, as the high

temperature of the air could melt these.

Where it's impossible to run the tubes in the wall, you can

create a false ceiling, false beams or boxes.

Important: Always seal the joint between the outlets and the wall

(with silicone, see pag. 9) to prevent air from escaping at these

points and so darkening the surrounding surfaces due to the

heat.

For better efficiency, fit an adjustable air vents (ø 120) in the

base of fireplace to allow the ventilator to intake 50% air from the

room.

ASSEMBLY INSTRUCTIONS

Pag.

BOILER HOOD

The boiler hood is a 2 mm stainless steel back-boiler,

pre-tested at 4,5 ate pressure, available in two versions: 60

or 90 litres.

It produces hot water at no extra charge, as it exploits the

heat of the fumes (or using electricity).

The hood contains 60-90 litres of water, which heats up

quickly at 60 - 70° (it depends on the type of fireplace) and

easily meets a normal family's requirements.

In 40 - 60 minutes at normal fire burning, the water

temperature can reach 60 - 90°C.

The size of the back-boiler hood makes it suitable for all

fireplace models:

- Aerjolly

- Aerjolly combinati

- Universaljolly aria forzata e tradizionali

- Superjolly

The boiler hood can produce hot water in summer, working

when the fireplace is not being used thanks to an electrical

heating element: consumption levels are the same as the

ones of a normal boiler.

BOILER HOOD ASSEMBLING INSTRUCTIONS

Place the boiler hood on the fireplace flue and fix to the top

of the flue using a stainless steel tube.

Insulate the boiler hood with a layer of fibreglass.

Plumb as shown in the figure.

A door must be fitted on the left of the hood to allow for

inspection of the valves and electrical coil.

The water temperature gauge must be built into the hood

and be easily visible.

An omnipolar switch must be used for the electrical coil.

HINTS AND UPKEEP

The efficiency of the boiler hood depends on the type of

fireplace, the quality of the firewood and the aperture of the

fume register.The risk of hood overtemperature is controlled

by the vent valve that ensures the temperature of the water

doesn't exceed 95°C by discharging the hot water. If you

find water escaping from these valves, check the pressure

(this should be 2 - 2.5 bar). Adjust the pressure using the

pressure reducing valve.

Cold

water intake

Safety

valve drain

Hot water

delivery

Hood emptying

Boiler hood

Fibreglass

insulation

Ball valve to drain

system to avoid risk

of frozen pipes

Pressure reducing

valve (recommended

setting: 1.8 - 2 bar) Heat vent valve

3 bar

safety valve

Sleeve

4 bar safety valve (extra,

do not connect to drain)

JOLLY vent valve

Water temperature

gauge

Electrical resistance,

connect to omnipolar

switch (optional)

We recommend using an

expansion tank to avoid

sudden variations in pressure

(optional)

600/900

200

440

Pag.

ASSEMBLY AND MAINTENANCE INSTRUCTIONS

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When the fireplace is burning wood, the fume register must

always be open: you can adjust the actual aperture once the

fire is properly lit for better efficiency and less consumption.

The fan only starts automatically when the air has reached the

set temperature on the fireplace thermostat (roughly 60°C). It

automatically stops when the temperature drops below the set

temperature (even when the control panel is switched off).

The fireplace fan must work, at the desired speed, when the

fireplace is lit.The fireplace can be used in Summer to ventilate

the rooms (turn the fan control to Summer).

The electrical control panel has three power stages to allow

setting the desired temperature.

The humidifying water must be manually added to the humidi-

fier trays.The humidifier is full when the water reaches the level

of the two trays (2-3 l capacity).

The fireplace can work also without water. You can add

balsamic essences to the water to perfume the air.

Never use thick or closing grilles on air intakes which

could stop the air flow. It is advisable the use of a wide net.

AERJOLLY MAINTENANCE

Routine and systematic upkeep is essential to ensure top

efficiency and max heat output.

All components must be cleaned and checked once a year. We

recommend carrying out the following operations to comply

with the safety standards and ensure the validity of the warranty:

-yearly general cleaning

-yearly flue cleaning

-yearly glasses cleaning (using a wrinkling sponge and a

specific product - such as Cif, Fornet, Vim)

-Be sure that the fireplace have a good draught, trying it with

a fired-paper at the beginning of the flue.

-There must be no other fireplaces, boilers or exhaust systems

in the same room

The manufacturer cannot be held liable for any problems

arising from non observance of the directions in this manual.

CERTIFICATE OF WARRANTY

JOLLY-MEC guarantees the boiler body for 5 years,

excluding all electrical components, consumable parts

and glass.

The relevant manufacturer warranties apply for the vari-

ous complementary accessories.

This warranty is valid only if the fireplace has been

installed and used in compliance with the instructions

and recommendations in this manual.

JOLLY-MEC reserves the right to make any changes

without prior notice.

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JOLLY-MEC Caminetti s.p.a.

24060 Telgate (BG) - Italy - via Fontana, 2

Tel. +39 035 830247 - Fax +39 035 833389

web: www.jolly-mec.it • E-mail: [email protected]

06-2003

Jolly Mec AERJOLLY 100 Assembly And Maintenance Instructions

Brand: Jolly Mec

Model: AERJOLLY 100

Category: Fireplaces

Type: Assembly And Maintenance Instructions

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