Water FOGHET stove INSTALLATION, USE AND MAINTENANCE MANUAL. FOGHET With curved front. FOGHET With straight front. WOOD version

Transcription

1 Water FOGHET stove INSTALLATION, USE AND MAINTENANCE MANUAL To be carefully kept by the owner FOGHET With curved front FOGHET With straight front WOOD version Curved or straight front

2 Read this card carefully and follow the instructions for quick installation and correct use of the fireplace. Before starting installation, read the card carefully and follow the instructions; failure to do so could invalidate the warranty and compromise fireplace performance and safety. This installation card is an integral and essential part of the product and must be given to the user. It must kept in safe place and carefully consulted, as it provides important information on safety during the installation, use and maintenance stages. Incorrect installation can cause damage and injury, for which the manufacturer cannot not be held liable. The unit must only be used for its intended purpose. Any other use is deemed improper and therefore dangerous. The manufacturer declines any contractual or non-contractual liability for damage caused by errors in installation or use, failure to follow the instructions contained in this card, or installation in places or rooms unsuitable for the characteristics of the product. All rights to reproduction of this card belong to 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 changes it deems necessary at any time. This card cannot be given to third parties to read without the written permission of JOLLY-MEC CAMINETTI S.p.A. The technical instructions for assembly contained in this handbook are considered basic requirements. The regulations in some countries may be more restrictive; in this case carefully comply with the regulations in the country of installation.

3 CONTENTS USE AND MAINTENANCE INSTRUCTIONS FOR THE USER 1.1 Introduction to the Foghet water stove Technical specifications Dimensions and components Example of combined Foghet stove with curved front installed and covered Burner and pellet hopper components New-generation simplified electronic controller Description and use of simplified electronic controller for water heating Setting the display language Ignition in pellet burning mode, controller Quick menu Power output setting for pellet burning mode Room temperature setting for pellet burning mode How to silence an alarm Summer operating mode Electronic component tests Solving problems related to combustion Use of the programmable thermostat Ignition in wood burning mode How to optimise combustion and use the damper Operating tips and warnings Cleaning the stove Components that can be removed for cleaning the stove Plumbing kit components requiring routine maintenance Troubleshooting Optionals Auxiliary large capacity pellet hoppers Pellet quality Use and conservation of the installation and maintenance manual Warranty Assistance Service...30 ASSEMBLY INSTRUCTIONS FOR THE INSTALLER 2.1 Flue Prearrangement for connections and air inlets of the stove positioned in a corner Prearrangement for electrical connections and air inlets with wall installation Adjusting the feet Damper and friction unit assembly Caldo Control Standard plumbing kit With production of domestic hot water in a sealed system Without production of domestic hot water in a sealed system Non-standard plumbing kit With production of domestic hot water in an open-vented system, connected to mains water supply for domestic hot water and boiler cooling Without production of domestic hot water in an open-vented system, connected to mains water supply for boiler cooling Installation examples Installation in autonomous sealed system with production of domestic hot water In a sealed system with production of domestic hot water, in parallel with wall-mounted boiler In a sealed system without production of domestic hot water, connected in parallel with a wall-mounted boiler for domestic hot water production In an autonomous sealed system with thermal cell and solar panels for radiator heating and domestic hot water In an autonomous sealed system with thermal cell and solar panels for production of domestic hot water and radiator and underfloor heating In a sealed system, without production of domestic hot water, connected in parallel to wall-mounted boiler with domestic hot water production and solar panels with thermo boiler, hot water storage cistern Electrical wiring diagram for simplified controller Purchased product data

4 1.1 Introduction to the FOGHET water stove The FOGHET with curved or straight front is a water heating machine type approved and tested according to European standards EN13229, EN14785, EN303/5 and German standards DIN18894, DIN18891, DIN18892 burning firewood or firewood and pellets (ALTERNATIVE AND RENEWABLE ENERGIES). Designed to meet today s market requirements of: energy saving, comfort and safeguarding the environment, it is the result of Jolly-Mec s 30 years experience. Foghet is a monobloc consisting of a double-wall heat exchanger in special steel whose particular construction allows maximum exploitation of the combustion heat, obtaining high efficiencies of up to 92.74%, making it one of the best in the category for efficiency and emissions. The Foghet with curved front can be clad as a fireplace or as a stove ( FOGO model); with straight front as a fireplace or stove ( FOGHEA model). The Foghet with curved front has an electronic controller (available in two versions, standard or simplified) that manages the stove when operating on wood or pellets. In both versions it has a programmable thermostat for automatic lighting and shutdown. With the new-generation simplified electronic controller version, when programmed, if the wood finishes and heating is required the boiler temperature probe makes the stove automatically switch from wood to pellet mode with automatic igniting of the pellets, maintaining the set temperature. The simplified controller warns when the pellets are finished with a beep and in addition makes it possible to manage an auxiliary pellet hopper or boiler connected in parallel, a hot water storage cistern (thermoboiler) or a thermal cell and the circulating pump of a central heating system. With the simplified controller it is also possible to run a check-up on the various components even with the fireplace out. The Foghet with straight front is supplied with a simplified controller only. When used with wood, it functions as a normal stove, but offers the advantages of controlled combustion thanks to the Jolly-Mec patented Caldo Control, which optimises combustion according to the water temperature. Wood-burning Foghet, with the specific pellet burner JOLLY ME-04-F fitted, becomes a continuous fire heating machine, exactly like a boiler. The pellet hopper has a capacity of approximately 46 kg, however, to obtain a longer burn time it can be coupled to a second and larger hopper, even located in another room. Operation can be quickly switched from wood to pellet mode or vice versa: by shifting the grille positioned over the burn pot and selecting the type of feed. In pellet mode, heating power is managed by means of the electronic controller provided: from 8,000 kcal/h on minimum up to 20,000 kcal/h on maximum. The stove can be purchased in the wood version and the burner can be fitted at a later stage, since the stove is already arranged for it. It has a large ceramic glass door and for the wood-pellet version with curved front a removable second inner door with glass is available, for those who want it to work as a boiler, which simplifies cleaning, keeping the glass of the outer door always clean, while reducing the temperature of the front. To use it as a fireplace the second door removes easily and can be placed in the special holder (optional) The water-heating Foghet can also autonomously heat an entire building with a floor area of up to 170m 2 (with radiators, underfloor heating, storage cistern, etc.) and produce domestic hot water. It is supplied as standard with a plumbing kit in a sealed system, already fitted and tested, with or without domestic hot water production and a cooler that monitors and governs the temperature of the water in the event of a power failure. On request, non-standard, Foghet can also be supplied with a plumbing kit for open-vented operation, with or without domestic hot water production. 4

5 1.2 Technical specifications Approval EN EN Code Description Value Unit 353 Burned power (by pellet) 25 kw 366 Thermal rated output (by pellet) 23,2 kw 361 Medium power (by pellet) 15,1 kw 362 Minimum power (by pellet) 9,3 kw 354 Economy power (by pellet) 0,5 kw 302 Consumption at max power (by pellet) 4,7 Kg/h 303 Consumption at med. power (by pellet) 3 Kg/h 304 Consumption at min. power (by pellet) 1,9 Kg/h 305 Consumption in economy power (by pellet) 0,1 Kg/h 357 Max power give to the environment (by pellet) 4 kw 053 Efficiency (by pellet) 92,74 % 352 Burned power (by wood) 27,8 kw 301 Consumption at max power 6,5 Kg/h 356 Max power give to the environment (by wood) 4 kw 052 Efficiency (by wood) 83,49 % 455 Max. heated area depending the kind of house m Surface exchange 1,7 m Nominal voltage/frequency 230/50 V/Hz 602 Electrilcal absorption (combined) min-max 360 / 220 W 251 Boiler weight 150 Kg 401 Standars tank capacity 46 l 402 Optional tank capacity l 702 Min. draft 12 Pa 653 Smoke exhaust Ø 150 mm 551 Sanitary water capacity ΔT 40 C 7 l/min 102 Max T smoke (by wood) 250 C 103 Max T smoke (by pellet) 193 C 105 Med T smoke (by wood) 196 C 106 Med T smoke (by pellet) 145 C 002 CO (13% O2) (wood) 0,13 % 003 CO (13% O2) (pellet) 0,0048 % 005 CO2 (wood) 9,61 % 006 CO2 (pellet) 11,1 % 202 Smoke volume (by wood) 26,3 g/s 203 Smoke volume (by pellet) 14,08 g/s 008 Dust (pellet) Dust (wood) 0 0 Recommended fuels: WOOD: dry beech, hornbeam, oak, locust (acacia) PELLETS: See pellet characteristics given in chap All testing, inspections and preparation of the Foghet were carried out using the recommended pellets. JOLLY-MEC CAMINETTI S.p.A. declines any liability for malfunctions, faults or problems due to the use of nonrecommended pellets, since the combustion parameters vary from pellet to pellet (they can even vary by approx. 30%). For optimum operation, combustion must be adjusted using the pellet feed control on the burner (see chap. 1.8). 5

6 1.3 Dimensions and parts The stove is supplied with a JOLLY ME04 F burner and preassembled and tested pellet hopper, in two wooden crates on pallets, packed with a cellophane hood, polystyrene and with the following parts: Assembly, use and maintenance manual Boiler body complete with tested hydraulic kit Standard pellet hopper with capacity of approx. 46 kg JOLLY ME04 F pellet burner Control panel with STANDARD electronic controller or control panel with SIMPLIFIED electronic controller Ø 80 mm flexible pipe (not extensible) for burner fan suction inlet Ø 80 mm flexible pipe 100 cm long (extensible) for primary combustion air suction from outside (CALDO CONTROL) Wood guard (on curved front model only) 2 cast-iron grilles for wood burning Wrench for burn pot locking screw Room temperature probe (with SIMPLIFIED electronic controller only) Room temperature probe (with STANDARD electronic controller only) Cleaning tools supplied (see chap. 1.10) Burn pot cleaning tool Poker Shovel Flue brush Cleaning brush OPTIONALS OPTIONAL SET for curved front models Holder for accessories and removable inner door Removable door Spring Foghet with straight front Foghet with curved front 6

7 1.4 Example of combined Foghet stove With curved front installed and clad Fume exhaust Hood front circulation grille 40x10 cm upper edge 10 cm from ceiling Hood Lifting hook Control panel Pellet loading door 50X35 cm min. lower edge 141 cm off ground MANDATORY Room temperature probe for simplified controller (stand out 2 mm from wall edge) room thermostat (for standard controller) Pellet hopper Damper control Smoke baffle Removable door (optional) Burner inspection door 80X35 cm min.lower edge 15 cm off ground MANDATORY Boiler Wood stopper Burn pot Burner JOLLY ME04 Pellet burner fan suction ducting Door handle Electronic control unit Plumbing kit Suction ducting caldo control Inspection door for controller, caldo control and plumbing kit 80x35 cm min. lower edge 50 cm off ground MANDATORY Omnipolar switch Ash pan with adjustable grille, for firewood Air adjustment caldo control (for firewood) Caldo control Electrical power supply 220V-50Hz NOTE! To allow boiler expansion the cladding must always be separated from the steel fireplace by 2 to 3 mm. 7

8 1.6 STANDARD electronic control panel Description of STANDARD electronic control panel the various led indicate how it is working Manual screw feeder refilling (press together) Increase room temperature (first press SET for 1 sec.) Flue Gas Temperature display Time-controlled Pellet mode led Automatic ignition led Wood mode led Select wood / pellet (first press SET for 1 second) Increase power display display Lower boiler water temperature (press SET for 1 second first) Select functions and programmes Combustion fan led Led pump Summer Led Winter Led Hopper cleaning led ON/OFF (press for 4 seconds) Manual hopper cleaning (first press SET for 1 second) Decrease in power Select summer/winter (first press SET for 1 second) CHECK IF THE HOPPER NEEDS CLEANING EVERY DAY N.B. If the fire goes out, it is not possible to re-light it until it has cooled down, wait for 10 minutes. Repeat the ignition sequence. TEXTS THAT APPEAR ON THE DISPLAY LOAD WOOD: automatic charging of the pellet in the burner hopper for ignition AIR INTAKE FAN : phase in which the electrical element is heated to light the pellet FIRE ON: pellet ignition phase and stabilising of the flame, wait for 5-10 minutes P01,P02,P03: fire output (varies the potential from 1 to 3) BRAC: phase in which the appliance is kept alight by the embers : load a minimum amount of pellet ECO:.the temperature of the water in boiler has reached the set threshold (detected by the water temperature probe) and the fire output goes to economy mode LE: burning wood FROM 30 TO 269 : Flue gas temperature PUL FIRE: automatic cleaning of the pellet burner hopper SET: press the SET key for 1", the led will flash and you can select from the various functions OFF: fire is out or is going out ALAR NO FIRE: the flue gas temperature during ignition is too low, the fire goes out ALAR NO WOOD: no pellets or pellets not loaded in the hopper ALAR SOUND FUMI : the flue gas temperature sensor is faulty, the fire goes out T OFF: he room temperature has reached the set threshold on the room thermostat DA 0.0b A 4.0b: Water pressure in boiler FROM 10 TO 100 : Water temperature in boiler ALAR PRES: the pressure inside the boiler is too high: use the pressure regulator on the delivery tap or plant drain tap to adjust the pressure to Bar (when hot) or Bar (when cold) TO You have accessed the control panel programs To exit press key 4 for 1 sec. ALAR SCAR FUMI: The pressure switch has cut in due to a poor draught (red indicator light on the burner ON)or the safety thermostat that stops the boiler has cut in to prevent the smoke blowing back. Check the position of the basket and clean it. Contact the assistance service if the problem persists. Foghet water fireplace combined wood-pellet version with JOLLY ME 04 F burner 11

9 1.6.2 Pellet Ignition, STANDARD control panel Before igniting the pellet fire it is necessary to complete some preliminary operations : Notch Ashpan Grate Caldo Control 1" 1" Press simultaneously 4 Cast iron bottomgrates Move the cast iron bottomgrate located above the pellet burner to uncover it 2. Clean the hearth, the burner hopper and empty the ashpan 3. Manually close the flue gas damper by rotating the knob until the notch indicates position C and block it by pressing the knob until the fastener screws click into place. 4. Check that the ashpan is correctly closed 5. Close the bottomgrate on top of the ashpan 6. Close the caldo control by pressing the lever as far as possible 7. Check that the control panel is set to pellet mode or the appliance will not ignite (the relative led must be on). See green arrow. If the control panel is in wood mode (the relative led is on) switch it to pellet mode. Press the SET key for 1 second and whilst the led flashes press key 6 for 1 second (the pellet mode led will come on) 8. Check that the control panel is set to winter mode or the appliance will not ignite (the relative led must be on). See green arrow If the control panel is in summer mode (the relative led is on) switch it to winter mode. Press the SET key for 1 second and whilst the led flashes press key 5 for 1 second (the winter mode led will come on) 9. Manual loading before ignition must be done only when igniting for the first time and when the hopper is clean (do not exceed the quantity shown in fig.1) At all other times MANUAL LOADING MUST NOT BE DONE because it is done automatically. When igniting for the first time and during the programmed ignitions with the chronothermostat, it Fig. 1 is ADVISABLE to open the smoke screen 45 (1/2) OK FOR THE IGNITION OF THE HEARTH Never ignite if there is a larger quantity of pellets 10. By pushing the button for ignition, the control panel AUTOMATICALLY loads the amount of pellets up 2 cm to 2 cm from the edge of the hopper; then the electric resistance starts the ignition phase of the pellets. If for any reason the level of pellets is higher, when the resistance starts ignition, remove the excess pellets because this could cause a violent ignition. Before igniting for the second time, the level of Fig. 2 pellets must absolutely be as shown in fig. 1 OK FOR THE IGNITION OF THE RESISTANCE 12 Foghet water fireplace combined wood-pellet version with JOLLY ME 04 F burner

10 The electronic control panel now automatically controls the entire ignition phase in the following order : 1. LOAD PELLET up to 2 cm from the top of the hopper, this lasts around 4 minutes (LOAD WOOD is indicated on the display 2. IGNITION OF THE RESISTANCE AND THE FAN the combustion begins, it lasts around 4 minutes (FAN ASP is indicated on the display) 3. COMBUSTION STABILISATION the flame spreads gradually to the pellet in the hopper, this lasts around 10 minutes (FIRE ON is indicated on the display) 4. CHARGING PHASE TO THE PREVIOUSLY PRESET OUTPUT The fireplace has terminated the ignition phase and starts automatically running at the output level set the last time it was switched off (e.g. Po 2) which is indicated on the display) Every 30 minutes the fireplace automatically cleans itself (lasting 2 minutes) with pellet feeding at the min level and combustion at the max level (the words PUL FIRE -CLEAN FIRE- appear on the display and the relevant LED comes on). The burner automatically adjusts its operation to suit the readings from the boiler water temperature probe and the room thermostat. Once the boiler water has reached the set temperature, the boiler switches to Economy mode (ECO) and starts again when the temperature drops. If it goes out, the fire will not re-light until the temperature has decreased (wait for about 10 minutes). If after a couple of hours burning there is eccessive blackening of the glass or you notice that the pellet hopper is completely full and is overflowing, or there is insufficient pellet and too much air which pushes the pellet out of the hopper, or the fire goes out, this means that the pellet you are using does not correspond to the type that was tested on the appliance (for pellet characteristics see par. 1.15). It is therefore necessary to carry out some corrective action to solve the problem (see par ) Output settings for running on pellet, STANDARD control panel Foghet, during pellet burning can be set to the following output levels which are indicated on the display: Po 3 Po 2 Po 1 ECO = Maximum output = Medium output (optimum output recommended for best efficiency and results) = Minimum output = Economy output (automatically enabled when the boiler water reaches the set temperature, see paragraph 1.6.5) 1.6.5) BRAC: = Ember mode This keeps the fireplace in stand-by, with min pellet consumption, ready for fast lighting WITHOUT THE NEED TO USE THE HEATING ELEMENT. The Ember mode is enabled/disabled just manually. - + To increase the output press key 6 (+) To increase the output press key 5 (-) Foghet water fireplace combined wood-pellet version with JOLLY ME 04 F burner 13

11 1.6.4 Setting room temperature in Pellet mode, STANDARD control panel To keep the required temperature constant, the Foghet is fitted with a room temperature thermostat (standard control panel) or a room temperature probe (simplified control panel ) that automatically control the pump. Once the set room temperature has been reached, the pump switches off and the words T OFF appear on the display; then, when the room temperature drops, the pump starts again. N.B. When in Wood mode, the thermostat is disabled to protect the fireplace. To adjust the room temperature: vary the amount of wood in the hearth, open the fume register and open the primary combustion air register Setting the Economy threshold for the boiler water in Pellet mode, STANDARD control panel You can set the min boiler water temperature at which the fireplace switches to Economy mode (ECO) to increase or reduce the temperature of the water sent to the heating and plumbing circuits. Once the min temperature has been reached, the fireplace switches to Economy mode (ECO) Press the SET key for one second. Whilst the led are flashing: press key 1 to raise the temperature of the water in boiler. press key 2 to lower the temperature of the water in boiler. Setting pump start temperature +/ times As far as A9 15 times confirm 1" Exit 2 The preset starting temperature of the pump is 55 C, the recommended value is between 55 and 75 C How to silence an alarm, STANDARD control panel If an alarm appears on the display, to silence it and allow the fire to function it is necessary to proceed as follows: 4 Press key 4 for 4 seconds. N.B. If the fire goes out, it is not possible to re-ignite it until it has cooled down, wait for 10 minutes and repeat the ignition sequence. 14 Foghet water fireplace combined wood-pellet version with JOLLY ME 04 F burner

12 1.6.7 Summer mode, STANDARD control panel If you want to use the fireplace in the Summer for hot domestic water: 1 1 Select the summer operating mode Press SET for 1 second. Whilst the led are flashing press key 5 per 1 second. Check that the green led is on (see green arrow). 4 To switch on the fireplace: Press SET for 4 seconds. For a more economical working, we recommend lowering the boiler water threshold temperature to 45C - 55C N.B. if the fireplace is set to summer mode IT IS NOT POSSIBLE TO PERFORM AUTOMATIC PELLET IGNITION as the selector valve is closed for domestic water only N.B. if the fireplace is set to summer mode the chronothermostat is not enabled If you want to use the chronothermostat in Summer as well, we recommend to set the WINTER mode, lowering the threshold for the room temperature probe at min, so that the heating doesn t start. Foghet water fireplace combined wood-pellet version with JOLLY ME 04 F burner 15

13 1.6.8 Correction of problems due to combustion STANDARD control panel If, having installed the fireplace following all the instructions, after carefully cleaning the pellet hopper, the boiler unit, the flue and the external air inlets, the pellet does not burn well (or you are using a pellet with different characteristics than that used for testing the appliance), it is possible to adjust the flow of pellets through the charger (see page 29) and of combustion air can be modified to achieve the correct combustion ratio and the best performance. The various procedures to follow are outlined below. Comply with the indicated times when pressing the keys as shown in the images and follow the correct sequence (from left to right). 1 1 Manual hopper cleaning times Scroll to 01 Increase combustion air by 20% confirm 1" If after a few hours burning, the colour of the flame changes (from yellow it turns orange or red); activate a hopper cleaning cycle (the pellet rate will be reduced to minimum and the combustion air will rise to maximum for 2 minutes, PUL will be indicated on the display and the relative led will come on). If the problem persists, follow the steps below. If the window after 2-3 hours burning is excessively dirty, the pellet is not burning well, increase the combustion air rate (automatic 20% increase of combustion air at all output modes) times Scroll to 02 confirm 1" If little pellet enters the hopper, and the flame is uncertain and shaky increase the pellet rate (automatic 20% increase at all output modes) Increase pellet by 20% times Scroll to 03 Decrease combustion air by 20% confirm 1" If there is excessive combustion air, raise the pellet until it falls out of the hopper; reduce the combustion air rate. (automatic 20% reduction of combustion air at all output modes) 5 3 times 1 Decrease pellet by 20% Scroll to 04 confirm 1" If the pellet rate is excessive the hopper will fill up too much and the pellet will not burn well, create black smoke and dirty considerably; reduce the pellet rate (automatic 20% reduction at all output modes) times times Scroll to 05 Increase air and pellet by 20% Scroll to 00 Resetting to factory standard settings confirm 1" confirm 1" If the fire goes out when it is running in minimum or economy mode, increase simultaneously the air and pellet rates (automatic 20% increase at all output modes) If during these various attempts, the combustion gets worse instead of improving, it is possible to reset the appliance to the JOLLY-MEC factory standard settings. 16 Foghet water fireplace combined wood-pellet version with JOLLY ME 04 F burner

14 1.6.9 Time-controlled thermostat,standard control unit All STANDARD electronic control units are fitted with a timer-controlled thermostat which can be set to automatically ignite and switch off twice a day seven days a week. It is possible to set it to ignite once or twice a day at the desired times. The timer-controlled thermostat led indicates when it is activated. To programme the timer-controlled thermostat proceed as follows: Comply with the indicated times when pressing the keys as shown in the images and follow the correct sequence (from left to right). day01 = Monday day05 = Friday day02 = Tuesday day06 = Saturday day03 = Wednesday day07 = Sunday day04 = Thursday OFF = disabled 5 Scroll until you reach the current day of the week 1 Scroll the days of the week Select the function days with ON-OFF 1 Setting the current day 6 Set the days it must function with ON or OFF to set the 7 days 1 hour + hour - 1 hour + hour - 2 Set the correct time 7 Set the second ignition time 1 Minutes + Minutes - 1 hour + hour - 3 Set the correct minutes 8 Set the second switch off time 4 Set the first ignition time 2 times hour + hour - 1 hour + hour Set the days for the second ignition Scroll the days of the week with ON or OFF to set the 7 days Select the function days with ON-OFF 5 Set the first switch off time To cancel a wrong command press key 4 (ON/OFF) for one second and re-programme as required To enable or disable the timer-controlled thermostat without losing the settings proceed as follows: Disabling the timer-controlled thermostat whilst maintaining the memory (for eventual reset) Press to 5 OFF confirm 1" exit Re-enable timer-controlled thermostat with the previous memory 5 Scroll until you reach the current day of the week confirm 1" exit N.B. The chronothermostat is disabled in Summer mode. Foghet water fireplace combined wood-pellet version with JOLLY ME 04 F burner 17

15 Wood Ignition, STANDARD control panel Before igniting the wood fire it is necessary to complete some preliminary operations : Cast iron bottomgrates 1. Clean the hearth, the burner hopper and empty the ashpan 2. Manually open the flue gas damper by rotating the knob until the notch indicates position A and block it by pressing the knob until the fastener screws click into place. Notch 3. Move the cast iron bottomgrate located above the pellet burner Grate 4. Open the bottomgrate on the ashpan. 5. Open Caldo Control by pulling the lever Caldo Control 6. Check that the control panel is set to winter mode (the relative led must be on) see green arrow. 1" 1" 7. If the control panel is in summer mode (the relative led is on) switch it to winter mode. Press the SET key for 1 second and whilst the led flashes press key 5 for 1 second (the winter mode led will come on) see green arrow 8. Check that the control unit is set to wood mode or the appliance will ignite in pellet mode (the relative led must be on) see green arrow. 1" 1" 4" 9. If the control unit is in pellet mode (the relative led is on) switch it to wood mode. Press the SET key for 1 second and whilst the led flashes press key 6 for 1 second (the wood mode led will come on and LE will be indicated on the display) 10. Press key 4 for 4 seconds to switch on the control panel 11. Load the wood into the fireplace and switch the fire on. 12. Close the door. The fireplace s capacity and the duration of the fuel are regulated by the quantity of combustion air and the flue drought. This is done by regulating the quantity of the primary air to the ashpan (open or close the bottomgrate) and open/close the fume register The fireplace has an automatic primary combustion air control thanks to the CaldoControl device, which controls the fume register to reduce the secondary combustion air passage once the temperature of the boiler water reaches 55 C - 65 C. In order to have an output of 20,000 Kcal/h (23.2 kw), you need to burn 5-6 kg of wood an hour. 18 Foghet water fireplace combined wood-pellet version with JOLLY ME 04 F burner

16 Summary of the main functions to use the fireplace performed by the STANDARD control panel Comply with the indicated times when pressing the keys and work from left to right. The pump starts when the boiler water temperature is higher than the temperature set in paragraph The ember bed phase is handled manually, both during enabling and disabling phases, and is useful to achieve extremely low consumption rates nd when necessary quick manual ignition without the use of the resistance. N.B. If the fire goes out, it is not possible to re-ignite it until it has cooled down, wait for 10 minutes and repeat the ignition sequence. CHECK IF THE HOPPER NEEDS CLEANING EVERY DAY. After each modification IT IS NECESSARY to enable the chronothermostat (because it is automatically disabled). 1 Switching from wood to pellet mode and vice-versa Increase combustion air by 20% 2 Manual pellet loading and trial loading Press simultaneously 9 Increase Pellet 20% times As far as 02 1 confirm 3 Ignition or Switching Off 5 ON 5 OFF 10 Decrease combustion air by 20% times As far as 03 1 confirm 4 Switching from Summer to Winter mode or vice-versa Decrease pellet quantity by 20% times As far as 04 1 confirm times As far as 05 1 confirm 5 Manual Hopper Cleaning 12 Increase air and pellet by 20% 6 To increase the output press key 6 (+) Power Ember bed 4 To reduce output press key 5 (-) Return standard correction and modification 1 3 times As far as 00 1 confirm 7 Setting the Economy threshold for the boiler water (recommended 60/75 C ) times 14 Setting pump start temperature (recommended C ) As far as times +/- 1 confirm + 2 exit To cancel a wrong command press key 4 (ON/OFF) for one second Foghet water fireplace combined wood-pellet version with JOLLY ME 04 F burner 19

17 1.6 New-generation simplified electronic controller Ignition in wood burning mode Before lighting the pellet stove, a few preliminary operations are necessary: 1. Clean the fire bed and empty the ash pan. 2. Open the damper, turning the knob it until the notch is aligned with A, then lock it by pushing in the knob to engage the locking screw. Notch Cast iron grate Ash pan 3. Move the cast iron grate over the pellet burner. 4. Open the grille positioned on the ash pan. 5. Open the Caldo Control by pulling the lever. 6. Check that the controller is set to Winter mode (for heating and hot water production the corresponding LED must be lit). 7. Check that the controller is set to wood mode otherwise the stove will light in pellet mode (the corresponding LED must be lit). 8. Press ON. 9. Load the wood and light the fire. 10. Close the door. Automatic switching from wood to pellet mode With wood mode set, press the button WOOD again (the corresponding LED flashes) to activate automatic switching from wood to pellet mode. When the wood is finished and the boiler water temperature falls below the set limit, the burner starts automatically after 30 minutes. Cast iron grate Caldo Control WARNING! BUTTONS To switch automatically from wood to pellet mode, the damper must be set to 1/2, and the burner will temporarily operate with the grate over the burn pot. ON WINTER WOOD ON For correct operation in wood mode, the SET WOOD AIR function must be set to the value 2 in the Quick menu. The stove output and load duration are regulated by the amount of combustion air; to adjust the amount, adjust the primary air of the ash pan (opening or closing the grille). The stove has an automatic draught adjustment by means of the CALDO CONTROL (also adjustable manually), which operates the damper to reduce the primary combustion air passage section when the air reaches a temperature of around 70 C. To obtain a heating power of 23.2 kw (20,000 Kcal/h), it is necessary to burn 6-7 kg of wood per hour. WARNING! NEVER LIGHT THE STOVE IN WOOD MODE WITHOUT THE POWER CONNECTED. 17

18 1.7 Optimising combustion and damper use This stove/boiler offers excellent performance. When using pellets, for optimum operation without overloading the burner respect the following rules, making use of the pellet feed control. FIG. 1 FIG. 3 FIG. 5 FIG. 2 2 cm FIG. 4 FIG. 6 Step 1: manually load a small quantity of pellets using the command on the electronic controller (see FIG. 1). Do not exceed the recommended quantity and make sure the burn pot is secured by forcing it with the special screw. Step 2: carry out lighting. At the end of automatic loading, in the electrical element lighting stage, the quantity of pellets must never exceed the level indicated (see FIG. 2) in order to avoid violent ignition. Step 3: adjust the quantity of pellets according to their type and size using the feed control (see FIG.3) and respecting the weights given in the technical data; set the electronic controller to medium power; close the damper and the Caldo Control; set the combustion air and the pellets to 0%. The flame should be as in FIG. 4. While burning, the pellets must always remain below the upper holes of the burn pot and the flame must be clear. Step 4: when unburned fuel remains in the burn pot, use the pointed end of the poker to break up the encrustations and then the flat part to remove it and clean the combustion air holes (seefig.5). Step 5: in case of incorrect combustion or lighting problems, clean the burn pot, following the procedure in the plastic-coated quick reference notice. Step 6: about every 20 days, remove the upper baffle and clean it. The combustion air percentage (%) must not be set below -5% to avoid possible spontaneous combustion, dirtying the boiler excessively and blackening the glass (see FIG.6). Using the damper The damper can be set to 3 positions: open, half-closed and closed. It allows the correct adjustment of combustion according to flue draught (which also varies according to atmospheric conditions). The user should become familiar with damper use in order to optimise stove operation. To adjust the damper: pull the knob; turn it until the notch is at the required position; push the knob in fully so that it engages the special locking screw. A A A C C C 1 /2 A 1/ 2 A 1/ 2 A Notch Notch Notch CLOSED POSITION (C): Operation in pellet mode only (with optimum draught) HALF-CLOSED POSITION (1/2): During first lighting with pellets For automatic switching from wood to pellets Operation in pellet mode with smoke on lighting and/or glass very dirty Operation in wood mode at minimum (with simplified electronic controller) OPEN POSITION (A): Wood mode Operation in pellet mode with non-optimum draught ADVICE If smoke escapes even when opening the door slowly, with damper open and the flue complying with that given in chap. 2.1, the precut part of the smoke baffle shown in the figure can be removed. Careful adjustment of the damper is all-important for correct stove operation. 18

19 1.8 Advice and warnings IT IS IMPORTANT THAT THERE IS ALWAYS WATER IN THE BOILER AT A PRESSURE OF 1 to 1.2 BAR WHEN COLD, AND THAT THE MAINS CONNECTION FOR THE WATER REQUIRED TO COOL THE STOVE IS NEVER OBSTRUCTED. With a zone heating system, when the stove is lit, it is essential that at least one zone of the heating system is always open in order to dissipate the heat produced (also in summer). THE combustion fan must be cleaned at least once a year. Only use original replacement parts; original replacement parts are available from authorised dealers and Assistance Centres, or directly from JOLLY-MEC. There must be no other boilers, chimneys, stoves, fireplaces or extractor blowers located in the same room as the stove. When purchasing firewood, it is advisable to vary the sizes: short lengths (30/32 cm) for quick lighting and longer lengths. The greater the quality of the firewood, the greater its efficiency and operation. If condensation forms inside the stove, this may be caused by the following: - the central heating circulating pump is set to start at too low a temperature (it should set to start at C at the lowest). - the recirculation valve should open at around 45 depending on the system head. - poor flue draught (clean the flue). - Insufficient combustion air (increase the air by means of the combustion fan). - boiler dirty: every days, remove the smoke baffle and clean the stove, particularly around the upper part where it is connected to the flue. Use the flue brush to clean up as far as the damper. If the glass turns black during normal pellet burning mode, this may be caused by the following: - poor flue draught (clean the flue or check that the flue dimensions conform to requirements). - Insufficient combustion air (increase the air by means of the combustion fan). - quantity of pellets in the burn pot (this varies depending on the type of pellets used) is different from that given in the technical data (chap. 1.2). Check that, at medium power, the hourly pellet consumption; adjust the pellet feed rate, if necessary, by way of the feed control. In the case of ignition with quantity of pellets greater than that indicated on page 20, contact the Technical Assistance Service. If pellets have not been used for a long time (usually in the spring-summer), the hopper, auger and burn pot must be WARNING! DO NOT TOUCH any parts of the firebox not covered by the cladding, except the handles and controls, as they can become very hot. completely emptied with the aid of a vacuum cleaner. Then clean thoroughly to remove all pellet residue, which could become compacted and block the auger or damage parts the next time the stove is ignited. To obtain a heating power of 23.2 kw (20,000 Kcal/h), it is necessary to burn 6-7 kg of wood or 4-5 kg of pellets per hour. Never ignite the stove, particularly in wood mode, without electrical power. The stove must not be used as an incinerator. Only use recommended fuels, otherwise the warranty will be invalidated. Every kg of pellets loaded into the hopper, check that there is no build up of sawdust on the bottom; if necessary, remove all the sawdust (sawdust reduces the capacity of the feed auger and creates operating problems for the stove). The stove must always be closed, except when loading fire wood, to prevent smoke escaping. Check for any obstructions in the flue and the outside air inlets before lighting the stove after a long period of disuse. The firebox cannot be modified; any unauthorised modification automatically invalidates the warranty and relieves the Manufacture of any liability. The stove must not be placed in direct contact with combustible materials; the minimum distance is 20 cm. Regular systematic maintenance is essential to maintain the stove in perfect working order and optimum efficiency. MORE CLEANING = MORE EFFICIENCY 19

20 1.9 Cleaning the stove Initially, for a few days during operation with pellets, check the burn pot to determine how often it needs cleaning. Before any cleaning, always turn off the main switch and make sure the stove is cold. Cleaning the burn pot Removing the burn pot after loosening the locking screw with the special wrench. Carefully clean all the air holes in the burn pot with a pointed tool. Make sure the burn pot support is clean (if the burn pot is not correctly positioned and air escapes, the stove will not light or operate properly; smoke could also enter the pellet hopper). Position the burn pot correctly, pushing it to the left by means of the locking screw located on the right side of the burn pot container (make sure to tighten the screw). Cleaning the smoke baffle Every days, or even more frequently, depending on the type of fuel used, flue draught and weather conditions, remove the smoke baffle by lifting it up and pulling out the fixing pin (FIG.1). Lower and remove it (FIG. 2). Carefully clean all the top part of the stove up to and including the damper. Refit the smoke baffle so that it rests on the rear support hooks obtained in the boiler body (FIG. 3) and insert the front pin in the hole on front of the stove. FIG. 1 FIG. 2 FIG. 3 Lift the baffle and pull out the fixing pin Hole for fixing pin Rear support hooks Cleaning the glass When using the stove in pellet mode, clean the glass every day with a damp sponge or a paper towel. If the glass becomes dirty with black smoke, clean the burn pot or increase the combustion air. When operating in wood mode, use specific products. Do not use aggressive cleaning products that could damage the paintwork. If the stove requires more frequent cleaning, check the flue draught and make sure the smoke baffle is clean (the minimum draught must be 12 Pascal; do not use the stove if the draught is less than the specified value). Cleaning the ash pan Empty periodically when necessary. Cleaning the stove body Remove the wood guard, cast iron grates and burn pot. Using the flue brush and brush supplied, clean the corrugated sheet, making sure the soot falls into the ash pan. Empty the ash pan and carefully clean the box. If necessary, use a vacuum cleaner to remove soot and ash. Clean the pellet burn pot with a wire brush and a pointed tool. Refit all parts correctly. Cleaning the flue Routine flue cleaning depends on the draught, stove use, weather conditions and the type of wood or pellets used. It is advisable to have the flue cleaned by a specialised technician once a year, in autumn before lighting the stove. Cleaning the pellet hopper Every kg of pellets burned, empty the hopper and remove any sawdust deposited on the bottom. Carefully clean the bottom of the hopper. In case of long idle periods, empty the hopper and the auger. Cleaning the fans Once a year remove the combustion fan and remove all dust and dirt from the blades. 20

21 1.10 Parts that can be removed to clean the stove A B A Cast iron grates B Pellet burn pot C Ash pan D Smoke baffle E Fire bed F Wood guard and removable door support (curved front model only) C D E F Cleaning tools supplied Burn pot cleaning tool Shovel Poker Flue brush Small brush 21

22 1.11 Plumbing kit components requiring routine maintenance Pump If the pump is locked up, to release it, remove screw 1 and turn the internal screw 2 using a screwdriver. Diverter valve No maintenance required. Pressure relief valves To be cleared once a year. 1 2 Pressure reducer with pressure gauge For annual cleaning of the filter, remove the cap 3 using a pipe wrench, extract the filter 4, clean it and replace it. Adjust the pressure (1.0 to 1.2 bar) by way of screw 5. Flow switch The hot water pump starts when a tap is opened. No maintenance required. Jolly bleed valves Bleed air from the system if air bubbles are present Temperature relief valve Button 6 is to be used to manually vent the temperature relief valve in the event of loss of water due to boiling and operation without water. Nut 7 to be slackened off in the event of water loss (maximum 1/2 a turn) and monitored thereafter. Plate-type heat exchanger If there is a drop in the hot water flow rate, have the heat exchanger either cleaned by a qualified technician (using specific cleaning products) or replaced (replacement heat exchangers are available from authorised dealers and Technical Assistance Centres). 6 7 Expansion tank Check once a year that the prefill pressure is 1.5 bar. 22

23 1.12 Troubleshooting WARNING! Do not use the stove if the draught is not regular and combustion is not optimum! PROBLEM CAUSE AND/OR CURE The electronic controller does not switch on No pellets enter the burn pot The auger does not rotate The stove does not light automatically in pellet mode The pellets burn poorly forming incompletely combusted residue in the burn pot, the glass gets very dirty and turns black At minimum power, the stove always goes off because not enough pellets are fed At minimum power, the stove always goes off because too many pellets are fed and do not burn Smoke escapes when the door is opened, the pellets burn poorly, or the glass gets dirty (particularly when used with wood) Check for possible power supply or mains problems. Check that the green connector of the display is correctly connected at the rear. The electronic controller is faulty. The electronic controller is in wood mode. Select pellet mode. The pellets are finished, refill the hopper. The auger is blocked by pellets that are too hard (only use pellets of the recommended type); free the auger by turning the pin protruding from the burner casing. The gear motor is not powered (check and eliminate the causes). The gear motor does not turn even though powered (remove the gear motor, free the auger with a screwdriver and refit the gear motor). The motor turns but the auger does not move. Replace the gear motor (broken gears). SUMMER MODE is set. The burn pot is dirty. Clean it thoroughly and refit correctly. The burn pot is not correctly positioned. Reposition and clamp it, tightening the locking screw with the special wrench supplied The electrical element is faulty; replace the electrical element. In the meantime, light the stove manually using firelighters (or similar products). The quantity of pellets fed into the burn pot at the various power levels does not comply with that given in the Technical Data (see chap. 1.2). Check and correct. Insufficient flue draught (do not use the stove, it could be dangerous). Clean the flue and the stove thoroughly. Pellet burn pot dirty. Clean it. Pellets damp. Replace with dry pellets. Insufficient combustion air; check that the combustion fan pipe is unobstructed and clean the fan. Insufficient combustion air setting. Increase the setting in the SET COMB. AIR function in the Quick Menu. Too much sawdust on the bottom of the hopper. Empty the hopper and refill with new pellets. (every kg of pellets loaded, empty the hopper and remove all the sawdust deposited on the bottom). Increase the pellet feed in the SET PELLET % function in the Quick Menu. Reduce the pellet flow rate in the SET PELLET % function in the Quick Menu. Increase the combustion air. If the stove is installed in a room in communication with a stairwell, close off the stairwell by installing a door. There are other appliances that use room air, creating low pressure. Use the stove when the other appliances are off. The outside air inlets and/or the flue are partially or completely obstructed. Clean or remove the obstructions. Insufficient flue draught: there are horizontal sections or 90 bends, or the chimney cap is located under the ridge of the roof (installation errors). Remove the precut part from the smoke baffle (see chap. 1.7); replace the horizontal sections with sections at 45 ; raise the chimney cap, or fit an antiwind cap. Check that the flue conforms to the indications given in chap. 2.1, clean the flue and smoke baffle, open the damper, open the door slowly. If after these operations smoke still comes out, eliminate the precut part of the smoke baffle (see chap. 1.7). 23

24 1.12 Troubleshooting PROBLEM CAUSE AND/OR CURE No hot water flows when a tap is opened THE electrical power is disconnected, reconnect it; or the controller is set to OFF; switch it on by pressing ON. The hot water flow tap is closed; open it. The diverter valve does not operate; check that it is connected correctly and not stuck. The pressure in the boiler is too low and the flow switch provides no contact. Return the pressure to 1 to 1.2 bar when cold by way of the pressure control-reducer and/or by checking the system. The flow control switch is disconnected, dirty or faulty; reconnect it or replace it. The pump does not start; check that it is connected correctly and not stuck; if necessary, free it using a screwdriver (as shown in chap. 1.11). Little hot water flow Excessive condensation forms inside the stove The circuit breaker trips The radiators do not get hot even if the water in the boiler is hot and the pump is running The plate-type heat exchanger is clogged with limescale; remove it and clean it or replace it. The pressure inside the boiler is too high and the 2.5 bar pressure relief valve discharges continuously. Restore the pressure to bar when cold using the pressure regulator-reducer. The recirculation valve is not sufficiently open; open it. The temperature at which the pump starts is set too low; increase the temperature setting. When the stove is first used, or after a long period of disuse, condensation may form in the igniter; carry out one or more manual cleaning operations by way of the controller to dry out the condensation in the igniter, or light the stove manually. The diverter valve does not operate; check that it is connected correctly and not stuck. There is air in the system; bleed all the radiators, the pump and the boiler. Main electronic controller alarms (see par ) PROBLEM CAUSE AND/OR CURE No pellets Boiler overheating Fume probe Boiler probe Room probe Combustion air blower stopped Fume exhaust Second ignition attempt failed Low pressure High pressure The stove hopper (or supplementary hopper) is empty. Add pellets. The water temperature is too high. The pellets or burner go out. Zone valves may be closed or problems in the system. Check and clean. Fume temperature probe faulty or not properly connected. Check the connection or replace the probe. Water temperature probe in stove faulty or not properly connected. Check the connection or replace the probe. Room temperature probe faulty or not properly connected. Check the connection or replace the probe. Blown fuse. Check and replace. Safety thermostat activated. Empty the ash pan and clean the surface under it. Wait until the stove has cooled then try again. Combustion fan faulty. Contact the Technical Assistance Service. Pressure switch activated. Check the flue. Empty the burn pot, check the gear motor and the electrical element. Try lighting again. System pressure below 0.5 bar (for sealed systems). The stove goes out. Increase the pressure by automatic filling, or clean. System pressure greater than 2.4 bar. The stove goes out. Reduce the pressure set for automatic filling and drain the boiler via the 2.5 bar pressure relief valve until the pressure falls to between 1 and 1.2 bar. WARNING! For alarms different from those listed, persistent problems or other problems not described above, contact the Technical Assistance Service. 24

25 1.12 Troubleshooting If the stove fails to light after the second attempt, proceed as follows: 1. Remove the burn pot, loosening the locking screw with the wrench supplied or pliers Clean and scrape the sides, clean all the holes. 3. Clean the burn pot chamber. 4. Refit the burn pot, paying attention to the pellet feed hole. 5. Make sure the upper flange is perfectly positioned on the support surface. 6. Secure the burn pot with the locking screw using a wrench or pliers. 7. Using the special wrench or a nail, make sure the hole in the burn pot and the hopper is aligned Press the button to manually load the stove until the pellets start entering 9. Before pressing the ignition button make sure the burn pot is empty except for just a few pellets on the bottom (FIG.8). Never light the stove if there are more pellets. THE STOVE can now be lit Press the ON button on the electronic controller (FIG. 9) to light the stove. 11. On pressing the ignition button, the electronic controller AUTOMATICALLY loads pellets up to 2 cm below the rim of the burn pot; the electrical element then starts the pellet igniting stage WARNING! If the lighting cycle fails again, contact the Technical Assistance Service. 25

26 1.13 Optionals H A B C D E F G I J K A Hood vent grille 400x100 mm B Universal flue connection C MF connection for Ø 150 mm double wall flexible pipe D Ø 150 mm double wall flexible stainless steel flue E Ø 150 mm smooth stainless steel flue F Connection for Ø 150 mm rigid pipe G Ø 80 mm aluminium ducting for combustion air fan H 230x230 mm grille for outside air inlet I Stainless steel meat grill with removable handle (320x190x100 mm) J Hood door for pellet feed K Side panel door for inspection and various maintenance L Second flap door to facilitate cleaning (for curved front model only) M Ash box and wood holder N Holder for second door (optional for curved front model only) complete with spring and stove cleaning accessories (standard) L M N To fit the removable flap door (optional for curved front model only) Open the outer door. Insert the pins of the removable door in the special holes obtained in the support, pushing it on one side. Close the removable door using the poker, engaging it with the hook provided at the top right. Close the outer door. 26

27 1.14 Larger capacity supplementary pellet hoppers For a longer burn time, it is possible to install a supplementary pellet hopper, available in various capacities according to needs. The pellets can be conveyed in two ways: by auger or with pneumatic conveyance. Pellet hopper with pneumatic conveyance Example with larger pellet hopper positioned in a room distant from the Foghet, with pneumatic conveyance. Larger capacity pellet hopper (400 kg or 700 kg) NOTE! Max. conveyance distance: 28 metres Max. height: 8 metres. Special lid Flexible pipes in PVC ø 50 mm Pneumatic conveyance fan Standard pellet hopper, 46 kg capacity Safety device with filter Pneumatic conveyance control unit Pellet hopper with auger Example with larger capacity pellet hopper positioned in a room adjacent to the stove. NOTE! Pellet feed auger with gear motor The downward inclination of the pellet conveyance pipe (PVC) must never be less than 45. ø 63mm PVC connection pipes Standard pellet hopper, 46 kg capacity Larger capacity pellet hopper (400 kg or 700 kg) 27

28 1.15 Pellet quality WARNING! THE QUALITY OF THE PELLETS IS VERY IMPORTANT. PLEASE READ THE NEXT PAGE CAREFULLY. IT is important to select pellets that are free of dirt and impurities. The Pellet Producers Association has established standards for producers of wood pellets. Ask your dealer for the best type of pellets. STOVE performance depends very much on the type and quality of the wood pellets used. The efficiency and heating capacity of the stove will vary according to the quality of the wood pellets used. JOLLY-MEC CAMINETTI S.p.A. recommends using the same type of pellets as those used to test the stove, since combustion parameters vary from pellets to pellets. JOLLY-MEC CAMINETTI S.p.A. declines any liability for malfunctioning, faults or problems due to the use of nonrecommended pellets. As JOLLY-MEC CAMINETTI S.p.A. does not have control over the quality of pellets used, it declines any liability for problems caused by the use of non-recommended pellets. STANDARD PELLET CHARACTERISTICS Dust Density Dimensions Ash content Moisture Heating power 1% max. through 3.2 mm screen 640 kg/m 3 min diameter 6 mm; max. length 25 to 40 mm 1% max 8% max 5,200 kwh/kg Store pellets at a distance of at least 1 m. from the stove. Do not use pellets that are very hard and of different sizes: the mechanical parts are sized and tested for use with pellets having the above characteristics. WARNING! Any fault or malfunction due to the quality or quantity of pellets used (see chap. 1.8) will not be covered by the warranty. 28

29 1.16 Use and keeping of the installation and maintenance card Card recipients The installation and maintenance card is intended for users responsible for stove operation; particular attention must be paid the parts concerning safety. Purpose of the card The card contains information on the correct use of the stove, according to the purposes for which it was designed and built. It also provides information about weights, commissioning, repair and maintenance of the stove in compliance with the limits laid down by the Manufacturer, specified inside the card. Keeping the card The installation and maintenance card is an integral part of the stove and must be kept until scrapping of the same. It must be kept in a safe and dry place away from direct sunlight, and near the stove so that it is always readily available for reference. If lost or damaged, the user should request a copy from the Manufacturer. Updating the card The installation and maintenance card reflects the state of the art at the time the stove was marketed. The Manufacturer reserves the right to make changes to the stove, and consequently to the relevant card, without having to update previous editions. The user can always request information and updates which, when issued, become an integral part of the installation and maintenance card. If selling or transferring the stove, the user is requested to also give the new owner the card and in any case to inform the Manufacturer, so that the new owner can receive subsequent supplements. Cases relieving the Manufacturer from liability The Manufacturer is relieved from any liability in the following cases: a) improper use of the stove. b) use not intended by specific national regulations. c) incorrect installation. d) feed defects. e) failure to carry out maintenance as prescribed. f) unauthorised modifications or operations. g) use of replacement parts that are non-original or not specific to the model. h) total or partial failure to follow the instructions. i) exceptional events (e.g.: breakage due to natural disasters). j) damage caused by electrical power cuts, sudden fluctuation of supply voltage, electromagnetic fields. k) the use of pellets with characteristics different from those recommended in this card. 29

30 1.17 Warranty The Warranty Certificate is based on the Warranty Terms given below. It is valid to all intents and purposes only if sent to JOLLY-MEC CAMINETTI S.p.A. within and not later than one month from the date of purchase. All parts of the Warranty Certificate must be filled in clearly and correctly. If sending this sheet by fax, please use the number For any technical requirements or servicing requests, please contact the Call Center of our Sales Support Office at the number , or Warranty terms 1. Duration: JOLLY-MEC CAMINETTI S.p.A. guarantees the boiler body for 5 years, and every other individual part for 2 years, as required by law, excepting those parts subject to wear due to use (glass, cast iron grates, ignition electrical element and burn pot). The accessories (electrical, etc.) will be covered by the warranties provided by the various manufacturers. This warranty is valid only if the stove is installed and used according to the instructions given in the manual supplied, which the purchaser declares to have received and read. Any fault or malfunction due to the quality of the pellets used will not be covered by the warranty. JOLLY-MEC CAMINETTI S.p.A. reserves the right to make improvement modifications without prior notice. WARNING! To be entitled to replacement of parts or the assistance of our technicians under the warranty, a copy of the receipt or purchase invoice MUST be attached to the Warranty Certificate. The warranty comes into effect only from the moment JOLLY-MEC CAMINETTI S.p.A. receives the Warranty Certificate duly filled in and sent within the terms and methods indicated in point (3). model; - total or partial failure to follow the instructions or complaints that do not conform to the constructional characteristics of the product; - exceptional events; - damage caused by power failures, voltage rushes, electromagnetic fields. 3. Variation: The right to the warranty undergoes variations with regard to the 5 year duration indicated in point (1) if the Warranty Certificate is not received by JOLLY-MEC CAMINETTI S.p.A. within 30 days of the date of purchase of the product. In this case, the 2-year warranty period will start from the date of purchase by the Customer. 4. Operations not covered by the warranty: If the Customer requests any assistance different from that provided for in the Warranty Terms he shall be required to pay the corresponding cost calculated on the basis of the prices normally applied by the authorised Technical Assistance Centre. 5. Transferability of the warranty: The warranty cannot be transferred to third parties and applies only to the first purchaser. 2. Exclusions: The Customer is not covered by the warranty in the following cases: a) if the data given on the Warranty Certificate does not correspond to a product sold by JOLLY-MEC CAMINETTI S.p.A. b) if the Warranty Certificate is incomplete or not filled in correctly c) if the cause of the fault is not due to defects in the product but to external factors, such as: - improper use of the product; - use not envisaged by the specific national regulations; - incorrect installation; - feed defects; - failure to carry out maintenance as prescribed; - modifications or operations not duly authorised; - use of non-original replacement parts or not specific to the 1.18 Assistance Service Should you require support, contact the dealer who supplied the product or the JOLLY-MEC CAMINETTI S.p.A. After-Sales Technical Service Dept. JOLLY-MEC CAMINETTI S.p.A. - Via Fontana, Telgate - BG - ITALY tel: fax assistenzatecnica@jolly-mec.it 30

31 2.1 Flue The flue is an all-important element for efficient stove operation. The cross section of the flue must be that indicated in the stove technical characteristics. Every stove must have its own flue, excluding other emissions (stoves, boilers, fireplaces, etc.) The dimensions of the flue depend on its height, to be measured from the stove to the bottom of the chimney cap. To ensure adequate draught, the fume outlet area of the cap must be double the cross section area of the flue. The pipe used to exhaust the fumes generated by the natural-draught stove must: - be fumetight, impermeable and adequately insulated according the conditions of use (see UNI 9615). - be made from materials able to withstand the normal mechanical stresses, heat, and be resistant to the action of fumes and possible condensate. - be mainly vertical, with deviations from the axis not exceeding be at an adequate distance from combustible or flammable materials (by means of an air space or suitable insulation) - preferably have a round internal section: square or rectangular sections must have rounded corners with radius of at least 20 mm. - have a uniform, free and independent internal section. - have the rectangular sections with a max. ratio between the sides of 1.5:1. An antiwind-type cap is advisable. If the flue is installed externally, it must be insulated to prevent the cooling of fumes and the formation of condensate. The same applies to the section from the roof to the chimney cap. For the connection between the flue and the stove, or in the presence of branches or bends, or for easier, quick and safe installation, it is advisable to use double wall stainless steel pipes without insulation inside hoods. Non-combustible materials resistant to the fumes and their possible condensate must be used for installing the fume ducts. The use of asbestos cement pipes to connect appliances to the flue is prohibited. The fume ducts must not cross rooms in which the installation of combustion appliances is prohibited. The fume ducts must be installed in such a way as to ensure fume tightness when the stove is in negative pressure operating conditions and to avoid the formation of condensate and its conveyance to the unit. Horizontal sections should be avoided as much as possible. For exhaust pipes which must reach ceiling or wall outlets that are not co-axial with respect to the stove fume outlet, changes of direction must be made using open elbows not exceeding 45 (see FIG.1). Do not use elements sloping in the other direction. The exhaust pipe must enable removal of soot and cleaning by brush. The exhaust pipe must have a uniform cross section. Any changes in section are only permitted at the generator outlet; reduction adapters must not be used at the connection with the flue. Do not route other air supply and system pipes inside the exhaust pipes even if the latter are over-sized. Do not support the weight of the flue on the stove/fireplace connection. Use special brackets or separate supports. Other stoves, fireplaces, boilers or air extractors must not be installed in the same room. Minimum height of exhaust pipe: 3 metres. FIG. 1 31

32 B 2.2 Prearrangement for connections and air inlets of the stove positioned in a corner Centre line Air inlet (mandatory) Pellet burner fan ducting (optional) A A Caldo Control ducting (optional) Ø 150 C C a b c d e Mains water inlet 1/2 Pressure relief valve discharge 3/4 Hot water flow 1/2 Heating flow 3/4 Heating return 3/4 D E F G Fan outside air inlet (optional) Ø b d a c e 300 Ø Ambient temperature or ambient thermostat probe Power supply 220V 50Hz 150 Outside air inlet 200x200 mm (mandatory) Outside air inlet for Caldo Control (optional) Omnipolar switch 1400 All measurements are in millimetres (mm) COVERING art. A B C D E F G DO-IT-YOURSELF , 14000, , (mod. wood) The positions of the holes for the fan and Caldo Control ducting can also be moved provided they remain inside the covering. For firewood-pellet Foghet stoves it is mandatory to have the three doors indicated in par. 1.4 to permit loading pellets, servicing the pellet burner and the plumbing kit. 32

33 2.3 Prearrangement for electrical connections and air inlets with wall installation a b c d e Mains water inlet 1/2 Pressure relief valve discharge 3/4 Hot water flow 1/2 Heating flow 3/4 Heating return 3/ b a Ambient temperature or ambient thermostat probe d c e 1400 Outside air inlet 200x200 mm (mandatory) Ø V 50Hz power supply Ø Burner fan outside air inlet (optional) 480 Centre line Outside air inlet for Caldo Control (optional) 800 (without bench) 1500 (with bench) Outside air inlet for Caldo Control (optional) Omnipolar switch All measurements are in millimetres (mm) The holes for the fan and Caldo Control ducting can also be moved provided they remain inside the covering. For firewood-pellet Foghet stoves it is mandatory to have the three doors indicated in par. 1.4 to permit loading pellets, servicing the pellet burner and the plumbing kit. 33

34 2.4 Adjusting the feet After preparing the flue and all the electrical and plumbing connections and air intakes, as described in the previous pages, position the stove and level it, adjusting the feet with a 19 mm wrench (seefig.1). FIG Damper and friction unit assembly Proceed as follows: Remove the gold knob from the rod by loosening the fixing grub screw with a 2.5 mm Allen key. Insert the rod in the hole provided in the electronic controller compartment. Prepare two ø 4 mm holes for the friction unit fixing screws (see FIG.1). Fix the position indicator and friction unit with the two screws supplied and screw the ring (see FIG.1). FIG. 1 Screws Position indicator Ring nut Rod Friction unit Knob Fit the gold knob so that when the damper is vertical, (i.e. open, as in FIG. 2), the Jolly-Mec logo is vertical and the notch on the knob is aligned with A (see FIG.3). FIG. 2 FIG. 3 C 1/ 2 A A Notch 34

35 2.6 Caldo Control The Caldo Control is a Jolly-Mec patented device enabling automatic adjustment of the primary combustion air according to the air temperature read by the bulb (FIG.5) in the boiler This device gradually reduces the combustion air flow when the air temperature rises. The Caldo Control optimises stove fuel consumption, thus extending burn time. The Caldo Control must only be activated in wood-burning mode (FIG. 1); during pellet mode operation, push the lever indicated in FIG.2all the way to close the air inlet. The Caldo Control can be adjusted, after a settling stage, by operating the adjustment screw (FIG.6). FIG. 1 FIG. 2 FIG. 3 Wood mode: pull the lever in the direction of the red arrow (air open) Pellet mode: push the lever all the way in the direction of the red arrow (air closed) Wood mode: Caldo Control grille open (with stove just lit or in shutdown stage) FIG. 4 FIG. 5 FIG. 6 Caldo Control adjustment screw (use an Allen key or by hand) Wood mode: Caldo Control grille open (with stove hot) Caldo Control bulb support (on top of stove) Detail of inside of stove after removing the cast iron grates and fire bed. Turn the adjustment screw until the damper starts to close. 35

36 2.7 Standard hydraulic kit With production of domestic hot water in a sealed system Pressure relief valve discharge 3/4 Mains water inlet 1/2 Heating system delivery 3/4 Heating system return 3/4 Boiler drain 36

37 2.7 Standard hydraulic kit Without production of domestic hot water in a sealed system Pressure relief valve discharge 3/4 Mains water inlet 1/2 Heating system delivery 3/4 Anti-condensation recirculation valve (behind check valve) Heating system return 3/4 Boiler drain 37

38 2.8 Non-standard plumbing kit With production of domestic hot water in an open-vented system, connected to the mains water supply for domestic hot water and boiler cooling To the expansion tank with float 3/4 Temperature discharge 3/4 Hot water flow 1/2 Mains water inlet 1/2 Heating system delivery 3/4 Anti-condensation recirculation valve Heating system return 3/4 Boiler drain 38

39 2.8 Non-standard plumbing kit Without production of domestic hot water in an open-vented system connected to mains water supply for boiler cooling To the expansion tank with float 3/4 Pressure relief valve discharge 3/4 Mains water inlet 1/2 Heating system delivery 3/4 Anti-condensation recirculation valve Heating system return 3/4 Boiler drain 39