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INSTALLATION, USE AND MAINTENANCE MANUAL

To be kept by the purchaser

Pellet operated air heating fireplace

INSERTO STAR 68 INSERTO SYNTHESIS 68

INSERTO STAR 80 INSERTO SYNTHESIS 80

INSERTO SYNTHESIS 68-80 INSERTO STAR 68-80

Dear Customer, thank you for having chosen to heat and save with a Jolly Mec product. Please carefully read and keep this sheet

before using the equipment. This sheet provides necessary information and suggestions on how to correctly install, use, clean and maintain

the product. Knowing and observing these instructions will allow you to fully and safely enjoy the potential your equipment can offer you.

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TABLE OF CONTENTS

CHAP.01 PREMISES...................................................................................................................................4 01.1 WARNINGS .................................................................................................................................................. 4 01.2 SYMBOLOGY ............................................................................................................................................... 5 01.3 APPLIED STANDARDS ................................................................................................................................ 5 01.4 USE AND STORING OF THE INSTALLATION AND MAINTENANCE MANUAL ......................................... 6 01.5 MANUFACTURER LIABILITY AND WARRANTY CONDITIONS ................................................................. 6

CHAP.02 ACCIDENT PREVENTION / SAFETY REGULATIONS ..............................................................7 02.1 GENERAL CONSIDERATIONS .................................................................................................................... 7 02.2 SAFETY REGULATIONS FOR ROUTINE MAINTENANCE AND USE ........................................................ 7 02.3 SAFETY REGULATIONS FOR EXTRAORDINARY MAINTENANCE AND INSTALLATION ....................... 8 02.4 EQUIPMENT FOR OPERATORS AND MAINTENANCE PERSONNEL ...................................................... 9 02.5 RESIDUAL RISKS ........................................................................................................................................ 9

CHAP.03 HANDLING AND TRANSPORT ................................................................................................10 03.1 RECEIVING GOODS .................................................................................................................................. 10 03.2 LIFTING AND TRANSPORT ....................................................................................................................... 10

CHAP.04 ECOLOGICAL REGULATIONS ................................................................................................ 11 04.1 WASTE MATERIALS AND THEIR DISPOSAL ........................................................................................... 11 04.2 DISPOSAL OF THE MACHINE .................................................................................................................. 11

CHAP.05 DESCRIPTION...........................................................................................................................12 05.1 PRODUCT PRESENTATION ...................................................................................................................... 12 05.2 PRODUCT IDENTIFICATION ..................................................................................................................... 14

CHAP.06 TECHNICAL DATA ....................................................................................................................15 06.1 HOMOLOGATION ...................................................................................................................................... 15 06.2 RECOMMENDED FUELS .......................................................................................................................... 16 06.3 COMPONENTS .......................................................................................................................................... 17 06.4 OPTIONALS ............................................................................................................................................... 18 06.5 DIMENSIONS ............................................................................................................................................. 19

CHAP.07 POSITIONING AND CONNECTIONS FOR THE INSTALLER ..................................................20 07.1 POSITION OF EXTERNAL AIR INTAKES AND ELECTRIC CURRENT .................................................... 20 07.2 ASSEMBLING AND INSTALLING THE FIREPLACE IN A PRE-EXISTING FIREPLACE .......................... 21 07.3 ASSEMBLING AND INSTALLING THE FIREPLACE IN A NEW FIREPLACE ........................................... 22 07.4 AIR CIRCULATION ..................................................................................................................................... 23 07.5 EXAMPLE OF AIR DUCTING IN THE VARIOUS ROOMS ........................................................................ 23 07.6 FLUE OR FUME EXHAUST SYSTEM ....................................................................................................... 25 07.7 INSTALLATION ROOM VENTILATION ..................................................................................................... 26 07.8 ELECTRICAL CONNECTIONS .................................................................................................................. 27 07.9 CONTROL UNIT ......................................................................................................................................... 27 07.10 CONTROL UNIT ELECTRICAL WIRING DIAGRAM .................................................................................. 28

CHAP.08 USE AND MAINTENANCE FOR THE USER ............................................................................29 08.1 APPLIANCE OPERATIONS ....................................................................................................................... 29 08.2 DOOROPENINGANDINSETFIREPLACEEXTRACTION(onlywithfireplaceoffandcold) ................... 29 08.3 EMERGENCY CONSOLE .......................................................................................................................... 30 08.4 REMOTE CONTROL ...................................................................................................................30 08.5 SAFETY THERMOSTAT PELLET TANK WITH MANUAL RESET ............................................................. 30 08.6 RECOMMENDATIONS AND WARNINGS .................................................................................................. 31 08.7 ORDINARYMAINTENANCE(tobedonebythecustomer) ....................................................................... 32 08.8 PREVENTIVEMAINTENANCEPROGRAM(TobedonebyaspecialisedTechnicalServiceCenter) ............................. 34

CHAP.09 FAULT DIAGNOSIS AND TROUBLESHOOTING ....................................................................35 09.1 PROBLEMS ................................................................................................................................................ 35

CHAP.10 ATTACHMENTS ........................................................................................................................36

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CHAP.01 PREMISES

01.1 WARNINGS

• Familiarityandcompliancewiththeinstructionsgiveninthismanualwillensurequickinstallationandcorrectuseoftheappliance.

• Readthemanualattentivelybeforecommencinginstallation,andbecertaintofollowthedirectionsitcontains,otherwisethewar-rantycouldbeinvalidatedandtheperformanceandsafetyoftheappliancejeopardized.

• Theinstallationmanualisanintegralpartoftheproductandmustbegiventotheuser.

• Itmustbekeptinasafeplaceandconsultedcarefully,asallofthewarningsprovideimportantinformationonsafetyduringinstal-lation,useandmaintenance.

• Incorrectinstallationoftheappliancecouldcausedamageandinjurytopeopleoranimals,forwhichthemanufacturecannotnotbeheldliable.

• InstallationshallbeperformedbyqualifiedoperatorsinaccordancewiththeregulationsinforceintheCountryofinstallation.

• Themanufacturerdeclinesanycontractualornon-contractualliabilityfordamagescausedbyerrorsininstallationoruseoftheapplianceorfailuretofollowtheinstructionscontainedinthismanual.

• AllrightsonthereproductionofthistechnicalmanualareownedbyJollyMecCaminettiS.p.A.

• Thedescriptionsandillustrationsprovidedinthefollowingpublicationarenotbinding.

• JollyMecCaminettiS.p.Areservestherighttomakeanymodificationsthatmaybedeemedappropriate.

• ThismanualcannotbegiventothirdpartiesforperusalwithoutthewrittenpermissionofJollyMecCaminettiS.p.A

• Thetechnicaldirectionsforinstallationcontainedinthismanualshouldbeconsideredasbasicrequirements.Regulationsinsomecountriesmaybemorerestrictive;inthisinstance,complyfullywiththeregulationsprevailinginthecountryofinstallation(all laws and local bylaws must be observed when installing and using the appliance, including those referring to national and European standards).

• Neverusetheapplianceasanincinerator,orinwayotherthanthatforwhichitwasdesigned.Anyotheruseisdeemedimproperandthereforedangerous.

• Donotusefuelsthatarenotrecommendedunderpenaltyofcancellationofthewarranty.

• Whentheapplianceisrunning,theglassandothervisiblepartsreachextremelyhottemperaturestothetouch;handlewithextremecaretoavoidburns.

• Donotplacetheapplianceindirectcontactwithcombustiblematerials.

• Donotmakeanyunauthorisedmodificationtotheappliance.Anyunauthorisedmodificationwillautomaticallyinvalidatethewarrantyandreleasethemanufacturefromallliability.

• Useonlyoriginalsparepartsrecommendedbythemanufacturer.Originalsparepartsareavailablethroughretailers,specialisedTecnicalServiceCenters,ordirectlyattheheadofficeofJollyMecCaminettiS.p.A.

• Acceptanceofthemachinebytheusermustbe“total”,includingthesoundlevelofoperation,comparabletoanelectricalappliance.Complaintsforcharacteristicsnotindicatedinthismanualshallnotbeaccepted.

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01.2 SYMBOLOGY

Inthismanual,pointsofconsiderableimportancearemarkedwiththefollowingsymbology:

INSTRUCTION: Instructionsregardingthecorrectuseoftheappliance.

WARNING: Thispointisparticularlyimportant.

DANGER: Animportantpointregardingbehaviourforpreventinginjuryanddamagetomaterialsisexpressed.

01.3 APPLIED STANDARDS

AllJOLLYMECproductsareconstructedaccordingtothefollowingdirectives:

• EU 305/2011 Europeanconstructionproductsregulation.• 2006/42/CE Machines.• 2014/30/UE Electromagneticcompatibility(EMC).• 2014/35/UE Lowvoltage(LVD)-electricalsafety.• 2011/65/EU (RoHs 2) Restrictionoftheuseofcertainhazardoussubstancesinelectricalandelectronicequipment• 2014/53/UE RadioEquipment• 2014/68/CE PressureEquipment(PED)

Andincompliancewiththestandards:

• CEI EN 61000-3-2 Electromagneticcompatibility(EMC)-Limits-Limitsforharmoniccurrentemissions(equipmentinputcurrent≤16Aperphase).

• CEI EN 61000-3-3 Electromagneticcompatibility(EMC)-Limits.Limitationofvoltagechanges,voltagefluctuationsandflickerinpubliclow-voltagesupplysystems,forequipmentwithratedcurrent≤16Aperphaseandnotsubjecttoconditionalconnection.

• EN 55014-1 Electromagnetic compatibility. - Requirements for household appliances, electric tools and similarapparatus-Emission

• EN 55014-2 Electromagnetic compatibility –Requirements for household appliances, electric tools and similarapparatus-Immunity.Productfamilystandard.

• EN 60335-1 Safetyofhouseholdelectricalappliancesandsimilarproducts.-Generalsafetyregulations• EN 60335-2-102 Safetyofhouseholdelectricalappliancesandsimilarproducts.-Specialregulationsforappliancesfitted

withgas,dieselorsolidfuelburnersandelectricalconnections.• EN 62233 Measurementmethodsforelectromagneticfieldsofelectricalappliancesforhomeuseandsimilargoods

regardinghumanexposure.• EN 50581 TechnicalDocumentationForTheAssessmentOfElectricalAndElectronicProductsWithRespectTo

TheRestrictionOfHazardousSubstance• EN 7129 Domesticandsimilargassystemspoweredbythedistributionmains.• UNI 10412-2 Hotwaterheatingsystem-Safetyrequirements-Specificrequirementsforsystemswithdomestictype

heatingdevicespoweredbysolidfuelwithbuilt-instove,withtotalfirepowernotover35kW.• UNI 10683 Heatgeneratorsoperatingwithwoodorothersolidbiofuels-Installationrequirements• UNI EN 303-5 Heatingboilers.-Heatingboilersforsolidfuels,manuallyandautomaticallystoked,nominal

heatoutputofupto500kW-Terminology,requirements,testingandmarking.• UNI EN 1443 Fireplaces-Generalrequisites• UNI EN 1856-1 Chimneys-Requirementsformetalchimneys-Systemchimneyproducts.• UNI EN 1856-2 Chimneys.Requirementsformetalchimneys-Metalfluelinersandconnectingfluepipes.• UNI EN 13229 Insertappliancesincludingopenfiresfiredbysolidfuels-Requirementsandtestmethods• UNI EN 13240 Roomheatersfiredbysolidfuel-Requirementsandtestmethods• UNI EN 13384 Fireplaces-Thermalcalculationsanddynamicfluid.• UNI EN 14785 Residentialspaceheatingappliancesfiredbywoodpellets-Requirementsandtestmethods• UNI EN ISO 12100 Machinesafety.

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01.4 USE AND STORING OF THE INSTALLATION AND MAINTENANCE MANUAL

• Recipients of the manual

Theuseandinstallationmanualisaddressedtousersresponsiblefortheinstallation,operationandmaintenanceofthestove;particularattentionmustbegiventhepartsofthemanualconcerningsafety.Iftheproductissubsequentlyresold,theuserisrequestedtohandoverthissheetandtoinformthemanufacturerofthenameofthenewowner,sothatthelattermayreceiveanyupdatesissued.• Scope of the manual

Themanualcontainsinformationonthecorrectuseoftheproductinaccordancewiththepurposesforwhichitwasdesignedandbuilt.Italsoprovidesinformationaboutloads,commissioning,repairandmaintenanceofthestoveinconformancewiththelimitssetdownbythemanufacturer.• Conservation of the manual

Theinstallationandmaintenancemanualisanintegralpartoftheproductandmustbeconserveduptothetimewhenthestoveisdismantled.Itmustbekeptinaprotected,dryplaceoutofdirectsunlightandneartheproductsothatitisalwaysreadilyavailableforconsultation.Shouldthemanualgetdamaged,theusermustrequestacopyfromtheretailerwherehepurchasedtheappliance.Whenrequestingassistance,alwaysmakereferencetotheMODEL,LOTandSERIALNUMBERindicatedonthelabelshowninCHAP.05.2 - PRODUCT IDENTIFICATION.

• Updating the manual

Theinstallationandmaintenancemanualreflectsthestatusofthetechnologyatthetimetheproductwasmarketed.Themanufacturerreservestherighttomakemodificationstotheproduct,andconsequentlytherelativemanual,withoutanyobligationtoupdatepreviouseditions.

01.5 MANUFACTURER LIABILITY AND WARRANTY CONDITIONS

Uponthedeliveryofthismanual,JollyMecS.p.A.cannotbeheldliable,whethercivilorcriminal,foraccidentsduetopartialortotalnon-compliancewiththespecificationshereincontained.Themanufacturerisespeciallyheldharmlessfromanyliabilityinthefollowingcases:• Improperuseoftheproduct• Usenotintendedbyspecificnationalregulations• Incorrectinstallation• Faultsintheelectricalconnections,theconnectionsofthefumeexhaustsystemand/orthecomburentairductingsystemeandin

plumbingconnections• Failuretocarryoutmaintenanceasprescribedinthismanual• Unauthorisedmodificationsoroperations• Useofreplacementpartsthatarenon-originalornotspecifictothemodel• Totalorpartialfailuretofollowtheinstructions• Exceptionalevents(e.g.:breakagesduetonaturaloraccidentaleventsaslightening,shortcircuitsetc.)• Damagecausedbyelectricalpowercuts,suddenfluctuationofsupplyvoltage,electromagneticfields• UseoffuelwithcharacteristicsotherthanthoserecommendedinthismanualIntheabovecasesthewarrantyisvoid.PleaserefertoAnnexSM082fordetailsonthewarrantyconditionsandcompilingtherelativecertificate.

IntheeventofamalfunctionorinterventionrequestbyaspecialisedTechnicalServiceCenter,theusermustbeabletodemonstratetheuseoffuelwiththecharacteristicsrequiredbythismanual.TheManufacturerdisclaimsallliabilityconcerninganomaliesormalfunctionscausedbyuseofFUELwhichdoesnotcomplywiththerecommendedrequirements.

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CHAP.02 ACCIDENT PREVENTION / SAFETY REGULATIONS

02.1 GENERAL CONSIDERATIONS

• Themanualreferstoessentialaspectsofthedirectives,regulationsanddispositionsonusingthemachine,summarisingitsmostsignificantpoints.

• General legal regulations andmandatory rules regarding injury preventionandenvironmental protectionmust beobserved.Theseobligationsalsoincluderegulationsregardingtheuseofpersonalprotectiveequipment.

• Forallworktobedoneonthesystem,thefollowingdispositionsandregulationsinforcemustbeobservedregardingaccidentprevention,followingtheindications.

• Beforeusingthesystemthefirsttime,theusermusthavereadandunderstoodtheinstructionmanualperfectlyandthischapterinparticular.

• Theusermustalsomakesurethatthemachineisalwaysingoodconditionasregardsitssafetyrequirements.• Duringmaintenance and inspection activities, wear the protective garments specified in followingCHAP.02.4 -

EQUIPMENT FOR OPERATORS AND MAINTENANCE PERSONNEL. Cleaningandmaintenanceactivitiesmayonlybeperformedwiththeequipmentcoldandpreferablydisconnectedfromthepowermainsorwiththemainswitchinthe“O”position.

• Dangerwarningsandsignalsintheformofplates,labelsandmarkingsmustnotberemovedormadeunidentifiable.Iftheyarewornorbroken,theymustbereplaced.

• Modifications, additions or transformations must not be made on the machine and its components without themanufacturer’sauthorisation.Thisisvalidfirstandforemostforinstallationandregulationoftheinstalledsafetydevices.FailuretocomplywiththiswarningrelievestheManufacturerofallandanyresponsibility.

• Makesure,beforestartingupeverytimeandaftercarryingoutmaintenance,thatdismantledpartshavebeenrepositionedcorrectlyandinparticularalltheprotectiondevicesthatimpedeaccesstothemachine.

02.2 SAFETY REGULATIONS FOR ROUTINE MAINTENANCE AND USE

• Theuserand/orowneroftheproductisrequired,inaccordancewiththelawsinforce,toassigntheinstallationandmaintenancetoqualifiedandspecialisedoperators,andacknowledgetherisksandhazardsshouldtheyfailtoobservethisrequirement.

• Childrenofatleast8yearsold,peoplewithreducedphysical,sensoryormentalcapabilities,orlackingtheexperienceortheneededknowledgecanusethedeviceonlyundersurveillanceorhavingbeeninstructedonthedevicesafeuseandontheunderstandingofthederivingdangers.Childrenarenotallowedtoplaywiththedevice.Cleaningandmaintenancearemeanttobeperformedbytheuserandnotbyunsupervisedchildren.

• Thesettingsandprogrammingoftheproductmustonlybeperformedbyadultswhohavereceivedsuitableandspecifictraining.Errorsorincorrectsettingscancreatehazardousconditionsandtriggermalfunctionswithrelativeconsequencesforpersonsandthings.

• Beforeanycleaningand/orroutineorextraordinarymaintenanceonthemachine,disconnectitfromallenergysources;inparticular,turntheelectricalpowerswitchto“O”.

• Priortoinstallation,theuserandinstallerareobligedtocheckthatthemainselectricalsupplytowhichthemachinewillbeconnected,correspondstothevoltageontheidentificationplate(seeCHAP.05.2 - PRODUCT IDENTIFICATION),andthatitisequippedwithallsuitablesafetydevicestoclassifytheelectricalsystemascompliantwithapplicablesafetystandards.Ifthisisnotthecase,contactaQualifiedTechniciantoadaptthesystemtorequiredstandards.

• Upstreamfromthemachine(attheuser’sexpense)ontheelectricalpowersupplyline,abipolarswitchmustbeinstalledthatisabletointerceptallthecurrentphases(seeCHAP.06 - TECHNICAL DATA).

• Theirradiationareaincludestheareabetweentheopeningofthehearthandupto1metreofspacefrontallyaswellaslaterally.Noinflammableobjectmustbeleftinthisarea(suchas:inflammableliquids,fire-startingproductsorfirewood,drapes,woodendecorations,rugs,etc.).

• Donotusethestovetodryclothes,itcouldoverheatandcauseanoutbreakoffire.• ATTENTION - BEWARE OF BURNS,mostoftheoutersurfacesofthestoveareveryhot,doorhandle,glass,metal

sides,majolicaormetaltop,fumeexhaustpipeetc.Nevertouchthestovewithnakedhandswhenitisrunning;alwaysuseheatprotectiongloves,suchasthosesuppliedwiththestove,whenhandlingallparts.

• Beforedoinganyinternalcleaningormaintenance,youmustwaituntilthemachinereachestheambienttemperature.• Ifthestoveisinalarmstatusduetoamalfunction,donotattempttorestartitbeforefindingoutwhathascausedtheheat

generatortoshutdown.• Neverwashtheinternalpartsofthecombustionchamberwithwater.

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• Inalarmstatusforfailedstartup,donottrytorestarttheapplianceuntilthefireboxhasbeenthoroughlycleaned.• Theappliancemustalwaysbestartedupwiththefireboxempty,withoutpelletsandwithoutunburnedfuelfromprevious

use.• Donotattempttoignitethefuelwithinflammableliquidsorsolids;thestovemustigniteautomaticallyviatheelectrical

componentsinstalledonboard.• Donotloadpelletsmanuallyintothefireboxbeforeorwhilsttheapplianceisrunning.• Keeptheventilationgridsintheareatheapplianceisinstalledincleanconditions.• Neverloadanyfuelotherthanpelletsintothestovestoragehopper.Corn,nutsorothercombustiblematerialsmustnotbe

usedasfuelfortheappliance.• Checkandperiodicallycleanthefumeexhaustpipe,fromtheappliancetotheflue(Union).• Itisstrictlyprohibitedtostartuptheproductwiththecombustionchamberdooropenorallowittorunwiththeglassbroken.• Incaseofneedandifanyoperatingproblemspersist,theusershouldcontactthespecialisedTechnicalAssistanceCenter.• Nevertrytostartthedeviceusingethylalcoholorotherflammableliquids..

02.3 SAFETY REGULATIONS FOR EXTRAORDINARY MAINTENANCE AND INSTALLATION

• Theuserand/orowneroftheproductisrequired,inaccordancewiththelawsinforce,toassigntheinstallationandmaintenancetoqualifiedandspecialisedoperators,andacknowledgetherisksandhazardsshouldtheyfailtoobservethisrequirement.

• Theinstallationoftheheatgeneratorandtherelativecombustionproductexhaustionsystem,theelectricalconnections,thecommissioningandextraordinarymaintenanceservicesMUSTalwaysbeperformedbyqualifiedand licensedprofessionalstaff.

• TheproductmustbeinstalledinaccordancewiththelawsandstandardsinforceintheState,RegionorAreainwhichthemachineisinstalled.

• Installationinbedrooms,roomswithavolumebelow15m3orwithexplosiveatmospheresisstrictlyprohibited.• ThesysteminstallerMUSTissueaDeclarationofcompliancefortheworkperformedaftercommissioningthesystem,

inaccordancewiththelawsinforcerelatedtosystemsafetystandards.• Theinstallationtechnicianmustinformtheuseronsafeequipmentuse.• Theinstallationoperatorisresponsiblefortheinstallationandisthereforerequiredtoperformtheworktotopworkmanship

standards.• Theappliancemustbeconnectedtoacombustionproductexhaustionfluebuiltinaccordancewithapplicable

standardsandcertifiedwithadeclarationofcompliance.• ShouldanyinstallationdefectsariseduringtheoptionalCommisisoningservice,thespecialisedTechnicalServiceCenter,

canrefusetoendorseuseoftheproductforsafetyreasonsandsubmitawrittenServicingReporttotheUserinforminghimthatheandtheInstallationoperatorshallbejointlyliableforanydamagetopersons,animalsorthingsifused.

• Beforeinstallingthemachine,thecustomerandinstallationoperatormustensurethattheflooringonwhichitwillbepositionedissuitablylevelledandcansupporttheweight(seeCHAP.06 - TECHNICAL DATA).IIfthereisanydoubtonthesolidityoftheflooring,itisessentialtohaveaStructuralEngineerverifyrelativeinstallationfeasibility.

• Onlyspecialisedandqualifiedpersonnelmayworkorcarryoutchecks inside themachine,complyingwithsafetyregulations.

• Priortoinstallation,theuserandinstallerareobligedtocheckthatthemainselectricalsupplytowhichthemachinewillbeconnected,correspondstothevoltageontheidentificationplate(seeCHAP.05.2 - PRODUCT IDENTIFICATION),checkthatthesystemissizedsoastobearthemaximumloadrequiredoftheproduct,andalsothatitisequippedwithallsuitablesafetydevicestoclassifytheelectricalsystemasCOMPLIANTwithapplicablesafetystandards.Ifthisisnotthecase,contactaQualifiedTechniciantoadaptthesystemtorequiredstandards.

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• ThepowercordplugmustbeconnectedonlyAFTERtheconclusionoftheinstallationandassemblyofthedevice,andmustremainaccessibleafterinstallationifthedevicedoesnothaveasuitableandaccessibledouble-poleswitch.

• Personnelassignedtohandlingthemachinesandequipmentmustalwayswearindustrialglovesandboots.• TheMaintenanceOperatormustrecommendtheCustomertosignanannualmaintenancecontractfortheproduct,so

astomaintainthelevelsofsafetyandefficientperformanceoftheproduct.• TheMaintenanceOperatormustchecktheworkinghoursoftheproductbetweenonemaintenanceinterventionand

another,toverifytheactualworkloadofthestove.TheactualhoursofoperationshallberesetattheendoftheTechnicalinterventionandindicatedontheServicingReport.

02.4 EQUIPMENT FOR OPERATORS AND MAINTENANCE PERSONNEL

Everyoperatorperformingmaintenanceonthemachine,mustwearsafetygarmentsandpersonalprotectiveequipment:

1 Protectionheadphones

2 Gloveshandprotections

3 Respiratorymask

4 Facemaskorgoggles

5 Accidentpreventionboots

6 Overallsorsmock

02.5 RESIDUAL RISKS

ThoughJOLLYMECCAMINETTIS.p.A.doeseverythingwithinitspowertoproduceitssystemswiththegreatestcompetenceregardingsafetyandconsultingallthedirectives,laws,andregulationsavailable,therearestill,ifminor,someresidualrisksduringthephasesof:

• TRANSPORT AND INSTALLATION• ELECTRICALCONNECTIONS(Whichmustbedonebyaqualifiedelectrician)• MAINTENANCE

Therefore,thetechnicianswhoperformthesetasksmusttaketheseresidualrisksintoaccount.

Removalortamperingwiththeprotectionandsafetydevicescanbeonlybedonevoluntarilyandmaycauseseriousinjurytopeople.Replacethesafetysignalswhentheybecomeillegibleorcomeoff.

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CHAP.03 HANDLING AND TRANSPORT

03.1 RECEIVING GOODS

Theproductisdeliveredonpallets,packagedinacardboardboxwithacellophanewrapping.whenreceivingmerchandise,checkthat:

• allpackagingisintact• allofthemerchandiseindicatedonthedeliverybillhasactuallybeendelivered• thesupplycorrespondstotheorderspecifications• ifthepackagingisdamaged,checktheconditionofthecontents,becauseanybreakagesmustimmediatelybereported

tothecarrierandtotheretailer• checkthereisnodamagetoanysuppliedelements;ifthereisanybreakagedetected,reporttothecarrierandretailer

assoonaspossibleIfanymateriallistedonthedeliverynoteismissing,reportittotheretailerassoonaspossible.

03.2 LIFTING AND TRANSPORT

Personnel in chargeof handling theproductmust have readand thoroughly understood the safety prescriptions inCHAP.02 - ACCIDENT PREVENTION / SAFETY REGULATIONS ofthismanualandmustwearworkglovesandsafetyfootwear.Forsafetyreasons,unauthorisedpersonsmustnotbeintheareawhiletheproductisbeingmoved.

Theproductmustbemovedonlywithatrolleyorpalletfork,andneverwithbelts,chains,overheadcranes(seeCHAP.06 - TECHNICAL DATAfortheweight).Allpartsofthepackagingcomingintocontactwiththecrane,beltsorstrapsmustbeprotected.Unlessthereareobstacles, lift theproducttoamaximumof30cmfromthegroundandmoveitslowly,avoidingjerkyorbrusquemovements.

Danger of crushing, collision and abrasions.WARNING

Danger of suffocationMakesurethatchildrendonotcomeintocontactwithpackagingmaterials,plasticfilmorpolystyreneasthiscouldcausesuffocation.

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Danger of environmental pollutionAdoptpositivecivicbehaviourandDONOTdispersethepackagingintotheenvironment,buttakeittowastedisposalcentresforrecycling.Allpackagingcanberecycled,asitconsistsofwood,polyethylenefilm,polystyreneandcardboard

WARNING

Themachinemustbedisposedofinamannerthatcomplieswiththelawsinforceandtheenvironment.Whentakingittothefirmsthatdisposeofferrousmaterials,handlethestoveasdescribedinCHAP.03 - HANDLING AND TRANSPORT.

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CHAP.04 ECOLOGICAL REGULATIONS

04.1 DISPOSAL OF THE MACHINE

Directive2012/19/UE(wasteelectricalandelectronicequipment-WEEE):informationforusers.Thecrossed-outwastebasketsymbolontheappliancemeansthatattheendofitsusefullifespan,theproductmustbedisposedofseparatelyfromordinaryhouseholdwastes.Theuserisresponsiblefordeliveringtheappliancetoanappropriatecollectionfacilityattheendofitsusefullifespan.Appropriateseparatecollectiontopermitrecycling,treatmentandenvironmentallycompatibledisposalhelpspreventnegativeimpactontheenvironmentandhumanhealthandpromotesrecyclingofthematerialsmakinguptheproduct.Formoreinformationonavailablecollectionfacilities,contactyourlocalwastecollectionserviceortheshopwhereyouboughtthisappliance.

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CHAP.05 DESCRIPTION

05.1 PRODUCT PRESENTATION

Jolly-Mecproductsaretheresultofoverfortyyearsexperienceinthewoodenbiomasscombustionsector;theyaredesignedandengineeredtomeettheincreasingdemandsoftoday’smarketswithhighperformancelevelsandsavingsenvelopedinamoderndesign.

ThepelletcassettefireplaceInsertoStar68,InsertoStar80,InsertoSynthesis68,InsertoSynthesis80isamonoblockheatingdeviceapprovedtoEN14785:2006StandardrequirementsbyathirdpartyfirmaccreditedbytheECasamachinetestingandcertificationinstitute.

Itisahighperformanceproductforairheating,operatingonalternativeandrenewableenergysources:pellets.Adesignthatisalwaysuptodate,maintainingthetraditionandirreplaceablecosinessofafireplace.

Itisaheatermadewithadvancedcharacteristics;theSYNTHESISmodelisequippedwitharobuststeelframeandfinishedingalvanisedsheetmetal(optionalaccessory)forgreateraestheticinsulationandeasierinstallation.

Thecassettefireplace featuresasupportbasewith runners foreasyextractionfornormalinspections,checks,maintenanceonelectricalandmechanicalpartsandahandyfrontdrawerforloadingpellets.

TheSTARmodelisfittedwithaheight-adjustablestandandismadetobesecuredtotheflooraswellasthewall,andpre-disposedforductinghotairtootherareaswithspecialinsulatedaluminiumpipes.Itisalsoequippedwithaconvenientchuteforloadingpelletsintothehopperandcanbepositionedonthesidesaswellasthefront.

TheBoileriscomposedofanexchangerinFIREFLECTORanddualheatdevelopmentcapacitysteel,betweenwhichairisblownwithafanwhichonceisheated,isdistributedintheroom.

It works by recycling the air in the installation area, or by ducting itexternally.Itoperatesonlywiththedoorclosed,insertedandlockedinitshousing.

Combustioniscontrolledbymeansofaradio-frequencyelectroniccontrolunitandwirelessremotecontrolwiththefollowingfunctions:• Remote control display Ample screen that

providesaninterfacewiththeproduct,tosetfunctionvaluesandreaddataonworkstatus.

• Chronothermostat On and off time setting functionprogrammedwithsettabletemperatureregulationprogram.

• Room temperature FunctionusedtosetanddisplaytheambienttemperaturereachedwithTLCorprobeupto3m.

• Power levels Controlpossibilitieson5heatpowerlevels.• Operating status Functionthatdisplaysproductand

connectedheatsystemoperatingstatusinrealtime.• Multilingual Possibility to select one of five different

Europeanlanguages(ITA-ENG-DEU-FRA-ESP).

Cassettefireplaceforapre-existingfireplace

Cassettefireplaceforanewfireplaceandducting

Inserto SYNTHESIS 68-80

Inserto STAR 68-80

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Theyarealsofittedwith:• Pellethopper((forthecapacityseespecifications).• “Humidifier”withincorporatedwatertanktohumidifytheheatingairintheenvironmentandpreventundesireddry throatsensationscausedbyexcessivelydryair;itispossibletoaddsomedropsoffragranceoilstothewaterto freshentheairinthehome.• Apracticaldrawertocollecttheashes.• Thermalsafetydeviceagainstpossibleoverheating.• Safetydeviceagainstpossiblecloggingofthefluepipe.• TangentialFanforhotairexchangeintheenvironment.• Fumeexhaustfan.• Electricalresistancetostartcombustion.

PELLETcombustionproductsmustonlybeusedwiththecombustionchamberdoorclosed.

WARNING

Thechromaticvariationsofthepaintedsurfaces,especiallythoseindifferentmaterialsandfinishesandsubjecttodifferenttemperatures,cannotbedeemedreasonfordisputeastheydependuponthenaturalcharacteristicsofthematerialsandtheuseoftheproduct.

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05.2 PRODUCT IDENTIFICATION

Theillustratedexampleplatemaydifferingraphicsfromtheoriginalaffixedtotheproduct.NOTA

1 ProductModel2 CEmarking3 Yearofcommisionignandcertification4 Referencestandard5 PerformancedeclarationNumber*6 ProductLOTNumber7 Productsalescode8 Productserialnumber9 Productlabelcode

*Pursuant to European Regulation No.305/2011,manufacturersarenowrequiredtohavethe DoP - Declaration of Performance for eachproduct of own design concerned; Jolly-Mec didnamely provide all of these documents indownloadableelectronicformthatyoucaneasilyseeon the website of the Company at the followingaddress:http://www.jolly-mec.it.

WARNING

ItisCOMPULSORYtoindicatetheproductMODEL,theLOTnumberandSERIALNUMBERinallcommunicationswiththeManufacturer.Identificationnumbersareprintedontheadhesiveplatelocatedontherightsideofthepelletcontainerasillustrated.StoveperformancevaluesmeasuredduringinspectiontestsaccordingtotheindicatedreferenceandECmarkingsarealsoincludedontheplate.

Via San Giuseppe, 2 - 24060 Telgate - BG - *Tel. +39.035.8359211 - fax +39.035.8359200

www.jolly-mec.it - info@jolly-mec.itEN 14785:2006

Inserto Synthesis 68

Apparecchio funzionanante a pellet -equipment with pellet feeding -betriebene Geräte Pellet -équipement alimentés à granulés -equipo alimentado pellets

Potenza elettrica nominaleRated electrical powerElektr. LeistungsaufnahmePuissance électrique nominalePotencia eléctrica nominal

Distanza minima materiali combustibili adiacentiMin. clearance from combustible materialsAbstand zu angrenzenden entzündlichen StoffenDistance matériaux combustibles adjacentsDistancia a materiales combustibles adyacentes

Utilizzare solo combustibili raccomandatiUse recommended fuels onlyVerwenden Sie nur die empfohlenen Brennstoffsort*Utiliser seulement des combustibles recommandésUtilizar sólo los combustibles recomendados

CO emissioniCO emissionsCO emissionEmission de COEmisión de CO

Tensione/Frequenza nominaleRated voltage/frequencySpannung/NennfrequenzTension/Fréquence nominaleTensión/Frecuencia nominalTemperatura media fumiMedium flue gas temperatureAbgastemperatur MittelwertTempérature moyenne des fuméesTemperatura media de los humos

Leggere e seguire le istruzioni di funzionamentoRead and follow the operating instructions.Lesen und befolgen Sie die BetriebsanleitungenLire et suivre les instructions de fonctionnementLeer y seguir las instrucciones de funcionamiento

Potenza termica nominaleRated heat outputNenn-HeizleistungPuissance thermique nominalePotencia térmica nominal

N° lotto:

230 V

Front 1000 mm

L000000

Pellet

Cod: SYNTHESIS/68/1

55

174,9 °C

Matr: 000000

P

Potenza bruciataBurned powerMax HeizleistungPuissance brûléePotencia quemada

Qtot

ta

14

Potenza termica ridottaReduced heat outputTeilwärmeleistungPuissance thermique réduitePotencia térmica reducida

50 Hz365W

2,8 kW10,0 kW

Dust @ 13% O

Ignition

Working100W

n° DOP JM 00039Athe dop was drafted on the basis to the test report of accredited laboratorythe accreditation number of the laboratory is 2456 TÜV Rheinland Energie und Umwelt

Emissioni polveriDust emissionsEmission poussièresStaubemmissionenEmission de polbo

24,3 mg/Nm3

Pr

RendimentoEfficiencyWirkungsgradRendementRendimiento 90,75%

87,47%

3,12 kW

11,46 kW

378,6 mg/Nm169,6 mg/Nm

CO @ 13% O

Back 150 mmSide 300 mm

Reduced

NominalNominal

Reduced

NominalReduced

22

ReducedNominal

18,1 mg/Nm3

3

3

1

2

4

5

3

6

7

9

81

2

45

3

6

7

8

Via San Giuseppe, 2 - 24060 Telgate - BG - ITALYTel. +39.035.8359211 - fax +39.035.8359200

www.jolly-mec.it - info@jolly-mec.it

EN 14785:2006

PotenzaelettricanominaleRatedelectricalpowerElektr.LeistungsaufnahmePuissanceélectriquenominalePotenciaeléctricanominal

DistanzaminimamaterialicombustibiliadiacentiMin.clearancefromcombustiblematerialsAbstandzuangrenzendenentzündlichenStoffenDistanceauxmatériauxcombustiblesDistanciaamaterialescombustiblesadyacentes

UtilizzaresolocombustibiliraccomandatiUserecommendedfuelsonlyVerwendenSienurdieempfohlenenBrennstoffsortenUtiliserseulementdescombustiblesrecommandésUtilizarsóloloscombustiblesrecomendados

COemissioniCOemissionsCOemissionEmissiondeCOEmisióndeCO

Tensione/FrequenzanominaleRatedvoltage/frequencySpannung/NennfrequenzTension/FréquencenominaleTensión/Frecuencianominal

TemperaturadeifumiFluegastemperatureAbgastemperaturTempératuredesfuméesTemperaturadeloshumos

LeggereeseguireleistruzionidifunzionamentoReadandfollowtheoperatinginstructions.LesenundbefolgenSiedieBetriebsanleitungenLireetsuivrelesinstructionsdefonctionnementLeeryseguirlasinstruccionesdefuncionamiento

PotenzatermicanominaleRated heat outputNenn-HeizleistungPuissancenominalePotenciatérmicanominal

N° lotto:

230 V

L000000

Pellets-Granulédebois

Cod: SYNTHESIS/80/1

EmissionipolveriDustemissionsEmissionpoussièresStaubemmissionenEmissiondepolbo

177,3 °C

Inserto Synthesis 80

Matr: 000000

Pt

CO @ 13% O

Tf

18

50 Hz

302 W

11,5 kW Nominal

Nominal

Ignition

170 W

Dust @ 13% O

n° DOP JM00157thedopwasdraftedonthebasistothetestreportofaccreditedlaboratorytheaccreditationnumberofthelaboratoryis2456TÜVRheinlandEnergyGmbH

299mg/m410mg/m3

Apparecchioperilriscaldamentodomesticoalimentatoapelletdilegno-Residentialspaceheatingappliancefiredbywoodpellet-MitHolzpelletsbefeuerteWärmeerzeugerfürdenWohnbereich-Appareildechauffagedomestiquealimentéaupelletdebois-Aparatoparacalefaccióndomesticaalimentadoconpelletsdemadera

Reduced5,5 kW

Qtot13,1 kW Nominal6,2 kW

PotenzabruciataBurnedpowerMaxHeizleistungPuiss.max.disponiblePotenciaquemada

88,2 %88,8 %

RendimentoEfficiencyWirkungsgradRendementRendimiento Reduced

Nominal

Working

3 2

2

109,1 °C

Reduced

Reduced

25mg/m3 Nominal

NominalReduced

B=200mmS=500mm

L'apparecchiononpuòesserutilizzatoincannafumariacondivisa-Theappliancecannotbeusedinflueshared-DasGerätkannnichtimgemeinsamenschorusteinverwendetwerden-L'appareilnepeutpasetreutilisèdansconduitpartagè-Elaparatonosepuedeutilisarentubodehumoscompartido

F=1000mm

15

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CHAP.06 TECHNICAL DATA

06.1 HOMOLOGATION

TechnicalspecificationsresultingfromlaboratorytestsconductedaccordingtoEN14785:2006testmethodsattheCERTIFICATIONinstitute.

Description InsertoStar68InsertoSynthesis68

InsertoStar80InsertoSynthesis80

UM

Burningoutput 11,46 13,1 kWNominalheatoutput 10,0 11,5 kWReducedburningoutput 2,84 5,5 kWNominaloutputconsumption 2,37 2,68 kg/hReducedoutputconsumption 0,65 1,26 kg/hNominaloutputefficiency 87,47 88,2 %Ratedvoltage 230 230 VRatedfrequency 50 50 HzElectricalabsorption(duringstart-up-working) 365 - 100 170 - 302 W

Totalweight 105(Synthesis)120(Star)

120(Synthesis)130(star) kg

Standardhoppercapacity 15 18 lMinimumfluedraught 10 10 PaFumeexhaustdiam. 80 80 mmAveragefumeTatnominaloutput 174,9 177,3 °CAveragefumeTatreducedoutput 77,7 109,1 °CCO (13% O2)nominaloutput 169,6 299 mg/m3

CO (13% O2)reducedoutput 378,6 410 mg/m3

CO2 nominaloutput 9,13 10,5 %NOx(13% O2)nominaloutput 145,4 124 mg/m3

OGC (13% O2)nominaloutput 6,2 14 mg/m3

Dusts(13%O2)nominaloutput 24,3 25 mg/m3

Nominalfumemassoutput 8,7 9,0 g/sReducedfumemassoutput 5,0 7,2 g/sAverageheatedarea* 67,3-105,8 77,4-121,7 m2

Minimumairdistancefrominflammablesidewall 300 500 mmMinimumairdistancefrominflammablerearwall 150 200 mmFrontalairdistancefrominflammablematerial 1000 1000 mmPercentagofoutputductibletootherrooms 40-60 40-60 %Diameterpipeforductingair 80(star) 100(star) mmComburentairpipediameter 80 80 mmEnergyefficiencyclass A+ A+ -

Thedeclaredoutputmayvaryaccordingtofueltype.The above technical specifications weremeasured with certified quality PELLETS. ONLY use this type of fuel asrecommendedlaterinCHAP.06.2 - RECOMMENDED FUELS.*Accordingtothetypologyofbuildingandinsulation(Referredtotheneedof55W/m3and35W/m3;roomheight2,7m).

Allappliancetests,finalinspectionandfine-tuningwasperformedusingtherecommendedcertifiedpellets.JollyMecCaminettiS.p.A.isnotresponsibleformalfunctions,breakdownsorproblemsduetotheuseofpelletsthatarenotrecommended,ascombustionparametersvaryaccordingtothequalityofthepellets.Toachievebestoperationalresults,itmaybenecessarytochangethedefaultfactorysettingsonthecontrolunitduringtheoptionalCommissioningservice.TheseoperationsmustonlybeperformedbyaspecialisedTechnicalServiceCenter.

WARNING

16

06.2 RECOMMENDED FUELS

Apelletproduct’sperformanceissignificantlylinkedandhighlyinfluencedbythetypeandqualityofwoodenpelletsthatisburned.Itisimportanttochoosepelletsthathavenodebrisorimpurities.TheAssociationofPelletManufacturerswiththeItalianThermotechnicalCommitteehaveestablishedstandardsforidentifyingpelletsintermsofenergy*.AstheefficienciesofdifferentwoodenPELLETSqualitiesdiffer,likewisetheefficiencyandheatcapacityemittedbytheproductrunningonpelletswillvary.Similarly,unburnedresidueleftinthecombustionchamberisinverselyproportionatetopelletquality:thelowerthepelletpurity,thefasterdirtaccumulatesinthemachine.JollyMecCaminettiS.p.ArecommendstheuseofthesametypeofpelletsusedduringtheoptionalCommissioningservice,i.e.whenthesettingsandcalibrationsweremadetosuittheloadedcombustiblematerials.ContinuousswitchingoftypesandqualitiesofcombustiblematerialswillrequirecontinuousadjustmentstosettingsbythespecialisedTechnicalServiceCenter,whichcannotbeendorsedbytheManufacturer.

ThemainqualitycertificationsforPELLETSontheEuropeanmarketareDIN Plus,Ö-NormM7135andUNI EN ISO 17225-2(classA1orA2),whichguaranteethefollowingqualitystandards:

Storepelletsatleast1mfromtheappliance,inadryplaceandnotoutdoors,notevenunderporchesorroofings.Donotusepelletsthatareveryhardandwithdifferentdimensions;themechanicalpartsaresizedandtestedforusewithpelletswiththeabove-mentionedcharacteristics.

Nobreakdownormalfunctiondependingonthequalityofthepelletsusedand/orbythedosageofthequantitywillbecoveredbythewarranty.

PELLETQUALITYISVERYIMPORTANT;PLEASEREADTHISSECTIONCAREFULLYWARNING

*CERTIFIEDPELLETCHARACTERISTICS

Powder 1%maximumthrougha3.2mmscreen

Apparent density 680Kg/m3minimum

Dimensions 6mmdiameterfrom25to30mmofmaximumlength

Ash content 1%maximum

Humidity 8%maximum

Heating power 4,9kWh/Kg

Packaging ineco-compatibleorbiodegradablematerialsacks

WHATYOUSHOULDKNOWABOUTPELLETS:pelletsareobtainedbyadrawingprocessusingsawdustdiscardedbyvirginwoodprocessingsystemsandthereforehavenochemicaladditives.Theconsistency,compactnessandstrengthwithwhichthepiecesremainintactisduetoasubstancecontainedinwoodcalledlignin;thisactsasabinderduringthecompressionphase.Thevariousqualitiesofcombustiblematerialscanalsodependonthesawdustmixusedtoproducethepellets,whichgenerallyhaveastandardlengthofbetween5and30mm,adiameterofbetween5and6mm,aweightoffrom600to700Kg/m3andahumidityofnomorethan8%ofitsweight.Oneadvantageoverwoodisitsgreaterheatingpower;infact,whenusinggoodqualitywood,itispossibletoachieveabout4.3kWh/Kgwithahumidityrateofupto15%,whilstwithpelletsthiscanclimbto4.9kWh/Kgandawatercontentofamaximumof8%.Thesacksofpelletsmustbestoredinaclean,dryplace.

NOTE

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06.3 COMPONENTS

Theinsetfireplaceissuppliedwithanassembledandtestedpellethopper,packedinacardboardcontainerinawoodbox,withpolystyreneprotectionandcellophanehoodwiththefollowingcomponents:• Usage,maintenanceandinstallationsheet• Controlpanelwithelectroniccontrolunit

Componentslist:

1. Airdiffusiongrid(Itcanbeopenedtoextract thepelletloadingdraweroradjusttheairdamper)

2. Electroniccontrolunit3. Pellet hopper (With front extractable drawer for filling

(model Jolly Synthesis); With overhead lateral filling(modelJollyStar)

4. Pressostat5. Supportbasewithrunners6. Emergencyconsole7. Combustionfanandfumedischarge8. Runnersforinsetfireplaceextraction9. HumidifierAccessiblebyopeningthedoor)10. Airdamperregulatinglever(Accessiblebyopeningtheair

diffusiongrid;onlyJollyStarmod.)11. Handleforopeningdoor12. Door13. Combustionbasket14. Ashgrid15. Lockingscrewslidinginsert(Accessiblebyopeningthe

door)16. Pelletloadingaugergearmotor17. Electricalheatingelementforlighting18. Heatingfan19. Safetymicroswitch20. Safetythermostatwithmanualreset21. Mainswitch22. Electricalsocketwithfuse23. Chuteforloadingpelletsinthehopper24. Supportframeforducting25. Supportframeandcassettefireplacefastening

12 3 4

5

78

9

10 1011

12

131415

23

24

25

6

17 18 19

20

222116

18

06.4 OPTIONALS

Automaticclosingboxforexternalairpassageway:Installed on the external airpassageway, it only allows for airintake when actually necessary,closing the cold air passagewhenthegeneratorisnotrunningtothusavoidcoolingtheinstallationroom

Insect- proof grate 230 x 230mm:Installed on the exterior of thecomburentairintake,itpreventsinsectentrancewithinthehome.Themeshmust be periodicallycleaned since dust, pollen orhumiditycanobstructairpassagethroughthegrateovertime.

FumeconnectionpipeØ80mm:Metallicpipeusedtoconnectthegeneratortotheflue.

JointforpipeconnectionØ80

T union for fume exhaust withcondensate drain cap:Tobeinstalledatgeneratoroutput.

AluminiumpipeforairductingØ80

Adjustableairgrillsforducting

YdeviationpipeØ80

Support for internal suction grille(onlymod.Synthesis)

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06.5 DIMENSIONS

Allmeasurementsareinmm.

-Insetfireplaceforpre-existingfireplaceINSERTOSYNTHESIS68-(80)

-InsetfireplaceforanewfireplaceandductingINSERTOSTAR68-(80)

Thepelletchuteforloadingthehoppercanbeassembled,accordingtothecladdingthathasbeenchosenontheright,leftorfront.

NOTE

403

580

983

580

583

403

430min.

680(800)

53

53

680(800)

580

583

60

20

CHAP.07 POSITIONING AND CONNECTIONS FOR THE INSTALLER

07.1 POSITION OF EXTERNAL AIR INTAKES AND ELECTRIC CURRENT

Themachinemustonlybeinstalledonsurfacesthatcansupporttheload.Iftheexistingconstructiondoesnotmeetthisrequirement,itwillbenecessarytotakeappropriatemeasures(e.g. installinga loaddistributionplate).Themachinemustbeinstalledinanareawherethemachine,gasexhaustpipesandfluecanbeeasilyaccessedforcleaning.

Theexternalairintakesmustbemadesothattheycannotgetaccidentallycoveredandiftheyhaveaninsectprotectionmeshtheymustbecleanedperiodicallytopreventcloggingwithdustanddirt,especiallyinperiodswithintensepollenconcentrations.

WARNING

INSTALLATION IN A NEW FIREPLACEAllmeasurementsareinmm.1. Werecommendtomounttheboxwithauthomaticaclosurefor

theexternalfreshairentry.2. OutdoorcombustionairoutletØ803. TakenoutsideairexchangeØ1204. Electricalsocket

INSTALLATION IN A PRE-EXISTING FIREPLACEAllmeasurementsareinmm.1. Werecommendtomounttheboxwithauthomaticaclosurefor

theexternalfreshairentry.2. TakenoutsideairexchangeØ1203. Create the room with the measurements shown, starting

65mmfromthewireglassfront4. InternalairintakeØ80foraircirculationinsideenvironmentor

tolevycombustionair5. Electricalsocket6. Raceway

1. Therearefourairintakepositionsfromwhichtheinstallermaychoose:

A - An air intake connecting outdoors of with aØ150mmflexiblepipewithoutadirectconnectiontothesupportplate.B -Anair intakeconnectingoutdoorswithaØ120mmflexiblepipe(exchangedair)andaØ80mmpipe(comburent air) to the support plate by its specialcollars.C -Anair intakeconnectingoutdoorswithaØ120mmflexiblepipe(exchangedair)tothesupportplateandtheinternalairintakeinthefireplaceskirtingforconnectingaØ80flexiblepipe(comburentair)oncemore to the support plate (illustrated in the aboveleftfigure). In thiscase,anotherair intakemustbecreatedwhichconnectstheinstallationroomwiththeoutdoors).D-Usethegridtosupportinternalaspiration(Optional)seepar.06.4.Inthiscase,however,isnecessarytocreateanairintakethatconnectsthelocalinstallationwiththeoutside.

1

2

3

4

6

5

260

450

400

1 2 3

4

110min.

110min.

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Phase 1: InsertthenewsteelflueØ80mminsidetheexi-stingoneinmasonry,makingsuretousesuitablesteelpipesandsealingthemhermetically(seepar.07.6FLUE OR FUME EXHAUST SYSTEMeFig. 1 alato).

Toseparatetheinsetfireplacefromthesupportbaseproceedasdescribedinpar..08.2

WARNING

07.2 ASSEMBLING AND INSTALLING THE FIREPLACE IN A PRE-EXISTING FIREPLACE

Electricalconnectionsmustbecarriedoutbyskilledpersonnelaccordingtotheregulationsinforce(CE2006/95and2004/108).

WARNING

2. Placea“SHUKO”plugwith230Vac50Hzcurrent,outsidethe fireplace, possibly to the left (for a pre-existingfireplace), inside thecladding (foranewfireplace), inaposition that issafe fromheatandeasilyaccessed.Setupa raceway thatgoes inside thefireplace (forapre-existingfireplace)toconnecttheelectriccablethatcomesoutoftheinsetfireplaceandisequippedwithitsownplug.Theelectricalsystemmustbedoneaccordingto standards, verifying in particular the efficiency ofthe grounding circuit. The power supply linemust beadequatelysectionedtotheoutputthecassettefireplacerequires(seepar.06.1).

3. Ifairductingisprovided,seepar.07.4- 07.5.

Phase 2: Unscrewthetwonuts(A)(arail)andthetwoscrews(B)(arail)whichsecuretheinsetfireplaceontotherunnersandliftit,usingthetwohandles,restingitonthefloorinordertoclearthesupportplatewiththerelativerunners(see Fig.2).

Phase 3: Fasten the attachments (D)(included) for pipesbelowthesupportplate(E)usingtherelativescrew(ifthissolutionisprovided,seepar. 07.1).

Phase 4: IInstallandfastenthesupportplatewiththeplugs(E)inthecassettefireplace’sdefinitiveposition,takingcaretocarryouttheseoperations IN THE MOST COMPETENT MANNER. Theresponsibilityfortheworkdonefor installationdoesnotunderanycircumstancebelongtoJolly Mec S.p.A.itisandremainstheresponsibilityoftheinstallertoverifythatthein-stallationsolutionsarecorrectandthattheycomplywithallthesafetyregulationsinforceinthecountryinwhichtheproductisinstalled.Putthenewflueonthecollar(F)ofthesupportplate(seeFig.4).

(1)Inspectionplateforeasyassembly

Phase 5: Removethetworunnersandproptheinsetfire-placeonthem,fasteningitwiththenuts(A)andscrews(B)dismountedinph.2(see Fig. 5).

Fig. 1

Fig. 2

A B

Fig. 5

A B

D E

Fig. 3

Fig. 4 FE

1

22

Phase 6:Slidethecassettefireplaceontotherunnersche-ckingthatitfastensandfastensproperly.

Phase 7: Shoulditbenecessarytoalignthefrontofthefire-placewiththeclassing,proceedasfollows:Loosenthenuts(A),oneoneachside,(see Fig. 8),Loosenthenuts(X),oneoneachside,(seeFig. 8),andusea4mmAllenkeytoadjustthegrubscrews(Y),oneoneachside,(seeFig. 8),tocompen-sateforanylevelandalignmentdefects.Oncompletingtheadjustment,fullytightenthenuts(A)e(X).

Phase 8:Carryouttheelectricalconnectionwiththepropercablewithitsownplug(seepar.07.8)insertingitinthesocketalreadysetupandmakingsurethatit isn’tinsertedbetweentheinsetfireplacebaseanditssupportplate,resultingindamageordisconnection.

Turnontheswitchlocatedclosetowherethepowercableentersthecassettefireplace,beforeinsertingitinitshousingandcheckthattheconnections,controlsandallmovingpartsfunctionproperly.

NOTE

TodefinetheexactpositionoftheINSERTOSTAR68/80foranewfireplace,youmustverifywithwhichcladding it will be finished, as the placement can be donedifferentlyaccordingtothemodelchosen.

The fireplace INSERTO STAR 68/80 is delivered com-pletely assembled on its easel. Read carefully and fol-low chap.10.1 for theAIRCANALISATIONGROUP andPELLET CHUTE ASSEMBLING.

Phase 1: PlacethefireplacecompletewiththeAIRCANALI-SATIONGROUPandPELLETLOADCHUTEonthefloorattheestablishedplace.Ifitcannotbefastenedtothefloor,fitthebracketsintherearpartofthesupport(seeFig.1)tofastenittothewall,makingsuretheseoperationsaredone“INTHE MOST COMPETENT MANNER”.TheResponsibilityoftheworkdoneforinstallationcannotbeconsideredtobelongto Jolly Mec S.p.A.butitistheresponsibilityoftheinstallerwhomustverifythattheinstallationsolutionsarecorrectandthattheycomplywithallthesafetyregulationsinforceinthecountryinwhichtheproductisinstalled.

Phase 2: Varytheheightfromthegroundthroughtheboltsandtheholes(H)onthestand(see Fig.2)andfixatthewalloronthefloorthroughtheblockstrip.

Phase3:Putthenewflueonthecollar(F) ofthesupportplate(see Fig..3).

07.3 ASSEMBLING AND INSTALLING THE FIREPLACE IN A NEW FIREPLACE

Turnontheswitchlocatedclosetowherethepowercableenterstheinsetfireplace,beforeinstallingthecladdingandcheck that the connections, controls and allmoving partsfunctionproperly.

NOTE

Ifthereareanyproblemsregardingalignmentorlevellingofthedevicewiththecladdinginplace,proceedasdescribedin Phase 7above.

Y

XA

Fig. 8

Fig. 1

Fig. 2

H

Fig. 3 F

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07.4 AIR CIRCULATION

1. Fumeexhaust2. Flexiblealuminiumpipesforhotairducting:ø80mmfor

mod.STAR68,ø100mmformod.STAR80,L.max.2x4m3. Chuteforloadingpellets4. Airdamperleverforregulatingtheflowofducting5. Humidifier6. Obligatoryexternalairintake(seepar.07.1)7. Ø80mmpipeforcombustionairintakebeconnectedto

internalorexternalasrequired(seepar.07.1)8. Handleforopeningdoor9. Airventsforaircirculationinsideenvironmentortolevy

combustionair10. Door11. Openablefrontgrid12. Adjustableventsforhotair180x120mm13. Recirculationgridobligatoryhood400x100mm(100mm

fromtheceiling)

07.5 EXAMPLE OF AIR DUCTING IN THE VARIOUS ROOMS

Toductairintotheotherrooms,connectthepipestothefireplace’supperrearoutlets.Todistributeairtothevariousareas,seeexample.Theaircanbebalancedwiththegridswithadjustableclosures.

NOTE

Theairpipesmustbebroughttotheroomstobeheated.Fromeveryroomwherehotairisducted,theairmustreturntothefireplaceroomthroughopeningsbeneaththedoorsorvents,whichmustbetakenupagainbythegridinthefireplaceskirting.Theflowofductedaircanbe increasedbyclosing the frontoutletusing theupper leveron therightbeneath thegrid.The twoairoutletscanalsobeunitedinonesingleoutletwitha“Y”pipe,inordertohavehotairinonesingleoutlet;inthiscaseitisnecessarytoincreasethediameteroftheoutputYofthepipelineatleasttoØ120mm(formod.STAR68)orØ140mm(formod.STAR80)diameter(bycustomer)andmaximumlengthofthepipes5m.

AirisdistributedwithflexiblecircularpipesinaluminiumØ80mm(formod.STAR68)orØ100mm(formod.STAR80).Thepipesmustbefastenedtotheunionswithpipeclamps.Pipeinsulationisvitalforthestove’sefficiency.Theymustbewrappedwithglasswoolpads(minimumthickness3cm)alongitsentirelength.

Makessurethatpipesdonotcontactwoodandinflammablematerials.WARNING

3

2

4

5

6

7

89

10

11

12

13

1

24

Itisalsoverydangeroustouseplasticpipestodistributeairsincethehightemperaturescoulddeformthemandreleaseharmfulgases.

Whereitisimpossibletowallupthedistributionpipes,theycanbehiddenwithasuspendedceiling,fakebeamsorcasing.

Thespacebetweentheventsandthewallmustbehermeticallysealedwithsilicone(A),topreventthatleakingairblackensitduetoheat(forexempledarkspotsoftheradiators).

IMPORTANT:UseaneutralcuresiliconesealWARNINGA

5m.max.

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07.6 FLUE OR FUME EXHAUST SYSTEM

Theflueorfumeexhaustsystemisafundamentalelementfortheproperfunctioningofthestoveandmustcomplywiththefollowinggeneralstandards:EN1856-1 Chimneys.Requirementsformetalchimneys-Part1:SystemchimneyproductsEN1856-2 Chimneys.Requirementsformetalchimneys-Part2:MetalfluelinersandconnectingfluepipesUNI10683 Heatgeneratorsoperatingwithwoodorothersolidbiofuels-InstallationrequirementsThediameterofthefluemustbesizedaccordingtothetechnicalspecificationsoftheapplianceandtypeandplaceofinstallation.Eachappliancemusthaveitsownchimneyfluewithoutanyinletsfromotherappliances.Theexhaustductofthecombustionproductsgeneratedbytheforceddraughtequipmentmustrespondtothefollowingrequirements:

• itisnecessarytouseunionjointsandpipeswithpressureresistantseals,astheunionofthefluecouldbeslightlypressurisedwhiletheappliancerunning

• allchangesindirectionmustbeopentoinspectiontofacilitatemaintenance• correctdraughttomaintaindepressioninthecombustionchamber,asperthetechnicalspecifications,mustbeguaranteed• itmustbewatertight,waterproofandsuitablyisolatedandinsulated• mustbemadeofsuitablematerialsthatresistnormalmechanicalstress,heat,theactionofthecombustionproductsandacid

condensations• mustbeprevailinglyverticalstructureswithdeviationsfromtheaxisnotgreaterthat45°• mustbeadequatelydistancedfromcombustibleorinflammablematerialsviaanairspaceorsuitableinsulation• musthaveaninternalsectionwhichispreferablycircular:squareorrectangularsectionsmusthaveroundedcornerswitha

radiusofnolessthan20mm• musthaveaninternalsectionthatisconstant,freeandindependent

Iftheflueisinstalledexternallyitmustbeinsulatedtopreventthecoolingoffumesandformationofcondensation.Thesameisvalidforthetractfromtherooftothechimneycap(Torrino).Fortheunionbetweenthestoveandtheflue,oriftherearedeviationsorcurves,foreasier,quickerandsaferinstallation,werecommendusingdouble-walledstainlesssteelpipes.Theuseofpipesinfibrecementforconnectingtheequipmenttotheflueisforbidden.Exhaustpipesmustnotrunthroughroomswheretheinstallationofcombustionequipmentisforbidden.Theunionmustbeconnectedtotheflueinsuchawayastoensuretheyremainairtightwhentheapplianceisoperatinginpressurisedconditionsandtoavoidtheformationofcondensationanditsconveyancetotheappliance.Ithastobeavoid,asmuchaspossible,theassemblyofhorizontalsections.Inanycase,thehorizontalsegment(oritshorizontalprojection)donothavetobelongerthantwometerswithminimumslopenotlessthan5%.Thehorizontalsectiondoesnothavetobeconnecteddirectlytothesmokefanoutputbutafterthefirstverticalsegment(6)Fig.1.

The chimney system for the smoke exhaust MUST bedimensioned and projected by a Qualified Engineer. Hewill determine the proper smoke exhaust system takinginto consideration the product technical data, kind ofinstallation,installationlocationandmostlytheinstallationtechnical regulation in force. The Engineer will giveindicationstotheinstalleraboutthematerialstouse,smokepath section, insulation thickness, corrosion resistance andallrequirementsneededforthecorrectworkingofthesystemproduct-chimney.Thecorrectdimensionoftheairintakeforventilationandaeration of the installation locationMUST be verified inconformitywiththetechnicalregulationinforce.Malfunctioningoftheproductcausedbyasmokeexhaustnot properly projected and dimensioned WILL NOT beobjectofobjectionstoJollyMecandinterventionsatJollyMec charge.Forappliance thatmust reachceilingorwallexhaustoutletsthatarenotcoaxialwithregardtotheissueofthefumesfromthemachine,changesindirectionmustbemadeusinganopenelbowof45°(seeFig.1).Theuseofcounterslopeelementsisforbidden.Theflueunionmusthaveaconstantsectionandallowsoottobecollectedandsweptaway.Changesincross-sectionareonlyallowedattheoutletoftheheatgenerator:theuseofadaptorsonthecouplingwiththechimneyflueisprohibited.Runningotherairductsandinstallationpipesinsidetheexhaustpipes,evenifoversized,isforbidden.

4

5

6

2

Fig. 1

1

23

40/50cm

3,0mm

in.

1,5mmin.

1,5mmin.

1. Airtightsteelsheetmetal

2. 45°Curves3. Fumeexhaust4. Externalinsulatedflue5. InsulatedTunionfor

condensation6. Non-insulatedpipe

26

Intheeventofablack-out,suitablesizingofthefumeexhaustsystemguaranteessufficientdraughttoexhaustthefumesgeneratedbycombustionwithouttheuseoftheelectricexhaustfan.Iftheperformanceofthefumeexhaustsystemisnotexcellent,itispossibletoadjusttheoperatingsettingsofthestovetoovercomedraughtdefectsbyamaximumof15%of the fumeexhaustdevice; thisadjustment ishowever theexclusivecompetenceof thespecialisedTechnicalServiceCenter. Oneairtightreadingpointisrecommendedonthefluetocheckemissionsafterinstallationandmeasuredraught.Supportingtheweightofthefluewiththeapplianceunionisstrictlyforbidden.Usespecificstandsorindependentsupportsforthispurpose.Toinstallothercombustiondevicesinthesameroomwherethepelletapplianceisinstalled,refertoUNI10683andUNI7129installationregulations.Theminimumflueheightmustbeover3,0m.Blockingofwallexhaustterminalsatanyheightandanydistancefromopenings,doorsand/orwindowsisnotpermittedandaveryimportantruletofollow.Installationofexternalfireplacesmustbeperformedusinginsulateddouble-walledpipes,topreventtheformationofcondensate;itmustalsobepossibletoinspectthebaseofthefireplaceforroutinemaintenancewhichmustbedoneatleastonceayear.Awindproofchimneycapmustbeinstalled;inthepresenceofadverseweatherconditions,especiallyhighwinds,thisaccessoryallowsthestovefluedraughtsystemtooperatemucheasier.Aminimumfluedraughtbetween10and14Pamustbeguaranteed.Thisvaluemustbemeasuredusingspecificandcontrolledinstrumentseachtimetheapplianceandflueundergomaintenance.Withstrongwindsandthechimneycapinstalledintherefluxarea(seeFig.2,zoneborderedbythedottedlineAforroofswithß>10°slant)oftherooforwithoutcomplyingwiththedistancesforeseenbyUNI10683situationsmayarisewherethestovedoesnotworkwhichwilltriggerthenodepressionalarm.Itisnotpossibletomakecorrectionsorresetthestoveoperatingvaluestooverridethealarm.

07.7 INSTALLATION ROOM VENTILATION

AccordingtoreferenceregulationUNI10683,4Padepressionmustbeverifiedbetweentheinstallationroominteriorandexterior.Prepareadequateventilationopeningsintheroomwheretheproductisinstalledtopermitatleast50m³/hcleancomburentairflownottakenfrompollutedrooms.Theventilationopenings,iffittedwithinsect-proofmesh,mustbeeasilyremovableandundergoperiodiccleaningtoensureclearairflowpassage.Ifthecomburentairinletisdirectlyconnectedtothestove,itmaybenecessarytomakeadjustmentstothecontrolunit,especiallyduringthestart-upphase,asthetemperatureandhumidityofoutdoorairnotonlyvariesduringtheperiodofuseoftheproduct,butalsocomeintodirectcontactwiththepelletsandtheignitionelement,generatingdifferentfuelburningtimes.JollyMecallowstheductingsystemattheinputofthecombustionairwithinandnotoverthefollowinglimits:thelengthcan’tbelongerthat1000mm,thediameterhastohaveatleastthesamesectionofthestove/boilerconnection,itispossibleonlyone90°changeofdirection,thecenter-to-centerdistanceofthecombustionairinputpipecanbe±300mm.

Itisonlyrecommendedtoconnectthecomburentairductingsystemtothestoveifabsolutelynecessary.Verycoldairandhumiditymaycausedifficultiesduringthestoveignitionphase.

NOTE

Asforthefuelproductexhaustsystem,airventsarealsoextremelyimportantandmustbegiventheappropriateconsiderationandrespect.Theinstaller isdirectlyliableforallelectricalsystemparts,generationhook-uptothesystem,ventilationandthefumeexhaustsystemandMUST,attheendofinstallationwork,issueadeclarationofconformityasperMinisterialDecree37/08.Ontheotherhand,thepurchaserMUSTassignallworktoaqualifiedprofessionaltechnician.ThedevicemustbeinstalledandusedinaccordancewithalllocalandnationallawsandECRegulations.

WARNING

Itisnotallowedtoinstallcoaxialsystemsforthesmokeoutput.WARNING

.

130cm

.

50cm

A

ß>10°

90°

Fig.2

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07.8 ELECTRICAL CONNECTIONS

Electricalconnectionsmustbecarriedoutbyskilledpersonnelaccordingtotheregulationsinforce(2014/30/UEand2014/35/UE).

WARNING

Connect the 230Vac 50Hz line with the proper cable with plug,suppliedwiththestove,whichpowersupthecontrolunitandalltheappliance’selectricalcomponents.Theapplianceisequippedwithapowersocketwithfuses(A),andabipolarswitch(B),(seeimageattheside).Intheeventthatthecontrolunitdoesnotswitchon,evenafter turning theswitch to I“ONE”,checkthatthefusesareintact

(C)Controlunitlid

07.9 CONTROL UNIT

Thecontrolunitmanagesallthefunctionsandiscotrolledbyremotecontrol (seepar. 08.4).Theradio-frequencycontrolunit(operatingbytheantennalocatedintheleftlateralpartofthecassettefireplaceandconnectedtotheconsole) is equippedwith a timed thermostatwith personalisableprograms, for simple management of functioning controls. Thefunctioning is given by the AMBIENT PROBE, located on theremotecontrol(orintheequipmentwiththesensorinstalledinsidetheconsole,whichcanbemoved intoanareaof thehousebyacable2x1mm²)andcontrolledbysafetydeviceswhichare:FUME TEMPERATURE PROBE:insertedonthefanexhaustfumes.PRESSURE SWITCH:insertedonthefanexhaustfumes.SAFETY THERMOSTAT PELLET TANK:insertedonPELLETtankanditIntervenesifthefireplace’sinternaltemperatureistoohigh.NB: if the remotecontrolbreaksdown, thefireplacecan functionwithpelletsusingtheemergencyconsole(asdescribedinpar.08.3 andintheSM095manualattachment).

1. Electroniccontrolpannels2. Groundsecurity3. Electricalconnectionwithcableintheequippment4. Switchbutton5. Fuseø5x20F4A250VIEC127-II

1 2

3

45

5

CB A

N

N

F

L

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07.10 CONTROL UNIT ELECTRICAL WIRING DIAGRAM

Electricalconnectionsmustbecarriedoutbyskilledpersonnelaccordingtotheregulationsinforce(2014/30/UEand2014/35/UE).

WARNING

Therepresentationofthecomponentsisapproximate,buttheycanchangeintermsofshape.NOTE

1 UserRadioConsole2 Electroniccontrolpannels3 Socket with bipolar switch and fuse holder for the electric

network4 Electricpowercordwithschukosocket5 Combustionfumesexhaustfan6 Pelletstart-upelectricresistance7 Hotairexchangecentrifugalfan8 85°Csafetybulbthermostat

9 Fumesafetypressureswitch10 PELLETaugermotor11 Roomtemperatureprobe12 Fumetemperatureprobe13 Automaticresetsafetythermostat14 Fumesfancondenser15 Airexchangefancondenser16 Microswitch:fireplacepositionswitch

1

2

3 4

6 7

5

10

11

12

14

15

9813

17

16

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CHAP.08 USE AND MAINTENANCE FOR THE USER

08.1 APPLIANCE OPERATIONSThe inset FIREPLACE uses pellets as fuel, whose combustion iselectronicallycontrolled.Pelletsaretakenfromthestoragehopper(A)bytheaugerB)controlledbythegearmotor(C)andconveyeddirectlytothecombustioncrucible(D).Theyareignitedbythehotairproducedbytheelectricheatingelement(E)andaspiratedintothecruciblebythecentrifugalfan(F)whichisthesamethatsucksupthefumesproducedbycombustion,expellingthemfromthelargevent locatedon theupperpartof thesupportplateandconnectedwiththeflue.Thefan(G)movesairintheairspaceonthebackofthefireplace,whereit isheatedand then released into theenvironment through theslotandthe front grid (H) and/or ducting(L). The hopper (A), on the rear part oftheinsetfireplace,isfilledbyaslidingdrawer(I)locatedonthefrontpartoverthefireplaceandbehindtheairgrid(H)(mod.SYNTHESIS)oramoreappropriateslide(mod.STAR).Pourthepelletsinthedrawerandwiththeappropriate tool push them into the hopper; the hopper is full when thepelletsstayinthedrawer.The fireplace is equipped with an exchanger in steel and dual heatdevelopingFIREFLECTOR,closedinfrontbyadoorinceramicglass.Thequantityof fuel, thefeedingofcomburentairandtheextractionof fumesare regulatedwithanelectronic card inorder toobtainahighefficiencycombustion.Alltheoperationsformanagingoperationarehandledbyasuppliedradioremotecontrol.Ititbreaksorislost,theemergencyconsoleinsidetheinsetfireplace(seepar.08.3)canbeusedtostartuporturnoffthemachine.

08.2 DOOR OPENING AND INSET FIREPLACE EXTRACTION (only with fireplace off and cold)

Openthefireplacedoorpullingtheleverforward(A)locatedbelowtotherightand,usingthesuppliedwrench(B),turnthescrew(C)belowtotheleftone fourthofa turnanticlockwise.Contemporaneouslypull the insetfireplaceoutwards.

Accompanythedooruntilitisclosedandlockitwiththerelativelever.

The inset fireplace is equipped with a safetymicroswitch(D),fittedbelowintherearpartofthebase(seeFig.1),whichswitchesofftheelectricalpowersupplywhenthefireplaceisextracted.

WARNING

Before closing the door, make sure you haveremovedthekey(B).

WARNING

Toclose,simplypushtheinsetfireplaceinwardsuntilyouhearaclickthatletsyouknowithasbeensecured.

A

F

E C G

B

L

H

D

I

C D

Fig. 1

B

A

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08.3 EMERGENCY CONSOLE

Iftheremotecontrolbreaksdown,thebasicfunctionscanbeaccessedby an emergency console (see also SM095 manual attachment),locatedunder thecontrolunit lid inside thecassettefireplaceon theleftside(seephoto).To access the console, you must extract the cassette fireplace asexplainedintheprecedingparagraph08.2,thenremovetheconsoleholder,whichisfixedontwopins,cuttheplasticbandbindingthecableandbringeverythinguptothedoor.Inside the door below to the left, there are two pins on which theconsole holder bracket can be fastened, fixing it so it stays turnedoutward,andmakingsuretothreadthecableintheremainingspacebetweenthebaseandthedoorinordernottocrushit.Tocloseit,seethepreviouspar.08.2.

08.4 REMOTE CONTROL

Theremotecontrolletsyouusethefollowingmainfunctions• Devicestartandstop• 5heatingoutputleveladjustment• Regulatethedesiredambienttemperature.• Optimisecombustion.• Manuallyloadpelletsintothebasket.• Managethetimedthermostatwithseveraldailystartups.• Reportanyfunctionirregularities.• Indicatetheheatingappliance’soperatingmode.

08.5 SAFETY THERMOSTAT PELLET TANK WITH MANUAL RESET

If the fireplace is switched off by the intervention of the safetythermostat,thecausecouldbetoohighoutput.Decreasetheoutput.Proceedasfollowstorestorethefireplace’snormaloperation:1)waituntilthefireplaceiscompletelycold(10-20minutes);2)extractthecassettefireplaceasexplainedinpar.08.2;3)resetthethermostatunscrewingthehood(A)locatedontherearpanel(photoalongside)anduseapointtopresstherelativebutton;4)refitthehoodandclosethecassettefireplaceagain,asexplainedinpar08.2;resetthealarmonthecontrolunitandstartupagain.

A

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08.6 RECOMMENDATIONS AND WARNINGS

Thefanbeginstorunautomaticallyfollowingthesmokestemperatures.

NEVER RUN THE FIREPLACE WITHOUT ELECTRICAL CURRENT AND WITH FUELS OTHER THAN WOOD PELLETS

WARNING

DONOTTOUCHthepartsofthefireplacewithoutcladding,excludingthehandlesandtheregulatingcontrols,astheyaresubjecttohightemperatures.Theroomwherethefireplaceisinstalledmustnotdirectlyadjoinmulti-flooredstairwells;theremustnotbeotherboilers,stovesorairextractorsinthesameroom(excludedofthetype“C”accordingtoUNI10683).AØ150mmexternalairintakeintheroomisobligatory.

WARNING

Use only original spare parts recommended by themanufacturer. Original spare parts are available through retailers, specialisedTecnicalServiceCenters,ordirectlyattheheadofficeofJollyMecCaminettiS.p.A.

Iftheglassbecomesverydirty(withvisibleblackening)whileoperatingonpellets,possiblecausescouldbe:•Littleuptakeintheflue(cleantheflueorcheckitscharacteristics).•Insufficientcomburentair(addmoreairwiththecombustionfan),cleantheairintake.

Pleasebeawarethattohavea10kWoutput,approximately2kgofpelletsperhourmustbeburned.Whenpelletsarenotusedforalongtime(spring-summerperiod),thehopper,theaugerandthebasketmustbecompletelyemptiedusingavacuumcleaner;cleancarefullytopreventthatpelletresiduedepositsthereanddamagescomponentsduringthenextstartup.Useonlyrecommendedfuelsotherwisethewarrantycouldbeinvalidated.Every500-1000kgofpelletloadedinthehopper,checkthattherearenodepositsofsawdustonthebottom,andremoveanysawdustthere(sawdustreducestheauger’scapacityandcreatesfunctionalproblemsforthefireplace).

Thepelletsmustbefedintothehopperusingascoop.Donotemptythesackdirectlyintothehopper.Thefiredoormustalwaysbeclosedduringnormaloperations.Thepellethatchmustbeclosedwhilethemachineisrunning.

Checkforobstructionsintheflueandintheexternalairintakebeforestartingthemachineafteraprolongedperiodofdisuse.Thefireplacemustnotbeusedasanincinerator.Donotusedfuelsthatarenotrecommended.Thefireplacemustnotbemodified;eachunauthorisedmodificationautomatically invalidatesthemanufacturer’swarrantyandeveryresponsibility.

Thefireplacemustnotbeplacedindirectcontactwithcombustiblematerials;theminimumdistancetobeobservedis50cm.

Promptandsystematicmaintenanceisafundamentalcomponentforperfectfunctioningandcontinousmaximumheatefficiency.

Tostartup,proceedasfollows:-theinsetfireplacemustbepushedandsecuredinitshousing-cleanthebasketandburningarea-loadthepellets-pourwaterwithessencesinthehumidifier(ifdesired)-closethefrontdoor-pressthestartupbuttonontheremotecontrol(seethespecificmanualalso)-adjusttheoutput

MORE CLEANING = HIGHER PERFORMANCE

Forproblemswiththedevice,pleasecontactthespecialisedTechnicalServiceCenter. Intheeventofafireintheflueorfireplace,switchoffthedeviceandcontacttheFireBrigadeimmediately.WARNING

Thehumidifyingwater (maxcapacity1 litre)mustbemanually inserted in thefireplace through thefillingwindow that is located totherightofthefireplace,beneaththeairdiffusiongrid(thehumidifierisfullwhenthewaterreachesthelevel).DorememberthatthefireplacecanalsooperatewithoutwaterAir humidificaton prevents physiological disorders such as: dry throat, migraine, various allergies and excess dust caused byenvironmentsthataretoodry.Aromaticessencescanbeaddedtothehumidifierwater(mixedwiththewaterthathasbeenpoured)toscenttherooms.Ifthereisairductingintheotherrooms,theflowcanbefurtherincreased,usingthespecificdamperleverlocatedbeneaththefrontgrid(upperright)onthefireplace.

32

• Pellet basket cleaning (recommended 2-5 days)Eliminateanydebrisinthebasket,turningitoverwithatoolandwithitstipremoveanymaterialthatmaybecloggingit,strikingtheinnerwallsofthebasketthenshakingit; orremovethebasketcompletelyfromitshousingtomakecleaningeasier.Cleantheairpassageholesinthebasketcarefullywithapointedtool.Makesurethattheareawherethebasketrestsiscleanedwell(ifthebasketdoesnotsitwellonitandairpasses,thefireplacewillnotstartupandoperatespoorly;itcanalsoletreturningsmokeenterthepellethopper)Repositionthepelletbasketperfectly.

• Glass cleaning (daily)Cleantheglassdailywithadampspongeorpapertowel.Iftheglassbecomesdirtywithblacksmoke,the,pelletbasketisprobablydirtyorthecombustionairmustbeincreased.Be careful not to use overly aggressive products to avoid ruining the paint.Never spray detergents directly onto the parts to becleaned. If thefireplacerequiresmore frequentanddeepercleaning,check thefluedraughtperformanceandthechimneycap.Awindproofchimneycapisstronglyrecommended.

• Ash compartment cleaningRemovetheashgridandemptythepelletashcompartmentperiodicallywhenevernecessary.Thepurposeofthiscleaningistoensurethefreeflowofcombustionairfromthebasket’sholes.Usea“drumtype”vacuumcleanerequippedwithafinemeshfilter,whichwillsimplifycleaningasitpreventsaspiratedashfromreturningtotheenvironment.

• Pellet hopper cleaningEvery500-1000kgofburnedpellets,emptythehopperandcheckthatnosawdusthasdepositedonthebottom.Cleanthebottomofthehoppercarefully.Afteralongperiodofinactivity,emptythehopperandaugercompletely.

Supplied tools for cleaning, loading and extracting

A. ScoopforpelletsB. SprayforthehumidifiertankC. CleaningbrushD. HeatproofgloveE. Handle/keyforextractinginsetfireplace

08.7 ORDINARY MAINTENANCE (to be done by the customer)

Forthefirstfewdaysduringpelletoperation,keepthepelletbasketunderobservationtodetermineafterhowmanydaysitmustbecleaned,asdifferentqualitiesofpelletshavedifferentquantitiesofresidue.

Beforestartinganytypeofcleaning,switchoffthemainswitchandmakesurethatthefireplaceiscold.WARNING

A

B

C

D

E

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1. Cleaninsidethefireplacewiththeprovidedtools*2. Removethesteelgrid(seeFig. 1).3. Takeoutthepelletbasketandcleanit(seeFig. 2).4. Removethetilesinsequence,startingfromtheside,eitherleft

orright:a)Grasp the topof the side tile (seeFig. 3), lift it and turnit inwards(seeFig. 4) to free it from itsslotand leaning itbackwards(seeFig. 5)removeitfromthefireplace.

b)Proceedinthesamewaywiththeotherlateraltile.c)Grasp the top of the front/middle tile (seeFig. 6)pullingit forward, lift it(seeFig. 7)andleanit forward,tofreethepellet loadingchute fromtheauger, (seeFig. 8) remove itfromthefireplace.

5. Cleantheboiler’sinternalsurfaceswithabrush(seeFig. 9-10-11).

6. Withavacuumspecific(can)orpaletteandbrushescleantheashesandresidues.

7. Reassembleallpartsfollowingthesequencecarefully.

*Recommendedcleaningonceamonth(butcheckthemanual).

• Loading the pellet hopper (Inserto Synthesis 68-80)Thepellethopperisfilledthroughtheopeningonthehotairdiffusiongrid(Fig. 12).Removethepelletdrawer(Fig. 13)13andpourthepelletsintothedrawerusingashovel(notsupplied) (Fig. 14).Thepelletsmustnotbepouredindirectlyfromthesack.Asseenin(Fig. 15)usethedesignatedtooltopushthepelletsinsidethepellethopper.Whenloadinghasbeencompleted,closethedrawerandgrid.Itisrecommendedtofillthehopperwhenthedeviceiscoldandswitchedoff.Ifthehopperisfilledupwhenthedeviceisrunningorhot,itiscompulsorytoweartheheatprotectiongloveprovidedas,duringthesephases,thesurfacesoftheventilationgridtheloaddrawerhandlecangetextremelyhot.

Fig. 1 Fig. 2

Fig. 3 Fig. 4

Fig. 5 Fig. 6 Fig. 7 Fig. 8

Fig. 9 Fig. 10 Fig. 11

Fig. 12 Fig. 13 Fig. 14 Fig. 15

34

• Loading the pellet hopper (Inserto Star 68-80)Thepellet loadingchute isusedtofillupthepellethopper.Accessthechuteviatheflaponthecladding,asseeninthecladdingexampleFig. 16 (Fig. 16-17-18).Pourinthepelletsusingashovel(notsupplied)(Fig. 19).Thepelletsmustnotbepouredindirectlyfromthesack.

• Cleaning fireplace main body (to be verified according to usage)• Cleaning of flue once a year to be verified according to the usage (attention to horizontal lines)• Cleaning of fans once a year (to be verified according to the usage)

Tocarryouttheseoperations,theelectricalcurrentmustbeturnedoff;youmustwaituntilthefireplaceiscoldandcomplyrigorouslywiththesafetyregulationsinforce.

WARNING

WewishtoremindyouthattheExtraordinaryMaintenancetobecarriedoutonthistypeoffireplacemustbedoneobliga-torilyeveryyearbyqualifiedmaintenancepersonnel,inordertomaintainitsfunctionality,efficiencyandcomfort.

Foranyfurtherqueriesyoumayhave,weinviteyoutocontactthespecialisedTechnicalServiceCenterthroughyourretailer.

08.8 PREVENTIVE MAINTENANCE PROGRAM (To be done by a specialised Technical Service Center)

Fig. 16 Fig. 17 Fig. 18 Fig. 19

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CHAP.09 FAULT DIAGNOSIS AND TROUBLESHOOTING

• Donotusethestoveiftheuptakeisirregularandthecombustionisnotoptimal!• Inaccordancewiththelawsinforceonsafetyforelectricalappliances,aspecialisedTechnicalServiceCenterorqualified

personnelmustobligatorilybecontactedforallinstallation,maintenanceorinterventionsthatrequireaccesstoelectricalparts.

WARNING

09.1 PROBLEMS

PROBLEM MAIN CHECKS TO BE PERFORMED

The Emergency Console isnot on

• Checkthat thefireplaceplug is insertedsecurely in themainssocketandthesocketat thebackof thefireplace.

• CheckthattheFLATcableisconnectedtotheelectroniccircuitboardcorrectly.• Checkthattheprotectionfusesareworkingefficiently,includingthoseconnectedtotheelectroniccircuit

boardandthoseinthefireplacesocket.

The remote controldoes not work

• Check that thebatteriesarenotdeadand theyare insertedcorrectly.Rechargeablebatteriesarebotallowed.

• Pointtheremotecontrolattheemergencyconsole.• Checkthatthefireplaceispoweredupandthedisplayisworking.

The pellets are not dropping into the firebox

• Thepelletshaverunout,refillthecontainer.• Thegearmotorisnotrunning,checkthereason:

- notconnectedtothemains - mechanicallydisconnectedfromtheauger.

• Theaugerisblockedbyaforeignbodywhichhasfallenintothecontainer.• Theaugerisblockedbyveryhardpellets;usetherecommendedpellettypes.

The fireplace does not start up automatically

• Thefireboxisdirty,preventingincomingairflow.Cleanitthoroughlyandcheckitiscleaneachtimeyoustartitup.

• Thebasketispositionedincorrectly.• Theresistanceisfaulty.

The pellets burn poorly and uncombusted material forms in the basket, the glass gets very dirty and blackened

• TheamountofpelletsloadedinthebasketforthevariousoutputmodesdoesnotcorrespondtotheamountsindicatedintheTechnicalSpecifications(seepar.06.1).Verificareecorreggere.

• Lowfluedraught,donotusethefireplace,itcouldbedangerous;carefullycleantheflue,thestoveandthefumeextractor.

• Thepelletburningpotisverydirty.Switchoffthefireplaceandcleanit.• Humidpellets.Replacethefuel.• Lackofcomburentair,checkthatthefrontdoorisfirmlyshutagainstthefireplacestructure.• Incorrectfansettings;checkthedefaultandfactorysettings.

The fireplace switches off when running at minimumpower.

• Thecombustionfanspeedisveryhighandthepelletsareburningtooquickly.• Thepelletsupplyisrunningout.• Thefluedraughtrateishigh.• Theamountofloadedpelletishigh,itdoesnotallburnwithinthesettimeandfreshpelletsaccumulate

insidethefirebox.• Pelletsizeisverysmall,adjustloadingtime.

The flame is very inconsistent

• Checkthebottomofthepelletcontainer;theremaybelargedepositsofsawdust.• Thegearmotormayhavebrokengearings.

The exchange and/ or combustion fan are running when the fireplace is switched off

• Theflueprobeisbroken.Replaceit.

The electric components are running when the fireplace is switched off

• Theelectroniccircuitboardisbroken.Replaceit.

The exchange fan air smells of smoke

• Checktheexchangefan,itmightbedirty.

The exchange fan whistlesor is very noisy

• Checktheexchangefan,itmightbedirty.

PleaseseetheattachedmanualSM095ENtoseethealarmmessageslistNOTE

36

10.1.1 Components for canalisation group and for pel-let chute system

CHAP.10 ATTACHMENTS

10.1 INSERTO STAR 68/80 - AIR CANALISATION GROUP AND PELLET CHUTE ASSEMBLING

The fireplace INSERTO STAR 68/80 is delivered completelyassembledonitseasel(seeFig. 1)andcompletewiththerequiredcomponent tofix itand thecomponentsof thecanalisationgroupandpelletloadchute(seeFig. 2).

1. Lateralshafttofixtheeasel(n°2pcs.)2. Assemble the lateralshaft forcanalisation(nr.2

pcs.)3. Topbar4. Hotairbox5. Pelletloadchutesupport6. Containmentrubber7. Fixingplatesforrubber(nr.3pcs.)8. Pelletloadchute9. Adjustablelegs(nr.4pcs.)

• ScrewM8x16(n°30pcs.)• NutM8(n°30pcs.)• WasherØ8(n°30pcs.)• ScrewM5x16(n°11pcs.)• NutM5(n°4pcs.)

Fig. 1

Fig. 2

9

4

1

2

8

7

6 2

3

5

1

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10.1.2 For a correct assembling of the following parts:

1. Fix the lateral shaft 1 (Fig. 3), usingthe screws M8x16 with their nuts andwashers, in the equipment, following theinstallationtype.

2. Fix the lateral shafts 2 (Fig. 4), usingthe screws M8x16 with their nuts andwashers, without tightening it, onlypreassemblyit.

3. Fixthetopbar3 (Fig. 5),usingthescrewsM8x16 with their nuts and washers,withouttighteningit,onlypreassemblyit.

Fig. 5

Fig. 3

1

1

3

Fig. 42

2

38

10.1.2 Foracorrectassemblingofthefollowingparts:

4. Fix the hot air box 4 (Fig. 6), using thescrews(nr.3)M5x16,withouttighteningit,onlypreassemblyit.

5. Nowfollowbyadjustingthehotairboxtillitfitsproperlywith thefireplace, toavoidairlosses:

• Byactingontheupperpartofthelateralshaftsyoucanadjustthetopbarupanddown(fig.A).

• Byactingon the lowerpartof the lateralshaftsyouobtaina regulation indeepofthetopbar(fig.B).

• Byactingon the topbar,using the threeslotsyouobtainanadjustmentofthehotairbox(fig.C).

Beforetighteningthescrewsthroughthenutandthewasher,verifythegoodplacementofthehotairboxandcheckthatbyslidingthefireplaceinandouteverythingisfittingcorrectly(seetheincludedinstructionmanualfortheopening).

Before you start to extract the fireplace, verify that it is properly fixed on a wall or at the floor to avoid a roll over which could be dangerous.

WARNING

6. Settle the mounting position of the pelletload chute (left, right, centre), as desiredand assembly the support 5 (Fig. 7) withthe help of the containment rubber 6 andthefixingplates7.Assemblefirsttherubberon the holes who will remain free after thepositioningofthepelletloadchute8dependingfromthechosenposition:n.°4 for rightor leftpositioningand2forcentralpositioning).withscrewsM5x16andnutsM5,thanfixthepelletload chute 8 only using the screws M5x16(n.°4).

Fig. 4

4

Fig. A Fig. B

Fig. C

Fig. 7

7

5

6

7

8

39

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10.1.2 Foracorrectassemblingofthefollowingparts:

7. Assemble the sliding group (Fig. 8),with the screwsM8x16 thenutsand thewashers in the equipment, inside theupperbarwiththehelpoftheupperholes,depending from the position chosenandfixtightly.

8. Usingthetwolateralscrews(Fig. 9)ontheslidinggroupyoucanadjustthedistanceofthechutetothecladding(Fig. 10).

Fig. 8

Fig. 9 Fig. 10

Lateralscrews

40

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42

43

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SM

05

3 E

N R

EV

07

20

18

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