Alarko HARMONY - D, Installation And Servicing Instructions

Page 1: ...1 USERS INSTALLATION AND SERVICING INSTRUCTIONS HARMONY D ...

Page 2: ...2 Code No A 1 2 8i Publishing Date 200114 Revision Date 200114 ...

Page 3: ...ler the user must read the USE section of this booklet carefully before using the boiler Other sections of this booklet are not for the end user People or organizations authorized to install commission and service this boiler must follow the instructions in INSTALLATION AND MAIN TENANCE section of this booklet to ensure the correct installation and operation of the appliance For further informatio...

Page 4: ...of the Boiler 17 2 4 Water Circuit 18 2 5 Control Panel 19 2 5 1 ON OFF and Domestic Hot Water Control Knob 19 2 5 2 Central Heating Control Knob 20 2 5 3 Pressure Gauge Manometer 20 2 5 4 LCD Display 21 2 5 5 Reset Button 21 3 BOILER OPERATION 22 3 1 Start Up Pre Checks 22 3 2 Water Filling 22 3 3 Domestic Hot Water Operation 23 3 4 Central Heating Operation 23 In Summer 3 5 Turning the boiler OF...

Page 5: ...ith 90 Turning Kit 41 4 2 8 Installing Flue System with Elevation Kit 42 IMPORTANT NOTES ON FLUE SYSTEMS 44 4 3 COMPONENTS SYSTEM 44 4 3 1 Filling the system 45 4 3 2 DOMESTIC HOT WATER 46 4 3 2 1 Showers Bidets Taps and Mixing Valves 48 4 3 2 2 Water Quality 48 4 3 2 3 Water Pressure 48 4 4 ELECTRICAL 49 4 4 1 ELECTRONIC BOARD WIRING DIAGRAM 51 4 5 CONVERSION TO DIFFERENT GASES 52 5 OPERATING PAR...

Page 6: ... maximum and minimum 64 7 5 Final Operational Checks 65 7 6 Commissioning Heating System 65 7 7 INSTRUCTIONS TO THE USER 66 8 SERVICING 66 Appendix A 70 FAULT FINDING 70 TABLES Table 1 Technical Data 15 Table 2 Clearances for boiler installation 26 Table 3 Minimum clearances for cupboard installation 27 Table 4 Minimum ventilation areas for cupboards 28 without sufficient clearance Table 5 Setting...

Page 7: ...e Terminal Dimensions 32 Figure 14 The Parts of the Flue Kit 33 Figure 15 Wall Connections 36 Figure 16 Extensions Elbow 36 Figure 17 Standard Flue Kit Installation 37 Figure 18 Extension Flue Kit Installation 39 Figure 19 Shortening the Ducts 40 Figure 20 90º Turning Kit Installation 41 Figure 21 Elevation Kit Installation 43 Figure 22 a Additional Expansion Vessel b Methods of Filling the System...

Page 8: ...le for sealed systems only Our authorized seller and services will give you the enough information about use and maintenance after setting up the boiler You can ask any further question to them Our experts will be glad to answer your ques tions In order to use the boiler in safe high efficiency and economic way for a long life period please read these instructions carefully and obey the safety rul...

Page 9: ...mbar inlet pressure 3 G30 G31gases with non governed gas supplies at 29 37 mbar inlet pressures respectively TERMS AND CONDITIONS OF GUARANTEE AND SERVICE Your boiler is guaranteed for material defects and mechanical failure as written on the Guarantee Form The guarantee is only valid if the appliance is installed in accordance with this manual Guarantee is not valid under below conditions Install...

Page 10: ...er gas use condition is al lowed for the boiler The particular gas type that the boiler is already adjusted to is written on its data badge unless it is converted to another gas by a compe tent person Make sure that the boiler is not used with a different gas other than which it is adjusted for or it is finally converted to 1 2 Course of Action in case of Gas Leakage If you smell gas or the gas al...

Page 11: ...local gas distri bution organization After approval of local gas distribution organization and precise application of installation have your boiler commissioned by an Authorized Service Commissioning is a free service Do not let unauthorized people to interfere or service the boiler Gas conversion process if necessary must be made by an authorized service only Conversion is paid by the end user Ke...

Page 12: ...nts of Packaging The following items below are included in the package Check if any item is missing Hanging bracket connection screws 4 pcs and wall plugs 4 pcs Installation operating and maintenance Instructions Warranty Document Standard Flue System is supplied in a separate package 1 4 ECONOMY MEASURES Your boiler is designed and manufactured to minimize the gas consump tion For further saving ...

Page 13: ...ue LCD screen located on the fascia panel A degree of frost protection is built into the boiler controls When the boiler temperature falls under 6 C the boiler starts to operate until a temperature of 15 C is reached on CH side Additionally there is also an antifreeze DHW protection function that operates under 5 C until 8 C is reached These control functions prevent the boiler from freezing When ...

Page 14: ...tic hot water frost protection Central heating and domestic hot water pump overrun Energy saving circulation pump Pump jamming prevention Central heating low and high pressure safety Domestic hot water low pressure safety Automatic by pass Hermetic pipe blocking and fan malfunction safety Suitable for use with under floor heating The technical data is shown in Table 2 1 ...

Page 15: ...M DATA Pressure max min bar 3 0 0 3 Expansion Tank Volume Pressure lt bar 6 0 0 2 Maximum Water Temperature C 85 Temperature Range C 30 80 or 30 50 Frost Protection Operation Temperature C 6 DOMESTIC HOT WATER SYSTEM DATA Temperature Range C 35 60 Pressure max min bar 6 0 2 DHW minimum flow rate lt min 2 2 DHW Flow Rate at a Temp rise of 30 C lt min 12 PHYSICAL DATA Flue Diameter mm 100 suction 60...

Page 16: ...16 2 2 Dimensions HARMONY_D USERS INSTALLATION AND SERVICE MANUAL Figure 1 Boiler Dimensions 2 3 Internal Parts of the Boiler ...

Page 17: ...e shown in Figures 2a and 2b Front view backside view and Figure 3 HARMONY_D USERS INSTALLATION AND SERVICE MANUAL The main parts of the boiler and water circuit are shown in Figures 2a and 2b Front view backside view and Figure 3 Figure 2a b Main Parts of the Boiler Front Backside View ...

Page 18: ...18 2 4 Water Circuit HARMONY_D USERS INSTALLATION AND SERVICE MANUAL 2 4 Water Circuit Figure 3 Water Circuit Diagram ...

Page 19: ...nobs LCD panel will automatically starts emitting light and LEDs will be OFF LED Figure 4 Control Panel Appearance light will start to give light again 5 seconds after setting of the control panel with knobs according to the relevant parameter input described above Figure 5 DHW Knob 2 5 1 ON OFF and Domestic Hot Water Control Knob This feature allows the user to ON OFF the boiler and set the desir...

Page 20: ...e can be adjusted Turning clockwise increases the set tem perature When the indicator knob position passes over the legend 1 domes tic hot water mode is ON From number 1 to 7 domestic hot wa ter temperature can be adjusted Turning clockwise increases the set temperature 1 Lower red region Indicates that water pressure is not sufficient Boil er doesn t work in that region It should be pressurized f...

Page 21: ...grees When there is DHW demand sign appears on the screen and temperature of sanitary water on heat exchanger exit can be read as Celsius degrees During the operation of the boiler sign displays continuously The monkey wrench sign appears in some cases of operating errors indicating that there is a need for the service 2 5 5 Reset Button Boiler locks itself in the below conditions and waits for th...

Page 22: ...ly air may collect in the heat ing system or in the boiler Water should be charged until the pressure gauge indicates green region pressure Do not forget to turn the filling tap off after water fill ing is completed Turn the boiler ON Check the pressure on pressure gauge as the system heats up after a while Pressure should not exceed green region Open the air release taps on the radiators and at t...

Page 23: ...35 C and 60 C can be set 3 4 Central Heating Operation Turn the DHW control knob to ON position The LCD screen will turn on with its blue light Turn the central heating control knob ON position The system pump will now run and the boiler control algorithm will start the auto matic ignition sequence Set the heating temperature control to the desired level A temperature adjustment is possible betwee...

Page 24: ...scharge the system except for the necessary events When the boiler is switched off at the switch on the control panel the word OFF appears on the display The D H W and central heating frost protection system nevertheless remain enabled If the boiler was previously on it is switched off and the post ventilation pump overrun circulation pump and three way valve inactivity protection functions are en...

Page 25: ...ntact with the local gas supplier 4 1 INSTALLATION RULES 4 1 1 GENERAL 1 Current Gas Safety Installation and Use Regulations state that all gas appliances must be installed by a competent person in accord ance with the regulations and rules in force in the countries of desti nation 2 Failure to install appliances correctly could lead to prosecution 3 These appliances must be installed in accordanc...

Page 26: ... any room provided that attention is drawn to the requirements of the relevant national and local rules standards and regulations in force in the countries of destination Where it is installed in a room containing a bath or shower any electrical switch or appliance control using mains electricity must not be able to be touched by a person using the bath or shower 2 The appliance is not suitable fo...

Page 27: ...compartment with no vents as long as the minimum clearances stated in Air Supply are maintained 4 1 3 AIR SUPPLY The appliance does not require a separate vent for combustion air The appliance can be fitted in a cupboard with no vents for cooling but the minimum clearances must be increased to those given below Note the clearances at the front are for a removable panel e g a door Table 3 Minimum c...

Page 28: ...ICE MANUAL Take the boiler out by holding from two sides on both ends DO NOT TRY TO LIFT FROM THE MIDDLE Cut the bands to open the box The boiler is packaged in a cardboard box Warning signs are to be observed during transport and storing 2 1 packaging out from the box Open the nylon wrapping and take the upper moulded the symbol on top Put the box on the floor with 3 4 OPENING THE PACKAGE Boilers...

Page 29: ...lush the heating system and the cold water mains supply in accordance with the recommended methods After this operation HARMONY_D USERS INSTALLATION AND SERVICE MANUAL Figure 11 Mounting Schematic with essential dimensions 4 1 6 Water and Gas Connections to the Boiler CH water connections should be made via gas and DHW connections should be made via isolation valves see Fig 12 For copper installat...

Page 30: ...ICE MANUAL Figure 12 Gas Water Connections 4 2 FLUE SYSTEM AND INSTALLATION 4 2 1 Sitting the Flue Terminal The flue must be installed according to national and local regulations See Fig 13 The terminal must not cause an obstruction or the discharge cause a nuisance If the terminal is fitted within 1000 mm of a plastic or painted gutter or within 500 mm of painted eaves then an aluminum shield at ...

Page 31: ...e this could cause a nuisance should be avoided Take care to ensure that combustion products do not enter ventilated roof voids Where elongation of the flue pipe is a necessary only original extension pipe and elbow must be used The flue system can be installed from inside the room without access to the external wall and regardless of the wall thickness providing that a suitable wall liner is fitt...

Page 32: ... facing the terminal Distance from facing terminals Horizontal distance to an opening door window under the lean to roof Distance to another terminal on the same vertical axis Distance to an adjacent opening such as a door or window on the same horizontal axis Distance to lean to roof from below Distance to another terminal on the same horizontal axis 300 75 200 200 150 300 300 600 1200 1200 1500 ...

Page 33: ...NY_D USERS INSTALLATION AND SERVICE MANUAL 4 2 2 Parts of Harmony_D RSF Flue System Figure 14 The Parts of the Flue Kit HARMONY D HERMETİK KOMBİ BACA SETİ 58990220076 HARMONY D HERMETİK KOMBİ BACA SETİ 58990220076 HARMONY D YÜKSELTME SETİ 58990220076 ...

Page 34: ...ncentric flue extension ducts see Fig 14 the total flue length of the system measured from the centre of the fan outlet of the boiler to the outside surface of the wall or window can be increased up to 3000 mm 118 in See Fig 14 Each 1000 mm extension duct extends the flue length by 973 mm and each 500 mm extension duct extends the flue length by 473 mm b 90o Elbow Additional 90 elbows can be added...

Page 35: ...te in a horizontal position However 900 elbows may be used to drop the height of the flue system by 500 mm 3 The flue system must use either a flanged elbow or a flanged eleva tion duct at the entry exit to the appliance 4 All joints must be correctly made and secured in accordance with the installation instructions in Flue System Installation section Refer to Figs 15 16 to determine which flue op...

Page 36: ...36 HARMONY_D USERS INSTALLATION AND SERVICE MANUAL 27 Figure 15 Wall Connections Figure 16 Extensions Elbow ...

Page 37: ...Reference will be made to additional kits where necessary HARMONY_D USERS INSTALLATION AND SERVICE MANUAL 4 2 5 Installing the Standard Supply Each boiler is supplied with standard flue system for flue lengths up to 725 mm See Fig 17 to assemble and install the standard flue system Reference will be made to additional kits where necessary Figure 17 Standard Flue Kit Installation ...

Page 38: ...al The wall liner is a tube of 130 mm diameter with a wall thickness of 0 8 mm This step may be skipped where outside wall is accessible and the ter minal duct can be pushed through the wall from outside In this case an adequate smaller hole can be drilled on the wall to be able to pass the Ø100 mm terminal duct 4 2 6 Installing the Flue System with Straight Extension Kit In case the total length ...

Page 39: ...llation Before installing the flue systems either standard supply or with additional extensions and turns cutting operation might be necessary to shorten the flue ducts Determine the cutting length as described in other figures and referring to Fig 19 below to see the cutting operation ...

Page 40: ...t be necessary to shorten the flue ducts Determine the cutting length as described in oth er figures and referring to Fig 19 below to see the cutting operation Use aluminum saw and always ensure that the cut is square and free from burrs or debris HARMONY_D USERS INSTALLATION AND SERVICE MANUAL Figure 19 Shortening the Ducts ...

Page 41: ...ow with flange 1 To achieve this distance an extension kit of necessary lenght can be used between the elbow with flange and the straight ducts 1 15 3 18 19 9 7 9 7 9 B 15 C Measure lenght L from the wall outlet point A back to the 90 turning point B at the place of installation and install the terminal duct according to this lenght Installation is done as described in Fig 14 or Fig 15 according t...

Page 42: ...as to be used for this purpose and it can be applied to any of the standard extended and 90 turning flue systems described in the three sections above Refer to Fig 21 to carry out the operation The figure shows how to provide the elevation and this operation will only replace the final assembly between the elbow with flange and the boiler in other installa tions described in Figs 17 18 and 20 ...

Page 43: ...LATION AND SERVICE MANUAL elevation and this operation will only replace the final assembly between the elbow with flange and the boiler in other installations described in Figs 17 18 and 20 Figure 21 Elevation Kit Installation ...

Page 44: ...ys tem 1 The appliance must not be operated without the system being full of water properly vented and pressurized 2 The pressure relief valve operates at 3 bar 43 5 lb in The dis charge must be directed away from electrical components or where it might be a hazard to the user 3 The pressure gauge indicates the system pressure which must be maintained 4 The 6 0 liter expansion vessel is charged to...

Page 45: ...er must be filled by a competent and authorized person In this case there must be no permanent connection to the mains water supply even if a non return valve is fitted see Fig 23 ATTENTION Domestic hot water system parts should obey all local regulations If there is a need to fill water at low pressure a provision should be made HARMONY_D USERS INSTALLATION AND SERVICE MANUAL Figure 22 Additional...

Page 46: ...circuit design purposes one should consider the information given in Fig 24 relating to the available pump head 4 3 2 DOMESTIC HOT WATER ATTENTION Work must not be carried out on the appliance without the gas and electricity supplies being switched off The following are general requirements but reference should be made to any local Water Supply Company regulations before fitting the appliance Main...

Page 47: ...ted that long pipe runs to the taps or shower should be insulated to prevent the rapid cooling of domestic hot water after a tap or shower has been turned off Hot and cold taps and mixing valves used with this appliance must be suitable for operating at mains pressure and temperatures of 60 C No back siphonage arrangements are necessary except for some loose head showers The head of a loose head s...

Page 48: ...pplied direct to an over rim flushing bidet subject to Local Water Company requirements In all mains pressure systems the flow of water from individual taps will vary with the number of outlets operated simultaneously and with the cold water mains supply pressure to the property Flow balancing of water draw off circuits e g via using Ball o Fix type valves is recommended to avoid excessive reducti...

Page 49: ... 1 x 3 15AF 5x20mm The data mentioned above if no different data is indicated is referred to following standard conditions Temperature 25 C Power supply 230 V ac 1 It must be possible to completely isolate the appliance electrically 2 The following connection alternatives must be used A 3 amp fused three pin plug and unswitched shuttered socket outlet or a double pole isolator with a contact separ...

Page 50: ...ction is necessary for the system please contact the boiler supplier 6 Safety Check After installation or in the event of an electrical fault the electrical system should be checked for short circuits fuse failure incorrect polarity of connections earth continuity and resistance to earth 7 Electronic board wiring diagram is showed on Fig 25 Refer to detail X in Fig 25 if there is no need for room ...

Page 51: ...51 4 4 1 ELECTRONIC BOARD WIRING DIAGRAM HARMONY_D USERS INSTALLATION AND SERVICE MANUAL 4 4 1 ELECTRONIC BOARD WIRING DIAGRAM Figure 24 Main Board Diagram ...

Page 52: ...rsion process and use To adapt the boiler so as to work with a different gas within the above gas types 1 Check type of the gas to be used The conversion is only allowed to the above explained gases 2 Remove the burner see Servicing section to replace the injectors on the burner manifold Use a suitable socket driver to unscrew the injectors from the burner manifold Select the correct injector size...

Page 53: ...FF independently from LED strip configuration value Parameter P01 It controls the outlet gas pressure of gas valve during ignition period Default setting of P01 ignition capacity is 16 Parameter P02 This parameter is used to identify the type of gas that is used The default value of this parameter is adjusted for natural gas 00 Parameter P03 It is used to identify the burner switch ON delay in CH ...

Page 54: ...set point If parameter 6 is OFF burner is switched ON and OFF according to a fixed set point Parameter P07 If P07 is selected to be 00 the LED illumination is al ways ON If this parameter is 01 than the LED lights will be ON when there is flame and if this parameter is 02 LED is always off 5 1 Programming operating parameters 5 1 1 Parameter menu activation In order to enter parameter menu activat...

Page 55: ...oving DHW knob the desired value can be chosen SET word appears on LCD screen If RESET switch is pressed for a time greater than 5 sec the modification is memorized and the system returns to PARAMETER SELECTION MODE with the following parameter already selected By moving the CH knob it is possible to exit PARAMETER MODE After 2 minutes without performing anything through DHW knob an automatic exit...

Page 56: ...255 seconds period as percentage by using Table 6 4 Maximum Heat Capacity It controls the heat capacity by controlling the gas flow passing through the gas valve Default setting is 100 It can be adjusted between 0 100 5 Central Heating Range The boiler can work in two different modes using this parameter There are two choices ON and OFF Default setting is OFF 30 85 C The mode ON 30 50 C is recomme...

Page 57: ...k to normal working condi tion 5 2 OPERATING ERRORS When a problem occurs with operation the boiler exhibits this fault via LCD display The diagnosed fault encoding is shown in Table 7 HARMONY_D USERS INSTALLATION AND SERVICE MANUAL 5 2 OPERATING ERRORS When a problem occurs with operation the boiler exhibits this fault via LCD display The diagnosed fault encoding is shown in Table 7 Table 7 Fault...

Page 58: ...it for the system water to cool down before another try The flow pump control rema ins active depending on the type of demand in progress to execute any specified pump overrun functions 45 seconds for CH with room thermostat and 18 seconds for DHW demand Several unsuccessful trials may mean a service call is required Consult your authorized service dealer If H2O pressure switch cut in fault arises...

Page 59: ...ompetent person To ensure the continued efficient and safe operation of the appliance it is recommended that it is checked and serviced at regular intervals by the authorized service The frequency of servicing will depend upon the particular installation and usage but in general once a year is sufficient All service work must be carried out only by authorized service person nel The manufacturer wi...

Page 60: ...ith Wireless RF or cable remote control you can set your boiler to run at desired time intervals and temperatures during the week you can see all the operating modes temperatures and error codes of combi boiler on remote control display if an outside sensor is con nected you can also see outside temperature on remote control disp lay With outside sensor combi boiler can modulate whether depen dent...

Page 61: ...e LPG bottles water tempe rature should not exceed 22 C Do not place the boiler and the LPG bottles in the same cabinet Use certified bottles only Do not shake or lay the bottles Only use a certified 30 mbar regulator at every bottle exits If the bottles are to be placed in closed area provide adequate venting of the area If you smell gas turn the bottles off and follow the instructions in Gas Saf...

Page 62: ...ck the heating system and boiler for water soundness 10 Lower the pressure to the initial cold fill design pressure of 1 0 1 2 bars are attained 11 Open the front casing and undo the screw on frontal face of the pump to access the pump shaft 12 Check that the pump is not blocked by rotating the shaft with a screw driver the shaft can be forced an amount to rotate to get rid of pos sible adhesion d...

Page 63: ...U manometer connected to the gas valve will be adjusted as described below In order to calculate the heat output of the appliance for a certain pressure level multiply the corresponding input rate value by the efficiency To convert the unit kW to kcal h multiply the value by 860 ATTENTION Maximum heat inputs should not exceed the given limits HARMONY_D USERS INSTALLATION AND SERVICE MANUAL Figure ...

Page 64: ...NSTALLATION AND SERVICE MANUAL Figure 26 Gas Modulator 7 4 Maximum and Minimum DHW CH Input Adjustments mechanical maximum and minimum Loosen the screw of gas valve outlet pressure test point 1 and connect a U manometer to it Take apart the modulation cables from modulation terminals 5 Remove yellow cap 2 to expose pressure regulator adjustment screws 3 4 Turn the red pressure regulator adjustment...

Page 65: ...upply pressures do not ex ceed 29 mbar for G30 butane and 37 mbar for G31 propane set the maximum pressure regulator adjustment screw to its maximum position then set the minimum pressure regulator adjustment screw as above ATTENTION To disable unauthorized persons interference the yellow cap on the gas valve should be painted with a red paint to seal it 7 5 Final Operational Checks After the gas ...

Page 66: ...perty containing a gas appliance 5 It is the law that all servicing is carried out by a competent person 6 Advise the user of the precautions necessary to prevent damage to the system and building in the event of the heating system being out of use during frost and freezing conditions 7 Leave these instructions with the user 8 SERVICING NOTE Any service work must be carried out by a competent pers...

Page 67: ...r and the 2 at the front Pull the burner forward clear of the combustion chamber Check that the combustion chamber insulation panels are not worn out replace if needed Clean the burner blades with a soft brush Check that the injectors are free from dirt and debris If necessary clean each injector orifice using a soft brush or vacuum cleaner Do not use a wire brush or any abrasive material It is no...

Page 68: ...t connection The pipe coming from outside air should be plugged to the switch P1 inlet the pipe coming from fan should be plugged to the switch P2 inlet Remove the screw on the frontal face of the pump to access the pump shaft and rotate the shaft with a screwdriver to check for any blockage Clean any dirt and replace the screw Replace the combustion room front panel in hermetic models hermetic ro...

Page 69: ...ny blockage Clean any dirt and replace the screw Replace the combustion room front panel in hermetic models her metic room front panel and front casing panel in reverse order Do not forget to screw the two front panel retaining catches at the top RH and LH sides of the boiler Check the operation of the pressure relief valve as described in Commissioning section Check that the system is at the orig...

Page 70: ...70 HARMONY_D USERS INSTALLATION AND SERVICE MANUAL 55 Appendix A FAULT DETERMINATION ...

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