1
HARMONY – D
USERS, INSTALLATION
AND SERVICING
INSTRUCTIONS
2
Code No: A.1.2.8i
Revision Date: 200114
Publishing Date:200114
3
Thank you for choosing ALARKO brand.
This booklet covers room sealed model HARMONY-D natural gas/LPG
combination boilers in ALARKO-CARRIER boiler range.
In this booklet you will find the instructions for use in USE section and
instructions for installation and maintenance in INSTALLATION AND
MAINTENANCE section.
For long-term and safe use of the boiler, 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 MAINTENANCE section of this booklet to ensure the correct installation and
operation of the appliance.
For further information, please consult to the product introduction brochure or authorized dealers and services.
Keep this booklet on hand to consult to whenever you may need.
4
TABLE CONTENTS
USER INSTRUCTIONS8
1. Introduction8
DECLERATION OF CONFORMITY AND CERTIFICATION
9
TERMS AND CONDITIONS OF GUARANTEE AND SERVICE
9
Guarantee is not valid under below conditions.
9
1.1 Gas Safety10
1.2 Course of Action in case of Gas Leakage
10
1.3 Contents of Packaging12
2. Product Description13
2.1 Technical Data15
2.2 Dimensions16
2.3 Internal Parts of the Boiler
17
2.4 Water Circuit18
2.5 Control Panel19
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 Display21
2.5.5. Reset Button21
3. BOILER OPERATION22
3.1 Start-Up / Pre-Checks22
3.2 Water Filling22
3.3 Domestic Hot Water Operation
23
3.4 Central Heating Operation23
In Summer:
3.5 Turning the boiler OFF24
3.6 Central Heating System Discharge
24
3.7. Topping-up the system with water
24
INSTALLATION AND SERVICING24
4. INTRODUCTION25
4.1 INSTALLATION RULES25
4.1.1
GENERAL25
..
5
4.1.2 BOILER LOCATION26
4.1.3 AIR SUPPLY27
4.1.4 OPENING THE PACKAGE & TRANSPORT
28
4.1.5 MOUNTING THE BOILER29
4.1.6 Water and Gas Connections to the Boiler:
29
4.2 FLUE SYSTEM AND INSTALLATION
30
4.2.1 Sitting the Flue Terminal30
4.2.2 Parts of Harmony_D RSF Flue System
33
4.2.3 Standard Supply (concentric horizontal)
34
4.2.4 Additional Kits34
4.2.5 Installing the Standard Supply
37
4.2.6 Installing the Flue System with Straight Extension Kit:
38
4.2.7 Installing Flue System with 90° Turning Kit
41
4.2.8 Installing Flue System with Elevation Kit
42
IMPORTANT NOTES ON FLUE SYSTEMS
44
4.3 COMPONENTS & SYSTEM44
4.3.1 Filling the system45
4.3.2 DOMESTIC HOT WATER46
4.3.2.1 Showers, Bidets, Taps and Mixing Valves
48
4.3.2.2 Water Quality48
4.3.2.3 Water Pressure48
4.4 ELECTRICAL49
4.4.1 ELECTRONIC BOARD WIRING DIAGRAM
51
4.5 CONVERSION TO DIFFERENT GASES
52
5. OPERATING PARAMETERS53
5.1 Programming operating parameters
54
5.1.1 Parameter menu activation54
5.1.2 Parameter selection mode55
5.1.3 Parameter changing mode55
5.1.4 PARAMETERS’ ADJUSTMENT56
5.1.4.1 Parameters Menu Activation56
5.1.4.2 Parameter Selection57
5.1.4.3 Parameter Modification
57
6
5.2 OPERATING ERRORS57
5.2.1 Some Typical Problems58
5.3 PERIODIC MAINTENANCE59
Automatic Control Devices60
6. Use with LPG61
7. COMMISSIONING61
7.1 Pre Checks61
7.2 Start up62
7.3 Setting The Heat Input63
7.4 Maximum and Minimum DHW/CH Input Adjustments
(mechanical maximum and minimum)
64
7.5 Final Operational Checks
65
7.6 Commissioning – Heating System
65
7.7 INSTRUCTIONS TO THE USER
66
8. SERVICING66
Appendix A70
FAULT FINDING70
TABLES
Table 1 Technical Data15
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 the Parameters
53
Table 6 Parameter Adjustment55
Table 7 Fault Display57
7
FIGURES
Figure 1 Boiler Dimensions16
Figure 2a-b Main Parts of the Boiler/ Front-Backside View
17
Figure 3 Water Circuit Diagram
18
Figure 4 Control Panel Appearance19
Figure 5 DHW Knob19
Figure 6 CH Knob20
Figure 7 Manometer20
Figure 8 LCD Display Screen
21
Figure 9 Hydraulic Group- Manual filling tab
24
Figure 10 Transport & Packaging28
Figure 11 Mounting Schematic with essential dimensions.
29
Figure 12 Gas & Water Connections
30
Figure 13 Flue Terminal Dimensions32
Figure 14 The Parts of the Flue Kit
33
Figure 15 Wall Connections36
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
45
Figure 23 Volumetric Flow Rate & Pressure Difference
Relation for the Circulation Pump
46
Figure 24 Main Board Diagram
51
Figure 25 Burner Pressure/ Heat Input Diagram
63
Figure 26 Gas Modulator64
Figure 27 Burner Plates, Igniters and Flame Sensors
68
8
USER INSTRUCTIONS
1. Introduction
In this booklet you will find users and servicing instructions of your new
Harmony – D digital screen combination boiler and some useful information and technical data about it. Harmony combination boilers are
the results of development, production and marketing experience, which
have resulted in the current highly efficient and user-friendly models.
The compact size and pleasing appearance enable them to be fitted in
a wide range of locations. Despite its compactness, all inner pipe-work
and components are designed to allow easy access for the service engineer.
The appliance is suitable 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 questions.
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 rules and warnings.
In addition to the users instructions in this booklet, there are also technical data and introductory information about the boiler.
Read the instructions and other labels carefully, before starting the
boiler.
Take into consideration all the warnings.
Do not handle the parts of the boiler in a different way than specified in the instructions.
9
DECLERATION OF CONFORMITY AND CERTIFICATION
Alarko Carrier manufacture boilers referred to in this booklet are produced in conformity with below: EC Directives and can hold the CE mark.
2009/142/EC Gas Appliances Directive
92/42/EEC Efficiency Directive
2004/108/EC Electromagnetic Compatibility Directive
2006/95/EC Low Voltage Directive
The appliances are certified to comply with the requirements of EN 297,
EN 483 and EN 625 using the gas categories listed below:
2H and 2E; G20 gas with a governed gas supply at 20 mbar inlet pressure
3 B/P; any mixture of G30 and G31 gases with a governed gas supply
at 29-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.
• Installation by unauthorized persons.
• Hazards due to service by unauthorized persons.
• Hazards due to natural disaster.
• Hazards due to bad weather conditions, especially frost, unless instructions in this booklet are obeyed.
•
Damaged or changed serial number of boiler.
•
Incorrect installation, use and maintenance with respect to the instructions and the regulations in force.
•
Boilers produced for display and exhibition purposes.
10
•
Absence of Guarantee Form.
•
The transportation risks belong to the customer if boiler is sent to
service by customer and belongs to the service if boiler is taken
by service.
1.1 Gas Safety
It is the law that all gas appliances must be installed by a competent
person in accordance with the current rules and regulations in force
in the country of destination. With the same scope, any gas conversion process carried out on the boiler must be done by a competent
person as well.
These appliances are certified to comply with the requirements of EN
483 and EN 625 using gas categories 2H, 2E, 3B/P, 3+, 3B and 3P
with prescribed gas inlet pressures. No other gas use condition is allowed 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 competent 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 alarm device signals;
•
Be calm,
•
Turn off the appliance,
•
Open all the doors and windows to vent the room,
•
Extinguish any flame,
•
Close gas valves of any appliance and at the apartment inlet,
•
Do not light anything and do not smoke,
•
Do not switch on or off and electrical device,
•
Do not attach or pull out electric plugs, do not ring the bell,
•
Do not use the telephone where the gas smell exists,
•
Contact your gas supplier and fire brigade and explain the situation.
11
Warnings!
This appliance must only be used for the intended purpose of manufacture.
Alarko Carrier Sanayi ve Ticaret A.Ş. does not take any responsibility for
the damage or injury on persons, animals or objects caused by incorrect
installation, service or maintenance, use except for the intended purpose or disobeying any of the warnings within this booklet.
Spaces allowed for installing a gas-fired boiler are defined by international and/or local regulations and rules of gas distribution companies.
You can supply detailed information about those limitations from your
installer. For your own safety, do not ask the installer to install your boiler
to prohibited spaces.
Before gas installation, a suitable gas installation project has to be prepared and approved according to the requirements of local gas distribution 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.
Keep flammable and combustible objects, either liquid or solid, away
from the boiler.
Do not place cooker near the appliance and protect the boiler from direct
vapor.
Do not use any spray, chemical solvent, chlorinated cleaner, paint or
adhesive near the boiler.
The boiler is to be connected to an earthed 230 V 50 Hz electric supply.
To enable the frost protection function in winter when the weather temperature might fall below 0°C, do not turn the boiler off.
Filter must be installed at the water inlet of the boiler to protect the pump
and the filter must be cleaned periodically. The pump shaft should be
12
rotated manually before starting the boiler after a long time of inactivity.
Apply the authorized service to take more information about this process.
If you charge the central heating system with hard water, this may cause
blockage of the heat exchanger.
Mains supply water should not exceed 15° French hardness value. To
prevent any corrosion, pH value of the water should be between 8,2
- 9,5, conductivity should be less than 30 μS/cm, and oxygen content
should be less than 0,1 gr/m³.
Hot water circuit does not need a pressure relief valve. On the other
hand, pressure should not exceed 6 bars. In case of doubt, a pressure
regulator should be fitted. Consult your installer on this issue.
1.3 Contents 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 consumption.
For further saving below are recommended:
• Your boiler is adjusted to 20.726 kcal/hour of output capacity. Down
rating of the heating capacity will save in houses where heating requirement is less. Consult the authorized service for adjustment.
• Use of thermostatic radiator valves or flow balance of radiators
brings additional saving due to homogenous heat distribution over
the house.
• Setting the temperature control knobs between the positions 4 and
6 reduces fuel consumption. On the other hand, they can be set to
13
other positions due to various heating and hot water requirements
with no inconvenience.
• Lower setting of DHW temperature reduces fuel consumption.
2. Product Description
Harmony-D is a room sealed mono-thermal exchanger combination
boiler with 24.1 kW nominal output to provide both central heating and
domestic hot water.
Despite the complexity of the system, all inner pipe work and components are designed to allow easy access for the service engineer.
Ignition of the burner is provided automatically by the electronic ignition
system.
The latest design of main integrated electronic board controls all safety
and operational functions automatically.
A diagnostic section monitors boiler operation mode and indicates faults
to the user by a Carrier© blue 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 there is no heat demand during 24 hours, pump is activated by the
control board for 30 seconds to prevent the pump from getting jammed
due to inactivity.
User controls are on a modern, aesthetic, and functional control panel
on the boiler front. The controls allow the user to set the central heating
temperature to between 30°C and 80°C and the DHW temperature to
between 35°C and 60°C.
Boiler has got those features:
• Continuous full modulation for both domestic hot water and central
heating,
• Three ignition attempts, (one ignition attempt for operating with
LPG)
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• High temperature limit thermostat safety,
• Temperature control with domestic hot water and central heating
sensors, sensor fault warnings,
• Flame detection,
• Heating and domestic 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.
HARMONY_D USERS INSTALLATION AND SERVICE MANUAL
15
2.1 Technical
DataData
2.1 Technical
TableTable
1 Technical
Data
1 Technical
Data
Product Model
HRD
Flue System/Type
Hermetic/C12 (x)
Gas Class
II2H3B / P
Reference Gas
G20
Maximum Heat Power (Net)
kW
24.1
kcal/hour
20726
Efficiency at 100 % Load
%
93.8
Maximum heat load (Net)
kW
25.7
Minimum heat power
kW
10.11
Minimum heat load (Net)
kW
11.8
Maximum gas inlet pressure
mbar
20
Burner pressure for maximum load
mbar
11.5
Burner pressure for minimum load
mbar
1.7
Injector Diameter
mm
1.35-0.80
Ignition System
Electronic
NOx Class
3
CENTRAL HEATING SYSTEM 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
Overall Dimensions
(Width, Height, Depth)
Weight – Net / Gross (except flue set)
mm.
100 (suction) / 60 (discharge)
mm.
400, 700.5, 340
kg.
30.6 / 33.5
Heating – Supply / Return Connections
in.
3/4"
DHW – Input / Output Connections
in.
1/2"
Gas Connection ( via Kit )
in.
3/4" (1/2")
Safety Valve Connection
in.
1/2"
ELECTRICAL DATA
Electrical Connection
V/Hz
Internal Fuse Rating
A
4
Power Consumption
W
110
Electrical safety class
2.2 Dimensions
230/50
IP X3D
16
HARMONY_D USERS INSTALLATION AND SERVICE MANUAL
2.2 Dimensions
Figure 1 Boiler Dimensions
2.3 Internal Parts of the Boiler
17
HARMONY_D USERS INSTALLATION AND SERVICE MANUAL
2.3 Internal Parts of the Boiler
The main parts of the boiler and water circuit are shown in Figures 2a and 2b (Front view,
The view)
mainand
parts
of 3.
the boiler and water circuit are shown in Figures 2a
backside
Figure
and 2b (Front view, backside view) and Figure 3.
Figure 2a-b Main Parts of the Boiler/ Front-Backside View
18
2.4 Water
Circuit
HARMONY_D
USERS
INSTALLATION AND SERVICE MANUAL
2.4 Water Circuit
Figure 3 Water Circuit Diagram
19
2.5 Control Panel
The control panel is specially designed considering both easy setting of
the boiler with only two knobs and a reset button on it and an aesthetic
outside appearance with a surrounding blue LED lightening along the
panel border. This lightening feature is arranged to be ON by default,
while there is flame in the boiler. This property can also be rearranged
according to customers liking so that the LED light can be ON or OFF
continuously all the time.
Warning!:
If LCD light is ON, LED light will
be OFF. They do not give light simultaneously. During setting up of
the DHW or CH temperatures with
control panel knobs, LCD panel
will automatically starts emitting
Figure 4 Control Panel Appearance
light and LEDs will be OFF. LED
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.
2.5.1 ON/OFF and Domestic Hot Water Control Knob
This feature allows the user to ON / OFF the boiler and set the desired
temperature for the domestic hot water. When the blue pin on DHW knob
indicates the gap under the temperature legend ‘1’, boiler is OFF and not
only the central heating mode but also the domestic hot water mode is
OFF position.
When the indicator knob position passes over the legend ‘1’,
domestic hot water mode is ON.
From number 1 to 7 domestic hot
water temperature can be adjusted. Turning clockwise increases
the set temperature.
Figure 5 DHW Knob
20
2.5.2. Central Heating Control Knob
This feature allows user to set the desired temperature for the central
heating system water. When central heating knob indicates the region
under the legend ‘1’, central heating mode is ‘OFF’. When it passes
over the position of legend ‘1’, central heating turns to mode ‘ON’. (Note
that domestic hot water knob should not be in ‘OFF’ position to ‘ON’ the
central heating mode.) From number 1 to 7 central heating water temperature can be adjusted. Turning
clockwise increases the set temperature.
When the indicator knob position
passes over the legend ‘1’, domestic hot water mode is ON. From
number 1 to 7 domestic hot water temperature can be adjusted.
Turning clockwise increases the
set temperature.
Figure 6 CH Knob
2.5.3. Pressure Gauge (Manometer)
The pressure gauge on the control
fascia panel indicates the central
heating system pressure. The normal running pressure is around 1
bar (cold) indicated by the solid
Figure 7 Manometer
green line.
1) Lower red region: Indicates that water pressure is not sufficient. Boiler doesn’t work in that region. It should be pressurized (filled) via
water supply into the system.
2) Lower green region: When the boiler isn’t working, water pressure
should be in that region.
3) Upper green region: Indicates the maximum pressure level while the
boiler is working.
4) Upper red region: Indicates that water pressure is over the required
level. Water should be removed from the system until the manometer
shows the lower green region. If the manometer shows the upper
solid red line, 3-bar safety valve removes the water from the system
automatically.
21
2.5.4. LCD Display
LCD Display shows boiler operating mode, temperature and indicates
the faults instantly as they arise. Digital numbers can be monitored on
the blue background screen during setting the CH and DHW heating
temperatures or parameters of the boiler.
When the boiler is OFF, power of the screen is cut off.
When there is CH demand, “
”
sign appears on the screen and
temperature of central heating water on heat exchanger exit can be
read as Celsius degrees.
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.
Figure 8 LCD Display Screen
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 the user interference.
1) Failure of three consecutive firing attempts.
2) Exceed the high temperature limit.
In those conditions the user should control if there is an operating error that requires resetting of the boiler. Following this, the boiler can be
started by switching the reset button (
).
22
3. BOILER OPERATION
3.1 Start-Up / Pre-Checks
• Check if the electricity, gas valves and water valves are open.
• Open the radiator valves.
• Check if there is mains water supply. If mains water supply is OFF,
heating system water might flow to the mains water installation, emptying the radiators.
3.2 Water Filling
WARNING! Do not charge water while the boiler is running. Wait for the
boiler to cool down before filling water.
• If the pressure gauge shows below the lower green zone, water must
be charged to the boiler and the heating system. To do this;
Turn the water-filling tap at the boiler bottom slowly to open.
WARNING! If you fill the system very rapidly, air may collect in the heating 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 filling 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 the highest point of
installation, if any. Wait until water drains continuously before closing
the air release taps.
• Check “insufficient system pressure” code and pressure gauge again.
If the code appears, charge water to the system again.
WARNING! If there is noise in the boiler or installation, repeat air-releasing process.
WARNING! It is recommended that the boiler be turned OFF during air
releasing process.
• Check the heating system pressure regularly.
23
3.3 Domestic Hot Water Operation
• Turn the DHW control knob to ON ( ) position. Sign “ ” will
appear and number on the screen will indicate set temperature of
sanitary water.
• When there is a call for hot water as a hot water tap is opened; the
boiler senses the flow to the taps and, if it is in stand-by, automatically
starts the ignition sequence.
“
” sign will appear on the screen.
• The 3WV valve shuts down the heating system and the full boiler
power becomes available to meet the hot water demand.
• The domestic hot water sensor controls the heat input to maintain
the hot water at the temperature level selected by the user via the
domestic hot water control knob.
• A temperature range between 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 automatic ignition sequence. Set the heating temperature control to the
desired level. A temperature adjustment is possible between 30°C
and 80°C.
The boiler control algorithm will now maintain the set temperature,
modulating the heat input to match the heating load. When the desired water temperature is reached and read by the sensor, the boiler
will shut down. The system pump will continue to run to dissipate the
heat from the boiler.
In Summer:
When there is no call for heating but only for hot water, e.g., in summer,
turn the CH control knob to the OFF position, but leave the DHW control
knob in the ON (
) position.
24
3.5 Turning the boiler OFF
• Turn both the CH control knob and the DHW control knob to the OFF
position.
• Turn the gas and electricity supplies to the boiler OFF.
• If the boiler is switched OFF when there is a likelihood of frost; water
in the boiler should be drained off by opening the house central heating drain tap.
3.6 Central Heating System Discharge
Do the following in case of a discharge of the central heating system
water;
• Turn on the drain tap at the bottom of the central heating system.
• Open the air release taps of radiators. Begin from top radiator to bottom one.
• Close the air release taps after draining the water.
ATTENTION! It is not recommended to discharge 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 enabled.
3.7. Topping-up the system with water
The water pressure in the central heating circuit must be checked in
case of a DHW request error notification. The pressure gauge located
in front of the pump, should be within the green region and must not be
less than 1 bar.
If there is insufficient water in the
boiler, the error code F0 (Table 7)
will appear on the display indicating that there is not enough water
in the system.
Figure 9 Hydraulic Group- Manual filling tab
25
To bring the system back up to pressure, open the manual filling tap
(Fig.9) and check the system pressure until it reaches to 1 bar.
Close the filling tab, when the operation is complete.
INSTALLATION AND SERVICING
4. INTRODUCTION
Please read these instructions carefully to ensure the correct installation
and operation of the appliance.
These instructions cover the room sealed HARMONY-D model in the
ALARKO-CARRIER boiler range.
This Installation and Servicing Manual contains information on installation, commissioning, servicing procedures, description of main parts,
wiring diagrams and electrical connections, adjustments and fault finding. A detailed fault finding section is included towards the end of the
manual.
Before commencing the installation of the boiler check the labels and
data plate on the boiler to ensure that the appliance is compatible with
the local gas and electricity supply conditions. In the case of any uncertainty, contact 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 accordance with the regulations and rules in force in the countries of destination.
2) Failure to install appliances correctly could lead to prosecution.
3) These appliances must be installed in accordance with relevant National and local rules and regulations in force. The manufacturer’s
notes must not be taken, in any way, as overriding statutory obligations.
4) To ensure that the installation will perform to the highest standards,
the system and components should also conform to any relevant
National and/or local standards in addition to those mentioned in the
instructions.
26
5) The advice and instructions given in this document covers, as far
as possible, the foreseeable situations, which may arise. Contact
manufacturer for further advice if required.
6) Installation using the standard flue kit is described in the main text of
.2 BOILERthese
LOCATION
instructions. NO OTHER FLUE KITS OR EXTENSIONS MAY
BE USED
WITH
THIS APPLIANCE
This appliance
may be
installed
in any room provided that attention is drawn to
requirements
of theappliances
relevant national
andwith
local
rules, SYSTEMS
standards ONLY.
and regulations in force
7) These
are for use
SEALED
the countries of destination. Where it is installed in a room containing a bath or show
4.1.2 switch
BOILER
any electrical
orLOCATION
appliance control using mains electricity must not be able to
touched by
a
person
using
or shower.
1) This appliance the
maybath
be installed
in any room provided that attention
is is
drawn
to the requirements
of installation.
the relevant national and local rules,
The appliance
not suitable
for external
standards and regulations in force in the countries of destination.
The appliance
does itnot
require in
any
special
wall protection.
Where
is installed
a room
containing
a bath or shower, any elec-
trical switch or appliance control using mains electricity must not be
The wall must
be capable of supporting the weight of the appliance. (See Table 1.)
able to be touched by a person using the bath or shower.
Always consider
the possible
need tofordisconnect
the pipes from the appliance a
2) The appliance
is not suitable
external installation.
installation.
3) The appliance does not require any special wall protection.
The following
clearances
must
be available
for installation
and for servicing
4) The
wall must on
be Table
capable2 of
supporting
the weight
of the appliance.
(See Table 1.)
5) Always consider the possible need to disconnect the pipes from the
appliance after installation.
6) The following clearances on Table 2 must be available for installation and for servicing.
Table 2 Clearances for boiler installation
Clearances
Above the casing
Below
Right hand side
Left hand side
200 mm
100 mm
30 mm
30 mm
7) If the boiler is to be installed in a timber framed building it
should be fitted in accordance with the relevant National and
boiler is to
be rules
installed
in a timberinframed
it should be fitted
local
and regulations
force, if building
any.
If the
with the relevant National and local rules and regulations in force, if any.
in accorda
No combustible surface must be within 75 mm of the casing. If there is need to adjust n
a combustible surface, follow the clearances on Table 2.
The appliance can be installed in a cupboard used for airing clothes provided that
27
HARMONY_D USERS INSTALLATION AND SERVICE MANUAL
8) No combustible surface must be within 75 mm of the casing. If there
is need to adjust near a combustible surface, follow the clearances
10) The airing space
must
on Table
2. be separated from the boiler space by a perforated non-combustible
partition. Expanded metal or rigid wire meshes are acceptable provided that the major
9) is
The
appliance
can be installed in a cupboard used for airing clothes
dimension
less
than 13 mm.
provided that the requirements of relevant National and local rules
11) Not withstanding
those rules
and regulations,
room sealed appliance may be fitted in a
and regulations
(if any)
are maintained.
compartment with no vents as long as the minimum clearances stated in Air Supply, are
10)The airing space must be separated from the boiler space by a
maintained.
perforated non-combustible partition. Expanded metal or rigid wire
meshes are acceptable provided that the major dimension is less
than 13 mm.
11)Not withstanding those rules and regulations, room sealed appliance may be fitted in a compartment with no vents as long as the
minimum clearances stated in Air Supply, are maintained.
AIR SUPPLY
4.1.3 AIR4.1.3
SUPPLY
The appliance
not require
separate
for combustion
The does
appliance
does anot
requirevent
a separate
vent forair.
combustion air.
The appliance
can be
in a cupboard
no for
vents
for cooling
butminimum
The appliance
can be fitted
in fitted
a cupboard
with nowith
vents
cooling
but the
the
minimum
clearances
must
be
increased
to
those
given
below.
(Note:
clearances must be increased to those given below. (Note: the clearances at the front are for a
clearances
at the front are for a removable panel, e.g. a door).
removablethe
panel,
e.g. a door).
Table 3 Minimum clearances for cupboard installation.
Above the flue turret
In front
Below
Right-hand side
Left-hand side
150 mm
250 mm
200 mm
75 mm
75 mm
If the appliance is to be fitted in a cupboard or compartment with less
clearance
those
the table or
above
(minimumwith
clearances
are given
If the appliance
is to than
be fitted
in in
a cupboard
compartment
less clearance
than those in
in
the
“Boiler
Location”
section)
then
permanent
air
vents
for
cooling
the table above (minimum clearances are given in the “Boiler Location”
section) then
located
at high and
levels,
vents
permanentare
air required.
vents for Both
cooling
are required.
Bothlow
located
at all
high
and connecting
low levels, all vents
directly
to
outside
air
or
to
a
room.
Both
vents
must
pass
thesame
same
connecting directly to outside air or to a room. Both vents must pass totothe
room or be
room
or
be
on
the
same
wall
to
the
outside
air.
on the same wall to the outside air.
The minimum free areas required are given in Table 4:
Table 4 Minimum ventilation areas for cupboards without sufficient clearance.
Position of air vents
High level
Air from another room
260 cm²
Air direct from outside
130 cm²
If the appliance is to be fitted in a cupboard or compartment with less clearance than those in
the table above (minimum clearances are given in the “Boiler Location” section) then
permanent air vents for cooling are required. Both located at high and low levels, all vents
connecting28directly to outside air or to a room. Both vents must pass to the same room or be
on the same wall to the outside air.
The minimum
free areasfree
required
given inare
Table
4: in Table 4:
The minimum
areasare
required
given
Table 4 Minimum ventilation areas for cupboards without sufficient clearance.
Position of air vents
High level
Low level
Air from another room
260 cm²
260 cm²
Air direct from outside
130 cm²
130 cm²
4.1.4 OPENING THE PACKAGE & TRANSPORT
HARMONY_D USERS INSTALLATION AND SERVICE MANUAL
Refer to the following diagrams. See Fig. 10.
TRANSPORT AND PACKAGING
The boiler is packaged in a cardboard box. Warning signs are to be observed during transport and storing.
MAX.
4
Do not step on the box.
When the boxes are placed on
the floor,arrows should point
upwards.
Maximum four boxes can be
placed on top of each other.
Do not drop the box.
Do not let the box get soaked.
19
- The boiler can be carried by two people by uplifting it through the two holes on both sides.
- The boiler should be stored in a place free of dust and moisture and should
not be taken out of its package until it is to be installed.
- When stored,maximum four boxes can be placed on top of each other.
- Boilers can be installed following the completion of water and electric systems.
OPENING THE PACKAGE
1
2
Put the box on the floor with
the symbol "
" on top.
3
Cut the bands to open the box.
4
Open the nylon wrapping and
take the upper moulded
packaging out from the box.
Take the boiler out by holding from
two sides on both ends.
DO NOT TRY TO LIFT FROM THE MIDDLE!
Figure 10 Transport & Packaging
29
4.1.5 MOUNTING THE BOILER
Determine the right position for the wall-hang boiler with respect to the
required clearances for servicing, general access and position of the
flue. Fix the mounting bracket to the wall, with the fixings provided, enHARMONY_D USERS INSTALLATION AND SERVICE MANUAL
suring that it is horizontal. Hang the boiler on the mounting bracket and
fix the boiler to the wall from the bottom. (See Fig. 11)
Figure 11 Mounting Schematic with essential dimensions.
4.1.6
Water
and and
Gas Connections
to the Boiler:
4.1.6
Water
Gas Connections
to the Boiler:
CH
water
connections
should
be¾’’,
made
viaDHW
¾’’, connections
gas and DHW
connecCH
water
connections
should be
made via
gas and
should be
made via
tions
should
be(see
made
via For
½’’ copper
isolation
valves ¾”
(see
12). For correspond
copper
½’’
isolation
valves
Fig. 12).
installations
and Fig.
½” dimensions
toinstallations
Ø 22 and Ø 15
Take care
that the seals
¾”mm
andrespectively.
½” dimensions
correspond
to Øprovided
22 andare
Ø correctly
15 mm fitted
rebetween
the installationcare
kit fittings
and seals
the connection
tails.are correctly fitted between
spectively. Take
that the
provided
Purge
the gas supplykit
before
finally
connecting
the appliance.
The complete installation must
the installation
fittings
and
the connection
tails.
be tested for gas soundness.
Purge the gas supply before finally connecting the appliance. The com-
Thoroughly flush the heating system and the cold water mains supply in accordance with the
plete installation
forensure
gas soundness.
recommended
methods.must
Afterbe
thistested
operation,
that the water filters at the water inlet are
cleaned
before finally
the boiler
to the and
waterthe
installation.
Thoroughly
flushconnection
the heating
system
cold water mains supply
Check
that no dirt is left
the gas or water pipe
work as thisAfter
could this
cause operation,
damage to the
in accordance
within either
the recommended
methods.
appliance.
30
ensure that the water filters at the water inlet are cleaned before finally
connection the boiler to the water installation.
Check that no dirt is left in either the gas or water pipe work as this could
cause damage to the appliance.
HARMONY_D USERS INSTALLATION AND SERVICE MANUAL
Figure 12 Gas & Water Connections
4.2FLUE
FLUE
SYSTEM
AND INSTALLATION
4.2
SYSTEM
AND INSTALLATION
4.2.1 Sitting the Flue Terminal
4.2.1 Sitting the Flue Terminal
The flue must be installed according to national and local regulations
The flue must be installed according to national and local regulations (See Fig. 13).
(See Fig. 13).
The terminal must not cause an obstruction or the discharge cause a nuisance.
The terminal must not cause an obstruction or the discharge cause a
If the terminal is fitted within 1000 mm of a plastic or painted gutter or within 500 mm of
nuisance.
painted
eaves, then an aluminum shield at least 1000 mm long should be fitted to the
underside of the gutter or painted surface.
If the terminal is fitted within 1000 mm of a plastic or painted gutter or
The terminal should be fitted less than 2 meters above a surface to which people have access.
In certain weather conditions a terminal may steam and sitting where this could cause a
nuisance should be avoided.
Take care to ensure that combustion products do not enter ventilated roof voids.
31
within 500 mm of painted eaves, then an aluminum shield at least 1000
mm long should be fitted to the underside of the gutter or painted surface.
The terminal should be fitted less than 2 meters above a surface to
which people have access.
In certain weather conditions a terminal may steam and sitting where
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 fitted.
ATTENTION! Flue terminal must be fitted with 3% downward inclination
to prevent rain leaking in to the boiler.
regardless of the wall thickness providing that a suitable wall liner is fitted.
ATTENTION! Flue terminal must be fitted with 3% downward inclination to prevent rain
leaking in to32
the boiler.
C
A
M
B,C
B,C
F
M
G
F
A
E
K
L
K
A
K
F
M
G
G
L
G
Q
430 mm
MIN.
J
H,I
D,N
F
P
R
O
K
O
G
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
Distance to an openable window,air vent or any other ventllation opening from below
Distance to roof gutter or drainage and soil pipes from below
Distance to eaves from below
Distance to balconies from below
Horizontal distance to vertical drainage and soil pipes
Distance to inner and outer corners of walls
Distance to adjacent ground or balcony level from above
Distance from a surface 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 another terminal on the same horizontal axis
Distance to an adjacent opening such as a door or window on the same horizontal axis
Distance to lean -to roof from below
From adjacent wall
From adjacent opening window
From another terminal
Minimum height
300
75
200
200
150
300
300
600
1200
1200
1500
300
300
600
300
1000
600
300
All dimensions are in mm.
Figure 13 Flue Terminal Dimensions
See figure 14 to identify the parts of the flue kit. Flue kit item numbers in this
See figurefigure
14 to are
identify
parts
of the installation
flue kit. Flue
kit item numbers in this figure are used
used the
in the
following
guides.
in the following installation guides.
33
HARMONY_D USERS INSTALLATION AND SERVICE MANUAL
4.2.2 Parts of Harmony_D RSF Flue System
4.2.2 Parts of Harmony_D RSF Flue System
HARMONY-D
HERMETİK KOMBİ
BACA SETİ
58990220076
HARMONY-D
YÜKSELTME
SETİ
58990220076
HARMONY-D
HERMETİK KOMBİ
BACA SETİ
58990220076
Figure 14 The Parts of the Flue Kit
34
4.2.3 Standard Supply (concentric horizontal)
The appliance is supplied with a standard concentric air and flue duct
system suitable for flue lengths of up to 725mm (28.5 in) measured from
the centre of the fan outlet of the boiler to the outside surface of the wall
(or window). The duct assembly is connected to the boiler via a turret
elbow, which can be positioned to exit the boiler in any horizontal direction (see Fig. 15).
For flue lengths less than 650mm (25.5 in) the outlet terminal duct must
be shortened. Shorten the duct by cutting approximately equal lengths
from both halves as required.
4.2.4 Additional Kits
The following additional concentric kits are available as optional extras
and these flue kits may be used with the standard flue kit to give an extensive range of flue options. Examples are illustrated in Fig. 14.
a) Extension Duct:
With the use of concentric 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 to the flue system to allow additional bends in the flue system to give greater flexibility in the location
of the boiler.
The resistance of the bends must be taken into account when determining the permissible maximum length of the flue system. A 90o elbow
has an “equivalent length” of 973 mm, one 1000 mm extension duct. No
more than two elbows should be used.
c) Elevation Duct:
This is to be used for elevated horizontal flues if required. With standard
elevation duct, 300 mm elevation is possible from the top of the boiler
before turning to the horizontal direction with elbow.
NOTE: Variations may be used providing that the following rules are
strictly adhered to:
35
1. The maximum permissible horizontal length of the flue system is:
3000mm. This length has to be considered 973 mm less for the use
of each additional 90° elbow.
2. The standard terminal must always be fitted horizontally. The flue
system must only terminate 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 elevation 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 options are required before commencing the installation.
HARMONY_D USERS INSTALLATION AND SERVICE MANUAL
36
Figure 15 Wall Connections
Figure 16 Extensions & Elbow
27
HARMONY_D USERS INSTALLATION AND SERVICE MANUAL
37
4.2.5 Installing the Standard Supply
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
Each
boiler
is the
supplied
withflue
standard
systemwill
for be
fluemade
lengths
up to
to assemble
and
install
standard
system.flue
Reference
to additional
kits
725 mm. See Fig. 17 to assemble and install the standard flue system.
where necessary.
Reference will be made to additional kits where necessary.
Figure 17 Standard Flue Kit Installation
38
ATTENTION! Step 3 of Fig.17 shows how to fit the terminal duct from
inside the room where access to the outside wall is not possible. Such
a sliding operating can be done providing that the optional wall liner is
used. (This is required to seal any cavity and to allow the sealing ring to
pass through from inside and provide an adequate external seal). 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 terminal 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 required for a straight outlet from the wall is more
than 725 mm, 500 and/or 1000mm extension kits should be used with
the standard kit. Refer to Fig. 18.
HARMONY_D USERS INSTALLATION AND SERVICE MANUAL
39
Figure 18 Extension Flue Kit Installation
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.
40
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. Use
HARMONY_D
USERS
AND SERVICE
MANUAL
aluminum
sawINSTALLATION
and always ensure
that the
cut is square and free from
burrs or debris.
Figure 19 Shortening the Ducts
41
4.2.7 Installing Flue System with 90° Turning Kit
It is possible to install the flue system with 1 or 2 pieces of 90° turns
between the boiler and the wall, provided that the total lengths allowed
are not exceeded. Refer to Fig.20 for installation.
HARMONY_D USERS INSTALLATION AND SERVICE MANUAL
INSTALLATION WITH 90 ° TURNING KIT(S)
The flue system can be installed without any 90° turning kit for positions shown in Fig.A below.
1 or 2 90° turning kit has to be used in positions like in Fig.B where the line from centerline of boiler outlet
to the outlet wall surface is not perpendicular.
Maximum total lenght "M+L" can be 2200 mm. for installations with one turning kit and
Maximum total lenght "M+N+L" can be 1200 mm. for installations with two turning kits.
L
Fig.A
Fig.B
A
N
B
B
C
M
L
M
A
1
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 to lenght "L".
15
Use elbow (15) instead of elbow with flange (1).
B
A
B
For a required "N" distance;
Prepare straight inner duct (19)of "N - 132" lenght and straight outer duct(18) of "N - 172" lenght.
Refer to Fig.17 for cutting operation.
Fit both inner and outer cut straight ducts to elbows (15) at both ends with
elbow seals (9) and clamps (7) and secure the clamps with screws(8).
N
2 (For installation with two turns)
C
B
15
9
7
7
9
18
19
9
15
C
8
3 To complete the installation from turning point to the boiler for a required lenght "M",
prepare straight inner duct of "M - 132" lenght and straight outer duct of "M - 172" lenght.
Complete the installation as described in step2 between the elbow (15) and the elbow 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
1
M
4 Secure the flue system from the elbow (1) to here with
4 self-tapping screws, such that the elbow gasket (6) will seat in between.
6
Figure 20. 90º Turning Kit Installation
4.2.8 Installing Flue System with Elevation Kit
42
4.2.8 Installing Flue System with Elevation Kit
It is also possible to elevate the flue system on top of the boiler before
it makes the first turn to its horizontal path. Flue elevation kit has 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 installations described in Figs.17, 18 and 20.
HARMONY_D USERS INSTALLATION AND SERVICE MANUAL
elevation and this operation will only replace the final assembly between the elbow with
43
flange and the boiler in other installations described in Figs.17, 18 and 20.
Figure 21. Elevation Kit Installation
44
IMPORTANT NOTES ON FLUE SYSTEMS
a) Flue terminal must be fitted with 3% downward inclination towards
outside to prevent penetration of rain.
b) Failing to comply with these instructions will invalidate the appliance
certification and therefore may contravene the appropriate EC legislation and local statutory requirements.
c) After the flue system is completely installed, check that the terminal
is correctly located on the outside wall (visibly check from outside the
building where possible) and check if the wall seals provide good sealing.
4.3 COMPONENTS & SYSTEM
Note: The Harmony_D boilers must only be installed with a sealed system.
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/in²). The discharge 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 1.2 bar.
5) With an initial system pressure of 1.0 bar, a system capacity of
about 120 liters can be accommodated. The charge pressure can
be increased but this will cause a decrease in system volume.
6) If the system water content is excessive, then an additional expansion vessel should be connected into the system as close as possible to the central heating return connection of the boiler, (see Fig.
23).
7) Water loss must be replaced.
45
4.3.1 Filling the system
By using the water-filling tap under the boiler, one can simply fill the system with water until system pressure reaches 1-1.2 bar and then close it.
If heating system has its own filling tap and if it is desired to use, the
water must be filled by a competent and authorized person. In this case
there must be no permanent connection to the mains water supply, even
RMONY_D USERS
INSTALLATION
AND(see
SERVICE
if a non-return
valve is fitted
Fig. 23).MANUAL
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.
Figure 23 Additional Expansion Vessel
Figure 22 Additional Expansion Vessel
46
IMPORTANT
All water pipe connections throughout the sealed system must be capable of holding a pressure of up to 3 bars.
Radiator valves must conform to the appropriate standard.
Relief valve discharge must be directed away from any electrical components or from positions where it would cause a hazard to the user.
A suitable drain cock must be fitted to the lowest point of the system. For circuit design purposes, one should consider the information given
in Fig. 24 relating to the available pump head.
Figure 23 Volumetric Flow Rate & Pressure Difference Relation for the Circulation Pump
*: Graph excludes the internal resistance of boiler.
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.
• Mains Cold Water Inlet. Devices capable of preventing the flow of
47
expansion water must not be fitted unless separate provisions have
been made.
• It should be taken into consideration that, in some countries, the final
600 mm. of the mains cold-water connection to the appliance should
be made in copper tube only.
• The appliance is suitable for mains pressure of up to 10 bar (150 lb /
in²).
• The appliance must be fitted with a mains supply-isolating valve.
• In hydraulic group there is a regulator that controls the hot water flow.
In places where main supply water pressure is low; if it is desired to
have much water flow, it can be taken apart.
• Higher flow rates will not damage the appliance but may result in
unacceptably low water temperatures.
• In winter (when the mains inlet water temperature is lower) a reduced
flow rate at the taps may be required to achieve the type of hot water
delivery temperature available in warmer weather.
• It is suggested 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 shower must not fall
closer than 25 mm (1in) above the top edge of the bath to prevent its
immersion in bath water. Alternatively the shower must be fitted with
an anti-siphonage device at the point of the flexible hose connections.
• Thermostatically controlled or pressure equalizing shower valves will
guard against the flow of water at too high a temperature.
• The supply of hot and cold mains water direct to a bidet is permitted,
provided that the bidet is of the over-rim flushing type, (subject to
Local Water Supply Company requirements). The outlet(s) should
be shrouded and unable to have any temporary hand held spray attached. No anti-siphonage arrangements are necessary.
48
• As the maximum temperature of the secondary (water-to-water) heat
exchanger is limited by the control circuit, there is normally no need
for water treatment to prevent scale accumulation. In exceptional circumstances a device to prevent scale formation can be fitted.
4.3.2.1 Showers, Bidets, Taps and Mixing Valves
• Hot and cold taps and mixing valves used in the system must be
suitable for operating at mains pressure.
•
Thermostatically controlled shower valves will guard against the
flow of water at too high a temperature.
•
If using a pressure equalizing valve, set the domestic hot water temperature control knob to the maximum (hottest) position.
•
Hot and cold mains fed water can be supplied 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 reduction in flow to individual outlets. For further information and advice contact the boiler
supplier.
4.3.2.2 Water Quality
If the appliance is installed in a hard water area, say over 150 ppm temporary hardness, the use of an in-line scale inhibitor may be beneficial.
Consult the water supplier in the case of doubtfulness.
4.3.2.3 Water Pressure
Whilst the boiler will operate at a low water inlet pressure, to obtain the
full boiler output 0.2 bar dynamic inlet pressures will be required.
49
4.4 ELECTRICAL
Cable adjusting and cable type between boiler and main supply, should
obey all related local and national regulations.
Properties of the Harmony_D PCB are as follows;
Supply voltage
230Vac +10%/-15%
Supply voltage frequency 50Hz +/-5%
Max power uptake
8VA
Maximum permitted humidity
max 90% @ 40°C no condensing
Class of protection against electric shocks
cl.II
Working environmentclean
Protection classIP00
Printed circuit material
FR4
Protective fuse (line)
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 separation of 3 mm in all poles and supplying the appliance and controls only.
3) The appliance must be earthed.
4) Use the original mains cable provided with the boiler. If there is damage, it should be replaced with an original spare by authorized Alarko
Carrier services.
50
5) The use of a frost thermostat on the boiler is not recommended since
the boiler provides internal automatic protection, as long as the mains
electricity and gas to the boiler are on. However, if frost protection 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 thermostat .
HARMONY_D USERS INSTALLATION AND SERVICE MANUAL
4.4.1
ELECTRONIC
BOARD
WIRING
DIAGRAM
4.4.1
ELECTRONIC
BOARD
WIRING
DIAGRAM
Figure 24 Main Board Diagram
51
52
4.5 CONVERSION TO DIFFERENT GASES
The boilers are supplied to work with one of the following gas supply
systems:
2H and 2E categories using reference gas G20 (Methane) at a supply
pressure of 20 mbar.
3 P category using reference gas G31 (Propane) at a supply pressure
of 37 mbar.
3+ category using either G31 (Propane) at a supply pressure of 37 mbar
or G30 (Butane) at a supply pressure of 29 mbar.
3 B/P category using either G31 (Propane) or G30 (Butane) at a supply
pressure of 29 mbar.
(The adjustment of the appliance is identical for systems 3P, 3+ and 3
B/P with the appliance governor out of action and the inlet pressure is
controlled by the supply regulator).
In case a mixed gas is intended for use, the boiler must be regarded as
G30 for conversion 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 for
the new gas (according to ‘Table 1’), obtain new injectors and check
if they are free from dust and dirt, and assemble the new injectors
using new joint rings.
3) Adjust the minimum and maximum outlet pressures of the boiler gas
valve to the correct value given in Tab.1 for that type of gas. Adjustment of pressure is explained in “Commissioning” section in detail.
4)Elektronic Board should also be adjusted. For this go to ‘PARAMETERS’ ADJUSTMENT’ part.
5) Check if the gas supply pressure to the boiler is correct for the type of
gas to be used.
53
For G20
20 mbar
For G30
29 mbar
For G31
37 mbar
For a mixed G30 and G31
29 mbar
HARMONY_D USERS INSTALLATION AND SERVICE MANUAL
6) Start and run the boiler to inspect any abnormal situation.
5.OPERATING
OPERATING
PARAMETERS
5.
PARAMETERS
Table 5 Setting the Parameters
Parameter
No
Description
Default
Notes
P01
Ignition capacity percentage;
can be modulated between 0-63%
16
%
P02
Gas Type
P03
P04
CH off time;
Maximum CH capacity
60
100
P05
Range CH
00
P06
DHW switch off temperature
01
P07
LED strip configuration
01
00-NG
00-NG
01-LPG
Sec
%
00-Normal
01-Reduced
00- 65 °C
01- ON (Set point)
00- LED always ON*
01-LED ON when flame is ON
02- LED always OFF
* When LCD backlight is ON, LED strip is switched OFF 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 %.
* When P02;
LCDThis
backlight
is isON,
strip is
Parameter
parameter
usedLED
to identify
theswitched
type of gasOFF
that isindependently
used. The default
valuefrom
of this
parameter
adjusted for natural
gas (00).
LED
strip isconfiguration
value.
Parameter P03; It is used to identify the burner switch ON delay in CH mode. During a CH
demand, burner is switched OFF when T flow sensor is greater than T set + 5 ºC while pump
is running. When T flow sensor is lower than T set -3 ºC, burner is switched ON after the
Parameter P01; It controls the outlet gas pressure of gas valve during
delay fixed by the parameter P03.
ignition period.
Default
setting
of P01burner
ignition
capacity
is 16 %.
Parameter
P04; While
adjusting
P4 parameter,
power
follows trimmer
P5 changes.
Parameter
P05;
If
parameter
5
is
OFF
(00),
CH
range
is
normal
(30ºC-80ºC),
if it is
ON
Parameter P02; This parameter is used to identify the type of gas
that
(01), CH range is reduced (30ºC- 50ºC), which is suitable for floor heating applications.
is used. The
default
value
of this
parameter
is adjusted
for natural
Parameter
P06; If
parameter
6 is ON,
burner
is switched ON
and OFF according
to set gas
point.
(00).
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 always 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
54
Parameter P03; It is used to identify the burner switch ON delay in CH
mode. During a CH demand, burner is switched OFF when T flow sensor
is greater than T set + 5 ºC while pump is running. When T flow sensor
is lower than T set -3 ºC, burner is switched ON after the delay fixed by
the parameter P03.
Parameter P04; While adjusting P4 parameter, burner power follows
trimmer P5 changes.
Parameter P05; If parameter 5 is OFF (00), CH range is normal (30ºC80ºC), if it is ON (01), CH range is reduced (30ºC- 50ºC), which is suitable for floor heating applications.
Parameter P06; If parameter 6 is ON, burner is switched ON and OFF
according to 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 always 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 activation, DHW knob must be outside the OFF range.
• Entering parameter menu any running request is respected.
• By pressing the RESET switch for more than 10 sec. P01* appears
on the LCD display.
• By rotating DHW knob P1 value can be set.
• To save the selected P1 value, leave DHW knob in the selected position and press RESET switch for 5 sec.
* Since the display has two digits, P letter and corresponding numbers
are visualized alternatively.
55
HARMONY_D USERS INSTALLATION AND SERVICE MANUAL
5.1.2 Parameter selection mode
• By pressing RESET switch for 1 touch it is possible to select param-
 By rotating DHW knob P1 value can be set.
eters.
 To
save the selected P1 value, leave DHW knob in the selected position and press
RESET
switch forRESET
5 sec.
• By pressing
switch for more than 5 sec., the modification
* Since the display has two digits, P letter and corresponding numbers are visualized
menu
is
entered
then
the actual value is shown.
alternatively.
5.1.2
Parameter
selection
mode
5.1.3
Parameter
changing
mode
 By pressing RESET switch for 1 touch it is possible to select parameters.
• By moving DHW knob, the desired value can be chosen (SET word
 By pressing RESET switch for more than 5 sec., the modification menu is entered then
appears
on is
LCD
screen).
the
actual value
shown.
• If RESET switch is pressed for a time greater than 5 sec., the modiis memorized
and the system returns to PARAMETER SE5.1.3fication
Parameter
changing mode
LECTION
MODE
with
the
following
parameter
already
 By moving DHW knob, the desired
value can
be chosen (SET
wordselected.
appears on LCD
screen).
If RESET switch is pressed for a time greater than 5 sec., the modification is memorized
By and
moving
the CH
knob,
is possible to
exit PARAMETER
the system
returns
to itPARAMETER
SELECTION
MODE withMODE.
the following
parameter already selected.

After 2 minutes without performing anything through DHW knob, an au-
tomatic
is knob,
forced
boiler
willPARAMETER
go back to MODE.
its normal operating conBy
moving exit
the CH
it isand
possible
to exit
dition.
After
2 minutes without performing anything through DHW knob, an automatic exit is forced
and boiler will go back to its normal operating condition.
Table 6 Parameter Adjustment
Description
Locally
on board
P1
Value
00
Ignition capacity
Value
01
Value
02
Value
03
3rd
4th
Adjustable 0 - 63%
P2
Gas type
P3
CH off time
MTN
LPG
P4
CH max capacity
P5
Range CH
Normal
Reduced
P6
DHW switch off temp
65°C
Set point
P7
LED strip configuration
(#12 leds)
Always ON *
ON when flame
is ON *
Adjustable 0 - 255 sec.
Adjustable 0 - 100%
Always
OFF
** = Since the display has two digits, if parameter is greater than 99, the first digit is displayed in turn with the other two digits:
e.g. if parameter = 136: 01 is displayed in turn with 36
* When LCD backlight is ON, LED strip is switched OFF independently from LED strip configuration value.
5.1.4 PARAMETERS’ ADJUSTMENT
Authorized service can change seven of the parameters related to boiler operation via using
the reset button and knobs on the control board.
1) Ignition Gas Pressure: It controls the outlet gas pressure of gas valve during ignition
period. By using Table 6, adjustment can be done as percentage. Default setting of P01
56
5.1.4 PARAMETERS’ ADJUSTMENT
Authorized service can change seven of the parameters related to boiler
operation via using the reset button and knobs on the control board.
1) Ignition Gas Pressure: It controls the outlet gas pressure of gas valve
during ignition period. By using Table 6, adjustment can be done as
percentage. Default setting of P01 ignition capacity is 16 %. In case
of a bursting type of burning, this parameter can be adjusted to meet
sufficient ignition capacity for a proper burning.
2) Gas Type: It makes the adaptation of the electronic board to gas type
change.
3) OFF Time: It is the time between boiler stop and restart again following the heat requirement. The boiler will not restart before this
time. Factory setting is 60 seconds. It can be altered between 0-255
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 recommended
for floor heating systems.
6) Domestic Hot Water Switch Off Temperature: It adjusts the switching
point of domestic hot water. There are two choices ‘ON’ and ‘OFF’.
Factory setting is ‘ON: boiler turns off at 71°C and starts at 70°C’.
With the other mode ‘OFF’ the boiler can be adjusted to ‘turn off at
“set + 8 °C” and start at “set + 7 °C”’.
ATTENTION! These adjustments should be done by authorized Alarko
Carrier Services.
5.1.4.1 Parameters Menu Activation
• In order to enter parameter menu activation DHW knob must be outside OFF range.
• Entering parameter menu any running request is respected.
57
• By pressing reset switch for 10 sec. P01 appears on LCD. Since the
display has two digits P letter and corresponding number are visualized alternatively.
• By rotating DHW knob P1 value can be set.
• To save P1 selected value leave DHW knob in the selected position
and press RESET switch 5 sec.
5.1.4.2 Parameter Selection
• By pressing RESET switch for 1 touch it is possible to select parameters.
• By pressing RESET switch for more than 5 sec. the modification
menu can be accessed, then the actual value will be shown.
5.1.4.3 Parameter Modification
• By moving DHW knob, the desired value can be chosen.
• 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 CH knob, it is possible to exit PARAMETER MODE.
• After 2 min. without performing anything through DHW knob, an automatic exit is forced and boiler will go back to normal working condition.
HARMONY_D USERS INSTALLATION AND SERVICE MANUAL
5.2 OPERATING ERRORS
5.2 OPERATING ERRORS
When
a problem
with operation,
the boiler
exhibits
thisdisplay.
fault via
When
a problem
occursoccurs
with operation,
the boiler exhibits
this fault
via LCD
The
diagnosed
fault encoding
is shown in Table
LCD display.
The diagnosed
fault7;encoding is shown in Table 7;
Table 7 Fault Display
No flame after ignition sequence
Spurious flame
High limit thermostat
Air pressure switch fault
Flow sensor fault
DHW sensor fault
H2O pressure switch cut-in
F4 + Reset + monkey wrench
F4
F1 + Reset +monkey wrench
F5 + Reset
F3 + monkey wrench
F2 + monkey wrench
E0 + monkey wrench
These errors mentioned above, are listed according to their priority orders.
In the case boiler goes through non-volatile lockout, user should switch reset button after
literally solving the main cause of the problem.
 If ‘no-flame fault’ arises, be sure that gas valves are open and gas flow exists. During
the first start-up the boiler may lockout since the gas line may contain air. This is quite
normal. Reset the boiler 2 – 3 times, waiting 20 seconds between the attempts. If the
58
These errors mentioned above, are listed according to their priority orders.
In the case boiler goes through non-volatile lockout, user should switch
reset button after literally solving the main cause of the problem.
• If ‘no-flame fault’ arises, be sure that gas valves are open and gas
flow exists. During the first start-up the boiler may lockout since the
gas line may contain air. This is quite normal. Reset the boiler 2 – 3
times, waiting 20 seconds between the attempts. If the boiler goes to
lockout state continuously consult your authorized service. This error
occurs after three ignition attempts for natural gas and one ignition
attempt for LPG.
• Spurious flame check will be performed before ignition attempts, so
that real flame can be differentiated from the fake one.
• If lockout is caused by excessive temperature, wait for the system
water to cool down before another try. The flow pump control remains 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, this means there is not
enough water in the circulation. In order to avoid this problem, the
boiler should be filled with water as it is explained in water filling part.
• For any other fault or repeated lockout conditions, consult your authorized service dealer.
5.2.1 Some Typical Problems
Boiler is running noisy!
Turn off the boiler. Release the air in the heating system. Fill water if
necessary. Start the boiler. If there is still noise, call the service.
There is continuous water loss!
Check if there is any leakage at the heating system. If not, call the service.
There is no or insufficient hot water flow through the taps!
59
Filter at the cold-water inlet of the boiler might be blocked, call the service.
Heating system temperature is rapidly increasing and the boiler is stopping!
There might be air in the system. Vent the system and re-start. If the
problem repeats, call the service.
5.3 PERIODIC MAINTENANCE
Harmony- D boilers require very little in the way of routine maintenance.
Check the system pressure gauge from time to time and report any continued fall in pressure to the authorized service personnel. Keep the
external casing of the boiler clean by wiping with a soft damp cloth - do
not use abrasive cleaners.
If it is suspected that there may be a fault with either the system or the
boiler, then do not use the appliance until the suspected fault has been
investigated and rectified by a competent 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 personnel. The manufacturer will not take any responsibility for any hazard caused by unauthorized people.
Controls to be done during routine maintenance are listed below:
• Listening to the user’s claims.
• Cleaning of main heat exchanger. Fan motor control
• Functionality control of air pressure switch and hose connection control (room sealed models)
• Control and cleaning of burner injectors.
• Control of insulation panels of combustion room.
• Control and adjustment of electrodes.
• Electric and electronic circuit control.
• Pump control and 3-way valve functionality control.
• Gas side pressure control of expansion vessel.
60
• Gas soundness control (between gas inlet valve and boiler).
• Water soundness control.
• Cleaning of heating and hot water filters.
• Safety valve control.
• Heating system pressure control.
• Capacity and combustion settings control.
• Combustion products analysis.
Automatic Control Devices
• You can use “room thermostat” with your boiler to maintain desired
room temperature.
• With “daily time programmer”, you can set your boiler to run at desired time intervals and temperatures during the day.
• With “weekly time programmer”, you can set your boiler to run at desired time intervals and temperatures during the week.
• With “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 connected, you can also see outside temperature on remote control display.
• With “outside sensor”, combi boiler can modulate whether dependent.
• With “outside sensor + room thermostat / daily-weekly time programmer/remote control”, combi boiler can modulate whether and also
room temperature dependent.
• With “telephone interface card” you can operate combi boiler on and
off from a distance by telephone.
If you have your boiler equipped with other appropriate automatic controllers, you can run your boiler with higher comfort and more economically.
61
All these controllers are optional. For the safety of your boiler, contact
the authorized installers or services to buy any of these options. Do not
forget to ask for user manual of the device.
6. Use with LPG
Your boiler can be used with LPG. The boiler must be adjusted to work
with LPG by the manufacturer of the authorized service. The boiler is
suitable to work with LPG bottles for only if they are connected to the
boiler via a special “collector kit” manufactured by Alarko Carrier. In cold
environments, the use of a special “heater kit” manufactured by Alarko
Carrier is recommended for economic and safe use. In case thermostatic hot water buckets are used to heat up the LPG bottles, water temperature 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
Safety section.
WARNING! The boiler must be adjusted to work with LPG by the Authorized Service.
The boiler will be out of guarantee unless 30 mbar certified regulators
and the collector kit made by Alarko Carrier are used with the boiler.
7. COMMISSIONING
WARNING: Several components operate on mains voltage and with the
outer case removed, live components can become exposed.
7.1 Pre Checks
1) Check that the boiler is isolated from the electrical supply, at the external isolator.
62
2) Fully open the domestic water supply stopcock or valve in the supply
to the boiler.
3) Open the domestic water isolation valve below and adjacent to the
boiler.
4) Open all hot water draw-off taps and close them when water flows.
Check for water soundness of the whole domestic water system and
boiler.
5) Pressurize the system until the pressure is 1.5 bars.
6) Open the automatic air vent cap located at the top of the pump. Ensure that the automatic air vent is operating correctly.
7) Check the operation of the safety valve by turning the safety valve
knob clockwise until venting can be detected.
8) Take care not to splash any of the electrical components.
9) Check 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 possible adhesion due to inactivity for long time).
7.2 Start up
• Open the gas isolating cock adjacent to the boiler.
• Turn on the electrical supply to the boiler
• Set the central heating temperature control to maximum.
• The automatic ignition will start. In new installations it may take a
short while for any air in the line to be expelled. If ignition does not
take place the burner lockout light will be lit.
• Reset the control system and repeat as required until the boiler fires
normally.
63
• Turn the DHW knob to a desired temperature position and open a
water tap fully and check that the boiler lights and operates.
7.3 Setting the Heat Input
The heat inputs for CENTRAL HEATING (CH) and DOMESTIC HOT
WATER (DHW) are already set on the boiler when supplied from the
factory. The default input settings for minimum and maximum rates for
both CH and DHW circuits are the nominal input rates of the boiler given
in Table1.
The diagrams in Fig. 26 show the correlation between gas pressure and
heat input for all possible gases. The pressure to achieve a desired power output can be found via this diagram. Then the pressure, which can
be observed from the 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.
HARMONY_D
USERS INSTALLATION
AND
SERVICE
MANUAL
ATTENTION!
Maximum heat
inputs
should
not
exceed the given limits.
Natural Gas (G20)
14
Burner Pressure (mbar)
12
10
8
6
4
2
0
10
12
14
16
18
20
22
24
26
28
Heat Load (kW)
Figure 25 Burner Pressure/ Heat Input Diagram
Before starting the adjustment, dismount the front panel.
ATTENTION! Manometer is fixed to the front panel. Dismount the front panel, as it is stated
below: Loosen the two screws, under the panel. Pull the panel slightly and loosen the nut.
Take out the manometer from the panel. By pushing the front panel upwards, it can be easily
64
Before starting the adjustment, dismount the front panel.
ATTENTION! Manometer is fixed to the front panel. Dismount the front
panel, as it is stated below: Loosen the two screws, under the panel. Pull
the panel slightly and loosen the nut. Take out the manometer from the
panel. By pushing the front panel upwards, it can be easily taken apart.
Loosen the screw that fixes the control box, then swing the control box to
left and allow the boiler to run for approximately five minutes to stabilize
before making the final adjustments to the gas pressure settings. To be
able to do the adjustments, the system should call for full heat input.
Refer to Figs. 26 and 27 for following steps.
HARMONY_D USERS INSTALLATION AND SERVICE MANUAL
Figure 26 Gas Modulator
7.4 Maximum and
DHW/CH
Input Adjustments
7.4 Maximum
andMinimum
Minimum
DHW/CH
Input(mechanical
Adjustments
maximum and minimum)
(mechanical
maximum and minimum)
 Loosen the screw of gas valve outlet pressure test point (1) and connect a Umanometer to it.
 Take apart the modulation cables from modulation terminals (5).
• Loosen
the screw
valve
outlet
pressure
test(3;point
(1) and con Remove
yellow capof
(2)gas
to expose
pressure
regulator
adjustment screws
4).
Turn the red pressure regulator
nect a U-manometer
to it. adjustment screw (3) clockwise up to its end position.

Set the maximum pressure to the desired value by rotating the pressure regulator
adjustment
(4) with a 10 cables
mm spanner.
Turning
clockwise increases
and anti- (5).
• Take apart
thescrew
modulation
from
modulation
terminals
clockwise reduces the pressure.
 Set the
minimumcap
pressure
value bypressure
rotating the redregulator
minimum pressure
• Remove
yellow
(2)to the
todesired
expose
adjustment
adjustment screw (3). Turning clockwise increases and anti-clockwise reduces the
screwspressure.
(3; 4).

Replace yellow pressure regulator cap (2) and the modulation cables.
NOTE: For I3+ category adjusted appliances, where adjustment of the maximum pressure is
not allowed and gas supply pressures do not exceed 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.
65
• Turn the red pressure regulator adjustment screw (3) clockwise up to
its end position.
• Set the maximum pressure to the desired value by rotating the pressure regulator adjustment screw (4) with a 10 mm spanner. Turning
clockwise increases and anti-clockwise reduces the pressure.
• Set the minimum pressure to the desired value by rotating the red minimum pressure adjustment screw (3). Turning clockwise increases
and anti-clockwise reduces the pressure.
• Replace yellow pressure regulator cap (2) and the modulation cables.
NOTE: For I3+ category adjusted appliances, where adjustment of the
maximum pressure is not allowed and gas supply pressures do not exceed 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 pressure have been set check for correct modulation as
follows.
• Set the DHW knob to the max level and fully open a hot water tap.
Check that the desired maximum burner pressure is attained.
• Slowly close the hot tap and note that modulation takes place.
• Close the tap and check that the burner goes off.
7.6 Commissioning – Heating System
•
Fully open all radiator valves.
•
Set the heating system in operation and balance the radiators.
66
7.7 INSTRUCTIONS TO THE USER
1) Instruct and demonstrate the lighting procedure, then advise the user
of the efficient and safe operation of the boiler.
2) Instruct and demonstrate the operation of any heating system controls.
3) Advise the user that to ensure the continued efficient and safe operation of the appliance it is recommended that is checked and serviced
at regular intervals. The frequency of servicing will depend upon the
particular installation and usage, but in general once a year is sufficient.
4) Draw attention, if applicable, to the Gas Safety (Installation and Use)
regulations, which imposes a duty of care on all persons who let out
property 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 person.
Before commencing any service work TURN OFF the gas and ISOLATE
the mains electricity supply to the boiler.
It is recommended that the boiler be serviced at regular intervals. In
general, once a year and
preferably before the heating season, is sufficient.
Unless the user has any particular claim about the appliance, steps of
recommended preventative maintenance are as follows:
• Start and run the boiler for 5 minutes to see any abnormality and shut
it down.
67
ATTENTION!
Manometer is fixed to the front panel. Dismount the front panel, as it is
stated below:
• Loosen the two screws, under the panel. Pull the panel slightly and
loosen the nut. Take out the manometer from the panel. By pushing
the front panel upwards, it can be easily taken apart.
• Disconnect the electric supply and isolate the boiler from gas and
water installations.
• Release the two front casing panel screws located underneath the
panel. Lift the front panel slightly to clear the 2 pins at the top and
remove.
• Undo the 6 fixing screws of front sealing panel and remove.
• Undo the 4 fixing screws of combustion chamber front panel and burner box skirt and remove.
• Pull off the plug connections to the flame sensing and ignition electrodes.
• Remove the 4 burner fixing screws located at the rear of the burner
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 not necessary to
remove the injectors unless there is evidence of debris in the orifice.
• Inspect the ignition and flame detection electrodes in situ. If necessary clean with a soft brush. If either the electrodes or the ceramic
insulation show signs of damage or wear, replace the electrode(s).
• Replace the burner and electrodes in reverse order, taking care not
to damage the lining of the combustion chamber. Check that the position of the electrodes is as shown in Fig. 28. Adjust if necessary by
carefully bending the tip of the electrode rod taking extreme care not
to put any pressure on the ceramic insulation.
68
HARMONY_D USERS INSTALLATION AND SERVICE MANUAL
Figure 27 Burner Plates, Igniters and Flame Sensors
















Before taking the hood apart, cover the burner openings for not splitting any dirt from
the
• hood.
Before taking the hood apart, cover the burner openings for not splitPullting
off the
anyelectrical
dirt fromconnections
the hood. from the spade terminals on the fan motor.
Disconnect the flexible air pressure sensing pipes from the fan venturi.
• Pull off the electrical connections from the spade terminals on the fan
Remove
the fixing screw to release the fan from the flue hood.
motor.
Withdraw the fan downward with a forward twisting action to disengage the fan
• Disconnect
theflue
flexible
air pressure
sensing
discharge
from the
connection
on the boiler
top. pipes from the fan venturi.the impeller and clean off any dust with a soft brush, or by blowing.
Inspect
Remove
the air
switchtoby
undoing
screws
fixing
the switch to the
• Remove
thepressure
fixing screw
release
thethe
fantwo
from
the flue
hood.
boiler top.
• Withdraw the fan downward with a forward twisting action to disengaUndo the fixing screw to remove the right and left air deflector parts of flue hood.
ge the fan discharge from the flue connection on the boiler top.
Remove the flue collector hood by undoing the four fixing screws holding the hood to
• Inspect
and
clean
off any
dust with
soft forward
brush, orclear
by of the
the
rear wallthe
of impeller
the boiler
inner
casing.
Withdraw
the ahood
blowing.chamber.
combustion
Cover
the burner
blades
to collect
any by
debris
and clean
the heat
exchanger
with a soft
• Remove
the air
pressure
switch
undoing
the two
screws
fixing the
brush
or
vacuum
cleaner.
DO
NOT
use
a
wire
brush.
switch to the boiler top.
Reassemble the flue hood taking care that the rear lip of the hood is correctly located
• Undo
thelip
fixing
screw
to remove
and leftchamber
air deflector
under
the top
formed
on the
top of thethe
rearright
combustion
wall. parts
of
flue
hood.
Replace the air deflector, fan and air pressure switch in reverse order.
Check
the air the
pressure
sensing
for damage
andfour
replace
as screws
required taking
• Remove
flue switch
collector
hoodpipes
by undoing
the
fixing
careholding
to preserve
the
correct
connection.
(The
pipe
coming
from
outside
air should be
the hood to the rear wall of the boiler inner casing. Withdraw
plugged
to
the
switch
P1
inlet;
the
pipe
coming
from
fan
should
be
plugged
to the
the hood forward clear of the combustion chamber.
switch P2 inlet. )
• Cover
burner
blades
to face
collect
anypump
debris
clean
heat
excRemove
thethe
screw
on the
frontal
of the
to and
access
the the
pump
shaft
and rotate
hanger
with
a
soft
brush
or
vacuum
cleaner.
DO
NOT
use
a
the shaft with a screwdriver to check for any blockage. Clean any dirt andwire
replace the
brush.
screw.
Replace the combustion room front panel, in hermetic models hermetic 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.
69
• Reassemble the flue hood taking care that the rear lip of the hood is
correctly located under the top lip formed on the top of the rear combustion chamber wall.
• Replace the air deflector, fan and air pressure switch in reverse order.
• Check the air pressure switch sensing pipes for damage and replace
as required taking care to preserve the correct 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 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 original (cold) design pressure. If
necessary, re-pressurize the system.
• Check the airside pressure of the expansion vessel and pump air to
increase it up to 1,2 bar.
• On completion of the service work and reassembly of the appliance,
check for gas soundness and the correct operation of the appliance as described “Commissioning” section. Reset the controls to the
users’ requirements.
• At final, adjust the boiler according to the customer’s desire.
HARMONY_D
USERS INSTALLATION AND SERVICE MANUAL
70
Appendix A
FAULT DETERMINATION
55
71
72
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