HARMONY – D USERS, INSTALLATION AND SERVICING INSTRUCTIONS
Code No: A.1.2.
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.
TABLE CONTENTS USER INSTRUCTIONS 8 1. Introduction 8 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 Safety 10 1.2 Course of Action in case of Gas Leakage 10 1.3 Contents of Packaging 12 2. Product Description 13 2.1 Technical Data 15 2.2 Dimensions 16 2.3 Internal Parts of the Boiler 17 2.4 Water Circuit 18 2.
4.1.2 BOILER LOCATION 26 4.1.3 AIR SUPPLY 27 4.1.4 OPENING THE PACKAGE & TRANSPORT 28 4.1.5 MOUNTING THE BOILER 29 4.1.6 Water and Gas Connections to the Boiler: 29 4.2 FLUE SYSTEM AND INSTALLATION 30 4.2.1 Sitting the Flue Terminal 30 4.2.2 Parts of Harmony_D RSF Flue System 33 4.2.3 Standard Supply (concentric horizontal) 34 4.2.4 Additional Kits 34 4.2.5 Installing the Standard Supply 37 4.2.
5.2 OPERATING ERRORS 57 5.2.1 Some Typical Problems 58 5.3 PERIODIC MAINTENANCE 59 Automatic Control Devices 60 6. Use with LPG 61 7. COMMISSIONING 61 7.1 Pre Checks 61 7.2 Start up 62 7.3 Setting The Heat Input 63 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.
FIGURES Figure 1 Boiler Dimensions 16 Figure 2a-b Main Parts of the Boiler/ Front-Backside View 17 Figure 3 Water Circuit Diagram 18 Figure 4 Control Panel Appearance 19 Figure 5 DHW Knob 19 Figure 6 CH Knob 20 Figure 7 Manometer 20 Figure 8 LCD Display Screen 21 Figure 9 Hydraulic Group- Manual filling tab 24 Figure 10 Transport & Packaging 28 Figure 11 Mounting Schematic with essential dimensions.
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.
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.
• 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.
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.
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.
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.
• 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 safe
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.
HARMONY_D USERS INSTALLATION AND SERVICE MANUAL 2.2 Dimensions Figure 1 Boiler Dimensions 2.
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.
2.4 Water Circuit HARMONY_D USERS INSTALLATION AND SERVICE MANUAL 2.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
HARMONY_D USERS INSTALLATION AND SERVICE MANUAL 4.2.2 Parts of Harmony_D RSF Flue System 4.2.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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).
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.
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.
• 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.
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.
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.
HARMONY_D USERS INSTALLATION AND SERVICE MANUAL 4.4.1 ELECTRONIC BOARD WIRING DIAGRAM 4.4.
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.
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.
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.
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.
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.
• 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.
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.
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.
• 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.
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.
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.
• 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.
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.
• 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.
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.
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.
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.
• 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.
HARMONY_D USERS INSTALLATION AND SERVICE MANUAL 70 Appendix A FAULT DETERMINATION 55
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