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Demir Dokum HK 50 M Service Bulletin

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HK 50 M – HK 100M – HK 100S
SERVICE BULLETIN
SERVICE BULLETIN -
MAXICONDENSE WALL TYPE
CONDENSING BOILER
07/03/11

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Summary of Contents for Demir Dokum HK 50 M

  • Page 1 HK 50 M – HK 100M – HK 100S SERVICE BULLETIN SERVICE BULLETIN - MAXICONDENSE WALL TYPE CONDENSING BOILER 07/03/11...

  • Page 2: Table Of Contents

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN TABLE OF CONTENTS PRODUCT INTRODUCTION...............................4 1.1. Product Specific Innovations............................4 1.2. Product Types ................................4 1.3. General Information ..............................4 Warnings regarding installation and use of the device and general warranty conditions…..………………………4-5 1.4.
  • Page 3 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 3.11. THERMALEGULATION SETTING ........................41 ADDITIONAL FUNCTIONS FOR CASCADE MANAGEMENT ..............47 3.12. ADRESSING SETTINGS FOR CASCADE CONNECTIONS ................53 3.12.1. Master card settings.............................. 53 3.12.2. Slave card settings ............................... 53 3.12.3.

  • Page 4: Product Introduction

    1.3. General Information HK 50 M, HK 100 M and HK 100 S are condensing wall type boilers for heating purposes, that run with natural gas or LPG and which have a wall-mounted premix burner, with one heating unit (50 M model) or two heating units (100 M - 100 S models).

  • Page 5: Products That Can Be Used Together

    Ventilation measurements below the specified dimensions are not acceptable. - If HK 50 M will be used as a single unit, the, the system can have a PP piping with a total length of 30 m, with a diameter of 50 mm. For every 90º bends, 2m should be deducted from the total length.

  • Page 6: Device Registry Label

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 1.6.2. Device registry label: Technical and performance data of the device is given. 1.6.3 Gas label: This label is on the side surface of the rear frame plate. It describes the type of gas in the country where the device will be used.

  • Page 7: Technical Specifications Table

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 1.6.4. Technical Specifications Table Maxicondense Definition Unit HK 50 M HK 100 M HK 100 S Fuel type G20 - G30 - G31 Device category II2H3 + Device type B23 - C63 Thermal load (Min.

  • Page 8: Main Heat Exchanger

    The cylinder shaped upper valve part is the body made of aluminum casting, including a heat exchanger within. (figure 1.6) HK 50 M type has 1 piece, HK 100M and HK 100S types have 5 pieces. (Figure 1.5) 1.7.4 Flame ignition and detection electrode The electrode is mounted on the upper left side of the combustion chamber.

  • Page 9: Flow And Return Ntc Probes

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 1.7.5 Flow and Return NTC probes With the sensors, the temperature measurements on the flow and return lines of the combustion unit are read on the electronic card. (Figure 1.8) 1.7.6 Safety thermostat...

  • Page 10: Fan

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 1.7.8. Fan It enables the air gas mixture to reach the burner and combustion chamber by means of the venturi (air gas mixer). The other task of the fan is to send the waste gas to the waste gas system. (Figure 11) 1.7.9.

  • Page 11: Condense Collection Siphon

    1.7.12. Control panel In HK 50 M and HK 100 M model products, it has one master card (main PCB) and one or two slave PCBs. HK 100 S model has 2 slave PCBs. In cascade applications, with HK 50 M and HK 100M, it controls the slave cards connected to the whole system via a BUS connection.

  • Page 12: Safety Valve

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 1.7.14. Safety valve It is on the water flow pipe. It must be connected to the waste water system with a drainage hose. It protects the hydraulic circuit at high pressures caused by overheating of the primary circuit. It is set to 6 bars.
  • Page 13 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN HK 100M HK 100S 1 First heating unit switch Operation mode selection button (Enables entering into the Parameter menu and the system display menu. 3 Reset button (Master) 4 Signal indicating that the system is powered...

  • Page 14: Display Mode

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 1.7.16. DISPLAY (Display Mode) 9. Increases the relevant value. Enables to reset the 10. Decreases the relevant device when the device value. is disabled in some way. Records the selected value.
  • Page 15 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 1.7.16.2 Readout mode (Temperature values and operational states in various circuits) Key is pressed (the point next to I is turned off (press once), then continue with the menu. The following data are observed in order.

  • Page 16: Monitor Mode (Used To Control Operation Values For Each Heating Unit)

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 1.7.16.3 Monitor mode (It is used to control operation values for each heating unit and 1-60 addresses can be defined.) Press "Set/Esc" key for 5 seconds to see U 01 on the display, then switch to the following other modes by pressing the key.

  • Page 17: Work Flow For Start-Up Of The Device

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN WORK FLOW FOR START-UP OF THE DEVICE START-UP OPERATION Gas connection: - The device works with natural gas or LPG. Gas connections must be made in accordance with the relevant standards.
  • Page 18 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN FILLING AND DISCHARGING THE SYSTEM 2.2.1 Filling - Open valves no (1) (Figure 2.4) - Turn on air discharge air relief cocks (2) (Figure 2.5) If there is a 2-way valve in the system, bring the position to MANUAL position (It is the handle below the two-way valve (Fig.
  • Page 19 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 2.2.2. Discharging the water inside the device The main power switch is turned OFF before draining the system water. The valves under the devices are closed. In each unit, plastic hoses are connected with 2-way valves and water is drained. / Electrical equipment must be protected from the discharged water.

  • Page 20: First Ignition

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN After draining water in each unit is completed, the 2-way valves are switched to the "AUTOMATIC" position. (Figure 2.11) 2.3. FIRST IGNITION - Turn the main switch to "ON" position.
  • Page 21 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN When the button is pressed, the maximum flow water temperature will appear, its symbol is 1. (In figure, 2.14 it is 80 - Press and hold the "Set/Esc" key until the screen flashes. (Figure 2.15) Press "+" and "-" to change, press "OK"...
  • Page 22 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN - Press and hold the "Set/Esc" key until the screen flashes. (Figure 2.15) Press "+" and "-" keys to change press "OK" key when desired value is reached. Here, the maximum temperature for the flow water of the low heating circuit is set.
  • Page 23 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN - Press and hold the "Set/Esc" key until the screen flashes. (Figure 2.15) Press "+" and "-" to change, press "OK" key when desired value is reached. Here, the maximum temperature for the Boiler flow water is set.

  • Page 24: Controls To Be Performed After Or During The First Ignition

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Errors A and E are removable errors. Type A errors can be removed by pressing the RESET key. Type E errors disappear automatically. (Section 6 provides information on the errors.) 2.4.

  • Page 25: Boiler Operation

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 3 BOILER OPERATION 3.1 FACTORY SETTINGS AND FUNCTIONAL PARAMETER SETTINGS During boiler installation, the following properties must be re-entered in the parameter blocks on the HK 50 M or HK 100 M master units.

  • Page 26: Central Heating Parameters

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 3.2. CENTRAL HEATING PARAMETERS Following parameters must be set for the Central Heating (CH) function. 3.2.1. Setpoint_T_CH_High Setting of high temperature circuit (parameter 1) - In case a constant value will be set in the operation mode, (par.14 = CH_type_high = 0) is entered.

  • Page 27: Central System Priority

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 3.2.3. CENTRAL SYSTEM PRIORITY (Parameter 16) - If parameter 16 = 0 is set, the central system has no high temperature zone (80/60 system) or low temperature zone (50/30) priority.

  • Page 28: Domestic Hot Water Parameter Settings

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 3.3. DOMESTIC HOT WATER PARAMETER SETTINGS The following set points are the functions set for the domestic water circle. 3.3.1. Setpoint_DHW (Domestic hot water setting) Domestic water hot water settings (parameter 2) It is the value that determines the requested domestic water temperature.
  • Page 29 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN C and the manifold temperature is above 5 C the system's pumps If the outdoor air temperature is below 3 will run until the outside air temperature rises above 3 3.4.3.

  • Page 30: Parameter Settings

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 3.5. PARAMETER SETTINGS 3.5.1 Password settings Parameters to be entered by the service personnel are done by entering 22 as a password in reading mode. The password can be changed by the user. The procedure for entering the password is as follows.

  • Page 31: Parameter List

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 3.5.2 Parameter list Master Card parameters are given below. No Name Explanation USER PARAMETERS If Par.14 = 0, It is high temperature heat circuit setting value. If 1 Setpoint_ch_high 10 Par.17...
  • Page 32 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN (DEP) 15 P_ch_max For central heating system: Maximum power and heating speed 0 = No priority for heating systems 16 CH_priority 1 = High flow water temperature heating circuit priority...
  • Page 33 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 43 Protocol C 0= Eco protocol 1=Argus link (new) Service Administration 03/2010...
  • Page 34 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN MANUFACTURER PARAMETERS (OEM) NOTE: These parameters cannot be modified 44 T_ch_high_max C Upper limit (for parameter 17) Proportional step constant for high hot flow water circle 45 P_factor_CH_high power modulation...
  • Page 35 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 70 Hyst_up_reduce_burner 71 Hyst_up_down-add_burner Service Administration 03/2010...
  • Page 36 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 72 Hyst_up_quick_stop 73 Quick stop time 74 Quick start time 75 T_H_correct_85 Wait time after burner_switched 77 circle_limitation 78 circle_limit_stop 79 circle_limit_inc 80 Cascade Rotation hours 0= Flow switch NO...

  • Page 37: Gas Settings

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Defines the waiting time for low temperature demand. If T flow temperature is above the temperature 99 Low_load period defined in PAR.9B, it waits until the time set by Par.

  • Page 38: Calibration Settings

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN NOTE: WHILE SETTING; THE ANALYSIS DEVICE MUST BE SET SO THAT THE PROBE TIP WILL BE AT THE CENTER OF THE WASTE GAS PIPE. 3.6.1 Setting of the CO value for maximum output (power): Press and hold for 5 seconds the "Set/esc"...
  • Page 39 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 3.7.3 To-do's and presets The steps below should be followed when gas conversion of the device is performed: The device should be disconnected from the mains. The gas valve must be closed - Remove the front panel (2) by removing the screws (1).
  • Page 40 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN - Attach the G31 gas information label by removing the G20 gas information label on the front panel. (Figure 3.9) - Remove the registry label on the side panel.
  • Page 41 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN - Remove the screw (3) on the gas valve (Figure 3.11) and connect a pressure gauge. - The system main switches are turned back on. In TEST mode, it is possible to generate maximum thermal power for heating at high temperature.

  • Page 42: Combustion Control

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Ensure that the boiler is switched off from the room thermostat. Press the "OK" key to exit the TEST mode. Unscrew the pressure gauge and tighten the screw again. (Figure 3.11) 3.9.
  • Page 43 In case of maximum thermal power demands in central heating system, linear change of Master and Slave boilers are set to 230 for HK 50 M, HK 100M and HK 100S models for Parameter 15. (P_ch_max; Par 15 = 230) 3.11.2.
  • Page 44 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Hysteresis ON can be set. Parameter 19= 7 C is the factory setting. It can be set between 0-20 (CH_High_mod_hyst_on=Par. 19) Master controller performs this operation for each slave control according to the heat requirement.
  • Page 45 In case of maximum thermal power demands in central heating system, linear change of Master and Slave boilers are set to 230 for HK 50 M, HK 100M and HK 100S models for Parameter 15. (P_ch_max; Par 15 = 230)
  • Page 46 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 3.11.2. Attenuation_Low (Deceleration-efficiency reduction low temperature heating circuit) (Parameter 25 = In low temperature heating circle, delay in set setting in case no room thermostat is present) Two cases are possible Application;...
  • Page 47 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Setting the application with the outdoor air sensor (Par. 22=1) If a low temperature circuit delay (reduction in efficiency) is not desired, parameter 25 = 0 and the system will operate according to the above application.
  • Page 48 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 3.11.5 T_out_correct (Outdoor air temperature correction parameter_parameter 39) The value that normally appears on the display is the value read by the outdoor air sensor. It is a value that can be entered for the calibration of the sensor.
  • Page 49 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Service Administration 03/2010...

  • Page 50: Additional Functions For Cascade Management

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN If the manifold temperature < set temperature - 5 C, the second burner will be activated. If, after 30 seconds manifold temperature < set temperature -5 C, condition is still maintained, the following burner will be activated.
  • Page 51 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Control of heat demand by analog input in high temperature heating circuit (Parameter 14 = 2 or 3) If system set values input signal is used (room thermostat is not used in high temperature heating circuit).
  • Page 52 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN - System temperature = set temperature (high heating circuit = parameter 1) - Hysteresis OFF (parameter 20). (Parameter 20 is set to 3 C as OEM.) - System temperature = set temperature (low heating circuit = parameter 3) - Hysteresis OFF (parameter 27).
  • Page 53 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN The burners stop as follows. - System temperature = set temperature (high heating circuit = parameter 1) - Hysteresis OFF (parameter 20). (Parameter 20 is set to 3 C as OEM.) - System temperature = set temperature (low heating circuit = parameter 3) - Hysteresis OFF (parameter 27).
  • Page 54 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Considering the above example, when the flow water temperature reaches 38 C, the mixing valve will wait until the time specified in parameter 28 (5 seconds in the example). After this time, the valve will open.
  • Page 55 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 4 = 15m large flue system and LPG 3.11.11 Burner ignition procedure Status TC> 24 hr 10 s 10 s Time >0 Required power Par.86 Par.85 Par.85 When Pre-...

  • Page 56: Slave Pcb Inputs

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 3.12 ADDRESSING SETTINGS IN CASCADE CONNECTIONS 3.12.1. Master card (Master PCB) Master card can manage up to 60 slave cards. Power demand 230 Vac (-15% +10%), 50 Hz 0-60...

  • Page 57: Addressing Settings

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN As described in Procedure 5.62, enter the slave cards in the master card. Follow procedure 3.12.5 for addressing settings. Make boiler connections with special bus cables (APPENDIX H) 3.12.5. Addressing settings Each slave card (one for each heating unit) must be configured in the correct order on the master card.
  • Page 58 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Service Administration 03/2010...

  • Page 59: Decommissioning The Boiler

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN DECOMMISSIONING THE BOILER TEMPORARY DECOMMISSIONING The following procedure is applied on occasions where a temporary shut-down is required on the weekend, during a short trip. Set room thermostat to 10 Set parameter "2"...
  • Page 60 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Service Administration 03/2010...
  • Page 61 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Water frost protection must be taken inside the unit or in the boiler. Service Administration 03/2010...

  • Page 62: Maintenance

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 5.MAINTENANCE It is necessary to fulfill all the features and characteristics of the products and meet the legal obligations, make systematic checks of the products at regular intervals. The frequency of controls depends on the installation site and usage conditions. Therefore, it must be checked at least once a year by an authorized service.

  • Page 63: Failure Maintenance Process

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 5.2. FAILURE MAINTENANCE PROCESS In case of interruption of boiler functions or in case of fault occurrences; replacing repair component control are made. Special tools must be used for disassembly and replacement and the instructions must be followed.

  • Page 64: Safety Rules

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 5.5. SAFETY RULES Installation and maintenance work of the devices must be carried out by authorized and trained personnel and all safety rules must be observed. Before each operation;...

  • Page 65: Dismounting The Control Panel

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 5.6.2. Dismounting the control panel OPERATION ORDER COMPONENT REQUIRED TOOL KIT Turn the system power OFF and close the gas valve 2.1 Remove the front cover. (Section Magnetic screwdriver 5.6.1)

  • Page 66: Dismounting The Electronic Card

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 5.6.3. Dismounting the electronic card OPERATION ORDER COMPONENT REQUIRED TOOL KIT Turn the system power OFF and close the gas valve 3.1 Remove the front cover. (Section 5.6.1) 3.2 Remove the control panel (Section 5.6.2)

  • Page 67: Dismounting The Ignition Electrode

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 5.6.4. Dismounting the ignition electrode OPERATION ORDER COMPONENT REQUIRED TOOL KIT Turn the system power OFF and close the gas valve 4.1 Remove the front cover. (Section 5.6.1) 4.2 Remove the electrode protection...

  • Page 68: Dismounting The Venturi

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 5.6.5. Dismounting the venturi OPERATION ORDER COMPONENT REQUIRED TOOL KIT Turn the system power OFF and close the gas valve 5.1 Remove the front cover. (Section 5.6.1) Remove the screws (1) and...

  • Page 69: Dismounting The Burner And Cleaning The Combustion Chamber

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 5.6.7. Dismounting the burner and cleaning the combustion chamber OPERATION ORDER COMPONENT REQUIRED TOOL KIT Turn the system power OFF and close the gas valve 7.1 Remove the front cover. (Section 5.6.1)

  • Page 70: Dismounting The Condensate Siphon

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 5.6.8. Dismounting the condense siphon OPERATION ORDER COMPONENT REQUIRED TOOL KIT Turn the system power OFF and close the gas valve 8.1 Remove the front cover. (Section 5.6.1) Remove the clamp (1) and...

  • Page 71: Dismounting The Ntc Sensors

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 5.6.9. Dismounting the NTC sensors OPERATION ORDER COMPONENT REQUIRED TOOL KIT Turn the system power OFF and close the gas valve 9.1 Remove the front cover. (Section 5.6.1) Flow water...

  • Page 72: Dismounting The Safety Thermostat

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 5.6.10. Dismounting the safety thermostat OPERATION ORDER COMPONENT REQUIRED TOOL KIT Turn the system power OFF and close the gas valve 10.1 Remove the front cover. (Section 5.6.1) 10.2 Remove the connector (1)

  • Page 73: Dismounting The Waste Gas Sensor

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 5.6.11. Dismounting the waste gas sensor OPERATION ORDER COMPONENT REQUIRED TOOL KIT Turn the system power OFF and close the gas valve 11.1 Remove the front cover. (Section 5.6.1) Disconnect the electrical 11.2...

  • Page 74: Dismounting The Gas Valve

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 5.6.12. Dismounting the gas valve OPERATION ORDER COMPONENT REQUIRED TOOL KIT Turn the system power OFF and close the gas valve 12.1 Remove the front cover. (Section 5.6.1) Remove the screws (1) connecting 12.2...

  • Page 75: Dismounting The Water Pressure Switch

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 5.6.13. Dismounting the water pressure switch OPERATION ORDER COMPONENT REQUIRED TOOL KIT Turn the system power OFF and close the gas valve 12.1 Remove the front cover. (Section 5.6.1) 12.2 Remove the connection tube nuts (1) 2 screws...

  • Page 76: Troubleshooting

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 6. TROUBLESHOOTING 6.1. ERROR MODE If there is a fault in any heating unit, the screen will flash. The procedure for fault identification is as follows. Procedure Display 1. If there is one or more errors on the screen, the screen will flash.
  • Page 77 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Cause Control and Resolution E 25 Unable to read EEPROM Reinsert the master card E 23 Temperature readout value is outside the limits Reinsert the master card E 24...

  • Page 78: Unexpected Errors And Measures

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Slave error list, Automatic reset Cause Control and Resolution E 33 Operation and neutral run in reverse Fix operation and neutral connection E 34 Reset key error Wait until the error disappears when the reset...
  • Page 79 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN PROBLEM CAUSE SOLUTION Burner gas pressure Check setting values Diaphragm is not suitable (LPG) Check diaphragm diameter Irregular combustion Burner and heat exchanger are not Check, clear clean Entries to the heat exchanger are...
  • Page 80 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN PROBLEM CAUSE SOLUTI There is air in the system Bleed the system air The boiler reaches the desired Pump is blocked temperature but the system is cold Check the pump, replace if...

  • Page 81: Installation

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 7. INSTALLATION 7.1. DEVICE HANDLING AND ACCESSORIES AVAILABLE BEFORE DELIVERY Transport After the device package is opened, it must be handled and lifted by 2 people as in Figure 7.1.

  • Page 82: Adaptation To Previous Devices

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 3. Natural waste is also possible without using a fan when the upper vent hole is open to the atmosphere in boiler rooms with forced ventilation. However, it is absolutely not possible to use in the application where the lower vent hole is natural and the upper vent hole is with fan, since it creates a negative pressure in the vent hole application.

  • Page 83: Hydraulic Connections

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Values of water to be used Can be set between 6-8 Electrical conductivity (25ºC) Less than 200mV/cm Chloride ions Less than 50 ppm Sulfuric acid ions Less than 50 ppm Amount of iron Less than 0.3 ppm...
  • Page 84 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Note: In case of using the original installation components of the device, the installation is done according to the original installation connection documents. After water is filled; - Make sure the valves are open.
  • Page 85 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 100kW < devices hydraulic installation (figure 7.4) - 1 gas manifold 45 mm (must be at least 300 mm above ground) - Water flow manifold 45 mm (must have socket connection)
  • Page 86 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 100kW > devices hydraulic installation (figure 7.5) - 1 gas manifold 3” (must be at least 300 mm above ground) - Water flow manifold (insulated) 3” (must have socket connection) 3”...
  • Page 87 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Under device pump kit (figure 7.6) 1. Gasket 1" (3 pieces) 2. Return tube (1 piece) 3. 1" brass reduction M-M (1 piece) 4. Reverse return blocking valve (1 piece) 5.
  • Page 88 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Gas cutting kit can be used in systems with hydraulic mixer. Systems with kit do not require safety valve. If the kit is attached to the left or right of the installation, it does not create any problems.
  • Page 89 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Water flow line (Figure 7.8) Service Administration 03/2010...
  • Page 90 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 11. Water flow manifold (gooseneck) 3" 12. Gas cutting system thermometer inlet (1/2") 13. Bend (1/4”9 M-F 14. Gas cutting system pressure gauge connection with 3/8" tap 15. Spiral copper pipe for manometer 16.
  • Page 91 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Water return line (Figure 7.9) 16. Water return manifold (DN 80 PN 6/PN16) Gas manifold (Figure 7.8) Gas cut-off valve connection 2” and 98 C adjustable –(flange connection) 17. /18 19 Nipel 2”...
  • Page 92 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Installation guide (for 400 kW <) (figure 7.10) First of all, install the hydraulic manifold (code_110 2409 (manufacturer code) to the wall using the suspension brackets (Given in Appendix I) (Carcass-systems are connected to the carcass) Remove the protective plastic cover on the hydraulic manifold flanges and adjust the flanged inserts and the hydraulic kit with hydraulic separator.
  • Page 93 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Installation of the low temperature circuit (figure 7.11) Low temperature circuit kit (code_110 2409 (manufacturer code) is given in Appendix I)); it comprises of a sensor and 3-way mixing valve.

  • Page 94: Gas Connections

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 7.6. GAS CONNECTIONS - The device works with natural gas or LPG. Gas connections must be made in accordance with the relevant standards. Following points must be observed before making connection: - The device to be connected and the gas type must be the same.
  • Page 95 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Service Administration 03/2010...
  • Page 96 IA: Analog input 0-10 V terminals (14-13) TA1: High temperature system (zone) room thermostat terminals (12-11) TA2: High temperature system (zone) room thermostat terminals (10-9) HK 50 M – HK 100 M TERMINALS ON MASTER CARD 230v-50hZ ATTENTION The following measurements and rules must be observed.

  • Page 97: Filling Water

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 7.8. Water Filling/Bleeding the Water Circuit/ Filling Water into the System: It does not contain a filling tap to fill water into the system. Therefore, a valve connected to the return line is used in the filling process.
  • Page 98 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Emptying the Water in the System: Make sure the valves are open in the water circuit Connect the drain hose to the drain plug in the return line (Figure 2.10 (component 5)) Switch the 2-way valve of each heating unit to the “MANUEL”...

  • Page 99: Waste Gas Discharge And Combustion Air Supply

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 7.9. WASTE GAS DISCHARGE AND COMBUSTION AIR SUPPLY Waste gas installation and flue connection should be made according to the standards and rules applied by gas companies. In applications over 50kW, in the systems connected to the waste gas flue with collector, for each heating unit it is necessary to use the waste gas flue cover recommended by DD.
  • Page 100 SERVICE BULLETIN 1 unit (50 kW) B23 type in the HK 50 M heating system, i.e. combustion air from the environment (Here, the gas company rules must be complied with and the vent hole conditions given in Article 7.2 must be ensured).
  • Page 101 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Service Administration 03/2010...
  • Page 102 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Service Administration 03/2010...
  • Page 103 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 7.9.2. Arrangement of condense drainage (Figure 7.28) In the normal operation of Maxicondense boilers, as a result of combustion with atmospheric pressure, condense is sent to the drainage from inside the device. However, under high temperature cycling...

  • Page 104: Valve

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 7.9.3 Valve (Figure 7.11) In applications above 50 kW, there must be valve between the waste gas system and the device. The table below gives the maximum flue heights for the DN 125 flue diameter.

  • Page 105: Outdoor Air Sensor Connection

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 7.10 OUTDOOR AIR SENSOR CONNECTION The outdoor air sensor is the basic part that automatically regulates the heating. The following steps should be followed for installation: The outdoor air sensor protection cover is removed and the connection terminals and screw nuts are accessed.
  • Page 106 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Measured temperature - corresponding resistance values Observed temperature ( C) - Sensor measurement resistance (ohm) R (ohm) R (ohm) (ohm) (ohm) (ohm) R (ohm) 67739 10382 2365 25044 4751...

  • Page 107: Appendix A-Main Components

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN APPENDIX A- MAIN COMPONENTS 1. Fan 2. Fresh air intake 3. Gas valve 4. Waste gas outlet pipe 5. Waste gas measuring point 6. Installation outlet (flow) sensor 7. Safety thermostat 8.
  • Page 108 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN APPENDIX B DEVICE MEASUREMENTS AND WEIGHT HK 50 M HK 100 M HK 100 S Width (W) Depth (D) Height (H) 1000 1000 1000 Net Weight [kg] Service Administration...
  • Page 109 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN APPENDIX C- TECHNICAL INFORMATION TABLE Maxicondense Definition Unit HK 50 M HK 100 M HK 100 S Fuel type G20 - G30 - G31 Device category II2H3 + Device type B23 - C63 Thermal load (Min.

  • Page 110: Appendix D - Hydraulic Circuit

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN APPENDIX D - HYDRAULIC CURCUIT 1.Fan 2.Gas valve 3. Automatic air relief cock 4.Burner 5.Heat exchanger 6.Condensate container 7.Discharging tap 8. Water differential 9. Safety valve (5.5 bar) pressure switch...

  • Page 111: Appendix E- Ntc Sensor Positions

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN APPENDIX E- NTC SENSOR POSITIONS Service Administration 03/2010...

  • Page 112: Appendix F- Pumps

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN APPENDIX F- PUMPS Boiler max. Water pressure 6 m WSS Pump circulation min: 2 m3/hr (For each pump SZ1 (High heating circuit flow sensor), SZ2 (Low heating circuit flow sensor) and SB (Boiler sensor) cables are connected together before entering into the boiler.
  • Page 113 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN APPENDIX G- ELECTRIC DIAGRAMS G.1 Maxicondense 50 M -100M (Master card - Manufacturer code: R105920) Note: Manufacturer's code. Manufactured in 2 different codes. Code on the card should be read.
  • Page 114 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 2nd section SYSTEM BOILER PB: Boiler pump VG: Gas valve PZ1: High temp. heating circuit pump TS: Safety thermostat PZ2: Low temp. heating circuit pump PD: Water differential pressure switch...
  • Page 115 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN G.2 Maxicondense 50 M -100M (Master card - Manufacturer code: R107854) Note: Manufacturer's code. Manufactured in 2 different codes. Code on the card must be read. 1st section Note: Pumps should be connected with appropriate connectors for emergency response situations.
  • Page 116 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Section 2: SYSTEM BOILER PB: Boiler pump VG: Gas valve PZ1: High temp. heating circuit pump TS: Safety thermostat PZ2: Low temp. heating circuit pump PD: Water differential pressure switch...
  • Page 117 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN G.3. Maxi condense 100 S Section 1 Note: Pumps should be connected with appropriate connectors for emergency response situations. Service Administration 03/2010...
  • Page 118 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN VG: Gas valve TS: Safety thermostat PDF: Water differential pressure switch SM: Outdoor air sensor SR. Return water sensor SF: Waste gas sensor EA/ER: ignition/surveillance electrode C: Two-way valve or pump under device IG.

  • Page 119: Appendix G- Electrical Diagrams

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN APPENDIX H - ELECTRICAL CONNECTIONS Master card terminal connection ATTENTION The following measurements and rules must be observed. 1. Cut off the main switch connection using the multi-polar thermal overload switch (Compatible with the CEI-EN standard) (contact gap is minimum 3mm) 2.
  • Page 120 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN CODE COMPONENT NAME TERMINAL 27-28 DHW (Domestic water) system pump 1st system (80ºC/60ºC) pump 25-26 2nd system (50ºC/30ºC) pump or loop pump PZ2, Pbas 23-24 20-21-22 Mixing valve (Balancing valve)
  • Page 121 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Contact should be avoided between the conductive leads used for the connection cable used between the sensor and the card and the power cable. If outdoor air sensor is not to be installed, Parameters 14 and 22 should be set to 0.

  • Page 122: Appendix H - Electrical Connections (System, Outdoor Air Sensor, Room Sensor, Remote Control)

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Before connecting the 3-wire connection cable (D) to the terminal (F), take it through the hole (E) by passing it under the rear panel (B) and connect it to the terminal (F). (Cable will be 0.5 and 1mm2 cross section.)
  • Page 123 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Figure H 5 Remove (I) screws, remove the front panel by moving the front panel forward and up. , remove 4 (Figure 6 –N) screws and Figure H 6 (M) tilt the main panel towards yourself for 90 remove the panel from the rear side.
  • Page 124 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Remote control Remote control; while following the connection to the device master card, observe the main system parameters and make changes in the program. (Time programming, operating times for 3 circuits (high temperature, low temperature and boiler), pump statuses, installation outputs etc.) Main characteristics of the...
  • Page 125 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Controlling of the remote control The images displayed on the remote control screen are numbered. Separate information are provided below. First image; (Figure H12) Displays information about the system.
  • Page 126 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN When an option is selected, the Active message will appear. Relevant menu data are entered with on/off. (Example CH 1 value is reached) If you want to switch to another screen in the menu, continue with "Continue".
  • Page 127 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN General Menu: Main display ((S) - Remote control's display menu), press "OK" button, Figure H 14 MENU screen is accessed. This screen has 4 submenus. These sub menus are accessed by using the cursors It is accepted by pressing "OK"...
  • Page 128 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Language is English and Italian. Since the English terms are used more frequently, English menu translation has been done. Date is the year, month, day, and hour-second setting is made. Press "ok" key to finish the setting.
  • Page 129 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN INSTALLATION mode This mode (Figure 19) is entered to modify the parameters of the boiler and the boiler heating circuit. (These values can be changed by entering the password by the service staff) Heating circuit controls (See Figure H 20-H21) Control circuits >...
  • Page 130 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN High temperature (80/60 ºC system) circuit: CH 1 Low temperature (50/30 ºC system) circuit: CH 2 Boiler circuit: San* (If no boiler is connected to the system, Parameter 6 = 0 and San is not displayed on the screen) Parameters related to three heating circuits can be controlled by remote control.
  • Page 131 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN If a boiler is connected to the system; Select Control circuit > San as in Figure H 24, it is entered as On and to remove the Legionella bacteria thermally, system Antilegionella 70 ºC adjustment is made.
  • Page 132 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN When the "OK" key is pressed in the Complete list key, it is possible to enter and change 1-43 parameters (shown on pages 31 and 32). POWER- Power related parameters.
  • Page 133 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN The first screen will appear (Figure H 29) Figure 29 shows that the example display where it will work every Monday from 20:00 to Wednesday 22:00. With the cursor keys, the date and time settings are made.
  • Page 134 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Attenuation function activation in the central heating circuit Delay parameter, in CH 1 and CH 2 heating circuits, the delay temperature value in (Menu > Installation > on/off active > continue) mode is always activate. (This value is entered with the parameters 21 and 25) Normally a delay temperature of 5 ºC difference is appropriate.
  • Page 135 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN On the information display about the system; If on the first screen, it the user desires to get info on the number of boilers in the system, the number of working burners and more information there is a 2-digit cursor to enter the number of each boiler.
  • Page 136 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Heating circuit temperature information (measured º C > set water temperature º C (1/5 screen) figure H 37 (shows 3 system information) In this chapter; it is the display that indicates the water temperature value set by the measured water temperature value in the desired heating circle.
  • Page 137 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Other information (Display 3/5) If the cursor moves forward , 3/5 screen will appear. In Figure H 39, in the screen 3/5 shown 70 º C: Legionella protection is on and the temperature is set to 70 º C Antileg.
  • Page 138 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Display of the total working hours of the system: (Figure H 41) Defines the final set value related to the operating time of the system. (For example, 40,000 hours - figure H 41) This function will be able to be restarted from the ANA software A05 version.

  • Page 139: Appendix I - Accessories

    HK 50 M – HK 10M – HK 100S SERVICE BULLETIN APPENDIX I - ACCESSORIES Accessory Code Waste gas kit 50kW (DN125) 1102819 Waste gas kit 100kW (DN125) 1102389 Condensate kit (DN125) 1102809 Service Administration 03/2010...
  • Page 140 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Hydraulic mounting kit <100kW 1102399 Hydraulic mounting kit >100kW 1102409 3" flange (for hydraulic kit > 200kW interconnection) 1102579 Service Administration 03/2010...
  • Page 141 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN 3” Blind flange (Hydraulic kit > 100kW blind flange) 1102589 Remote control kit 1102379 Pump kit 1102419 Service Administration 03/2010...
  • Page 142 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Fresh air connection kit 50kW (When fresh air must be taken from the outdoor environment) 1102439 Fresh air connection kit 100kW (When fresh air must be taken from the outdoor environment)
  • Page 143 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Polypropylene bend DN 125 90º bend Code Number 1102689 45º bend Code Number 1102769 ISPESL Kit and Hydraulic mixer Service Administration 03/2010...
  • Page 144 HK 50 M – HK 10M – HK 100S SERVICE BULLETIN Service Administration 03/2010...

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