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Assembly and operating instructions

1. 13 53 83 HHHHHE H HHHEB 3062555 201507 40 Wi Balanced flue routing Versions Maximum length m CGB 75 CGB 100 B23 in a duct and combustion DN 110 23 directly via the boiler open flue DN 110 160 50 B23 Two boiler cascade flue in a duct and DN 110 45 combustion air directly via the boiler open flue B33 Flue in a duct with horizontal DN 110 23 2 concentric connection pipe open flue DN 110 160 50 B33 Connection to a moisture resistant flue chimney with horizontal Calculation according to EN 13384 concentric connection pipe open flue balanced flue manufacturer 13x Horizontal concentric roof outlet through a pitched roof DN 110 160 14 14 balanced flue on site dormer 33x Vertical concentric roof outlet through a pitched roof DN 110 160 14 14 or flat roof balanced flue 43x Connection to a moisture resistant balanced flue chimney LAS flue Calculation according to EN 13384 Maximum pipe length from the centre of the boiler bend to the connector 2 m balanced flue manufacturer balanced flue C53 Connection to the flue in a duct DN 110 23 23 and ventilation air line through an external wall balanced flue DN 110 160 50 50 C53x Connection to a flue on an extern
2. 26 Commissioning setting the BUS address 27 Displaying modifying control 5 28 Adjusting the modulating 29 Limiting the maximum 30 Testing the combustion 5 31 CO adjustmelils cab ied 32 33 COMMISSIONING 34 Maintenance see maintenance instructions provided Maintenance and design data 35 36 Design 11 doute tede 37 49 Watertreatment on dre teret inne pesa esas ax dv 37 38 System 0 39 Design informato N 25552 5 a ie 40 49 50 m PEE 51 TROUDIC SHOOTING Eccc 52 53 Product fiche according to Regulation EU 811 2013 54 Technical parameters according to EU regulation no 813 2013 55 EC declaration e ee ear 56 3062555_201507 Wi The following symbols are used in conjunction with these importan
3. Note Provide a BDF valve at the lowest system point Safety equipment The minimum system pressure is 1 0 bar The gas condensing boiler is approved exclusively for sealed systems of up to 6 bar The maximum flow temperature is factory set to 80 and may be adjusted to 90 if required Generally the flow temperature is 80 for DHW operation Heating water General requirements There is a danger of damage to the wall mounted boiler leading to the escape of water poorer heat transmission or corrosion The heating system is to be flushed through before the connection of the wall mounted gas condensing boiler in order to remove residues from the pipework such as welding sputter hemp putty sludge deposits etc Installation of a sieve dirt trap in the return and regular maintenance of the sieve dirt trap see Wolf accessories 5 um The automatic vent of the appliance must be open during operation The max air volume of 100 l min 6000 l h may not be exceeded Potable water or saline free potable water is to be used as filling and supplementary water The hardness of the system water may not fall below 2 The system specific filling and supplementary water qualities are to be taken from the section Water treatment planning notes A hydraulic separator must be provided for if the entry of oxygen cannot be excluded The pH value of the heating water must lie between 8 2 and 8 5 n g
4. 3062555 201507 Wi Condensate drain connection Installation Connect the siphon supplied to the connector on the combustion chamber pan Please note The siphon must be filled with water prior to commissioning If condensate is directly routed to the public sewer ensure ventilation so that the public sewer cannot affect the condensing boiler Figure Siphon There is a risk of poisoning through flue gases being N expelled if the appliance is operated with an empty siphon Therefore fill the siphon with water prior to commissioning Undo the siphon remove and fill until water runs out of the drain hole on the side Refit the siphon and ensure the gasket seals tightly The condensate must only be routed through pipes that are resistant Observe the relevant instructions if you install a neutralising system accessory Figure Neutralising system accessory Condensate pump When using a condensate pump the alarm output can be connected at connection E1 Set the boiler parameter HG13 to 2 The alarm output switches the appliance OFF condensate cannot be pumped out correctly 3062555 201507 15 Wi Gas connection Routing the gas pipe as well as making the gas connections must only be carried out by a licensed gas fitter Close the gas ball valve on the condensing boiler to pressure test the gas pipe Remove all residues from the heating pipework and the gas pipe prior to con
5. Calculating the balanced flue length The calculated length of the balanced flue system or the flue is derived from the straight pipe length and the length of the pipe bends In this calculation a 90 bend or a 87 tee is calculated as being 2 m and a 45 bend as being 1 m Example Length of straight balanced flue 1 5 m Inspection tee 87 2 2 45 bends 2 x 1 L 1 5m i1x2m 2x1m L 5 5m Tee 87 with 2m inspection aperture Straight pipe Subject to length Table Pipe length calculation 3062555 201507 Wi Design information Balanced flue route vertical and concentric examples 3a Ta 10 11 12 13 14 15 16 17 18 19 20 in accordance with local regulations 150 cm or 2 x 75 Gas condensing boiler Gas condensing boiler connection C DN 110 160 Inspection piece 287 Inspection piece 87 tee Pipe clip DN 160 Balanced flue DN 110 160 c 8 500 mm E 1000 mm 2000 mm Mounting bracket DN 160 for roof outlet Universal tile for pitched roof 25 45 Klober adaptor 20 50 Flat roof collar Balanced flue routing vertical roof outlet for flat or pitched roof 2000 mm 45 bend DN 110 160 87 bend DN 110 160 87 bend for duct installation DN 110 160 Wall support bend F87 with smooth ends on both sides of the air pipe DN 110 160 Air inlet external wall F DN 110 160 PP wall outlet external wall F Wall bezel
6. Wi Assembly and operating instructions Gas condensing boiler CGB 75 Wall mounted gas boiler 100 Wall mounted gas boiler Wolf GmbH Postfach 1380 D 84048 Mainburg Tel 49 8751 74 0 Fax 49 8751 741600 Internet www wolf heiztechnik de Document no 3062555 201507 Subject to modifications Index gum T were T E MTM 3 Standards epe actae 4 5 Control Function Operation 6 7 Delivered condition standard 8 Layout COB 7597C OGB A00 9 11531211 1614 euo 10 11 Dimensions installation 12 I MEME IM LM MIL otc 13 16 Installation of the balanced flue system 17 Power connection 18 21 FIIO iare cis p Tc 22 Conversion to natural gas 520 525 23 Conversion to liquefied petroleum gas P G31 24 Conversion to other gas 25 Checking the gas supply pressure
7. downstream of diverters to prevent the pipe joints being pulled apart If this is not observed there is a danger of poisoning caused by escaping flue gas Furthermore equipment damage may result 43 Wi Flue gas temperature limiter The electronic flue gas temperature limiter switches the oil condensing boiler off when the flue gas temperature exceeds 110 C The boiler restarts when the reset button is pressed Connection to the balanced flue The unobstructed cross section of flues must be able to be inspected Therefore install an inspection and or test aperture inside the boiler room agree suitable arrangements with your local flue gas inspector Flue connections are created using couplings and gaskets Always arrange couplings against the direction of the condensate flow The balanced flue should be installed with N a slope of at least 3 6 cm m to the gas condensing boiler Install spacer clamps to secure the location see installation example In the worst case scenario a lesser slope of the balanced flue may lead to corrosion or operating faults Generally bevel or deburr trimmed flues to ensure a gas tight installation of pipe joints Ensure that gaskets are correctly fitted Remove all contamination prior to installation never fit faulty parts Between the flue terminal and the roof surface as of a rated output of 50 kW there must be a clearance of at least 1 0 m 44 Design information
8. ey y Settings 2 8 correspond when factory set to a heating water temperature of 20 80 C 2 gt The heating water thermostat setting becomes ineffective when the system is combined N with a digital room thermostat a weather compensated controller 6 3062555 201507 WL Setting niu Anti seizing pump protection Note 3062555 201507 Control Function Operation Winter mode settings 2 to 8 In winter mode the boiler heats to the temperature selected at the heating water temperature controller According to the pump operating mode the circulation pump operates constantly factory setting or only in parallel with the burner activation run on period Summer mode Winter mode is disabled by rotating the heating water temperature selector into position niu The boiler then operates in summer mode Summer mode heating OFF means only DHW heating Frost protection for the heating system and pump anti seizing protection however remain enabled Emissions test mode Emissions test mode is activated by rotating the heating water temperature selector into position A The illuminated signal ring flashes yellow After the emissions test mode has been activated the boiler will heat with the selected maximum heating output Any previous cycle block will be cancelled The emissions test mode terminates after 15 minutes or when the maximum flow temperature has been exceeded To reactivate turn the heating water t
9. heat exchanger and cylinder Max flow rate Excessive flow velocities may lead to erosion Maximum flow rate at Qmax CGB 75 100 6000 I h 100 l min Connection types Boiler Type Operating mode Can be connected to Open flue Balanced Moisture resistant Balanced Balanced Certified Moisture chimney flue flue balanced resistant flue chimney flue B23 B33 C13x X X B33 C53 C83x 43 C13x B23 C53x 75 100 C33x C43x C53 C33x C53x C83x C93x C53x C63 C83x C93x Category Germany ll g Austria Il2 3p Switzerland lz Mark x indicates that all components of the flue are munde by combustion air and meet higher requirements for gas tightness 2 Fortype B23 B33 the combustion air is drawn from the boiler room open flue combustion equipment For type C the combustion air is drawn through a sealed system from the outside balanced flue combustion equipment 36 3062555 201507 Wi Before commissioning the system must be thoroughly cleaned flushed through and a sludge filter 5 e g Wolf accessories installed in the return and in direct proximity to the boiler The filling and supplementary water may be treated only by means of a desalting procedure The degree to which water treatment is necessary can be taken from the Water treatment diagram and the Maximum permissible total hardness table The total degree of hardness of the system water may not fall below 2 dH th
10. Burner starts 20 per Flow rate through the heat exchanger too low or Check the flow rate 37 38 39 hour in case of cascade measuring point of the header Header sensor must measure the common temperature unsuitable or power consumption of the feed temperature of the cascade calorifier charging too low coding card coding card lonisation current The siphon is blocked or the flue gas system is Clean siphon check flue gas system m E 50 52 fluctuates blocked severe storm check ventilation air check monitoring electrode Poor gas quality monitoring electrode faulty severe storm ionisation electrode earthed casing electrode to burner Press reset 3062555 201507 53 Product fiche according to Regulation EU no 811 2013 Wi Product group CGB 75 100 Supplier s name or trade mark Wolf GmbH Supplier s model identifier Seasonal space heating energy efficiency class Rated heat output Seasonal space heating energy efficiency Annual energy consumption for space heating Sound power level indoors Any specific precautions that shall be taken when the space heater is assembled installed or maintained See installation instruction Wolf GmbH Postfach 1380 D 84048 Mainburg Tel 49 8751 74 0 Fax 49 8751 741600 Internet www wolf heiztechnik de Material number 3020294 03 2015 Technical parameters according to W EU regulation no 813 2013 m Condensing bolle Cogeneration
11. OFF Output A1 is constantly cycled in 5 minute intervals when no accessory controller is installed 3 DHW circulation pump 20 Output A1 is activated in cycles by control accessories timed if DHW has been enabled 2 minutes ON and 8 minutes OFF Output A1 cycles constantly when no accessory controller is installed Alarm output Output A1 is activated 4 minutes after a fault Flame detector Output A1 is activated after a flame has been recognised Cylinder primary pump factory setting for A1 Output A1 is activated during cylinder heating Ventilation air damper Output A1 is activated before each burner start The burner will however only be enabled after input E1 has been closed m Important In any case input E1 must also be programmed as Ventilation air damper For the feedback to input E1 use a zero volt contact 24 V Otherwise use an on site relay for potential separation External ventilation Output A1 is activated inverted to the gas combination valve Switching off external ventilation equipment e g extractor fan during burner operation is only required if the boiler is operated as an open flue system External LPG valve Output A1 is activated in parallel to the gas combination valve External pump Output A1 switches synchronously with the heating circuit pump HKP used for example with system separation 20 3062555 201507 Wi Electrical connection Connection input E1 24 V zero
12. at a pressure 1 0 bar combustion chamber increase system Combustion chamber cover pressure check dirt filter safety temperature limiter 4 No flame established No flame established during burner start Check gas supply line open gas tap if necessary Check ignition electrode and ignition cable Press reset button 5 Flame failure during Flame failure within 15 s after Check CO values operation flame recognition Check ionisation electrode and cable Press reset button TW excess temperature The flow return temperature has exceeded the limit for Check the system pressure Vent the system the TW shutdown temperature Set the pump to stage 2 or 3 TBA excess temperature The flue gas temperature has exceeded the Clean the heat exchanger limit for the TBA shutdown temperature Overpressure Flue gas system is blocked Check the flue gas system in the flue gas system Ventilation air is blocked Check the ventilation air Faulty flow sensor The sensor for the flow temperature or the cable is Check lead faulty or the Check flow sensor Gas pressure too low gas pressure than the selected value at the gas Check gas pressure governor only displayed after 15 min Check gas governor accessory EE Cylinder sensor faulty DHW temperature sensor or lead faulty Check sensor and lead 15 Faulty outside The outside temperature sensor or lead is faulty Check lead NE Return sensor faulty The return temperature sensor or lead
13. installing an intermediate heat exchanger Note from VDI 2035 Limescale formation can be influenced above all through the type and method of commissioning Heat up the system at the lowest power with an even and sufficient flow rate In the case of multi boiler systems it is recommended to put all boilers into operation at the same time so that the total amount of lime cannot concentrate on the heat transfer surface of an individual boiler Information on scaling Scaling can be strongly influenced particularly through the method of commissioning Heat the system at the lowest output with an even and adequate throughput For multi boiler systems itis recommended to commission all boilers simultaneously to prevent the overall amount of lime concentrating on the heat exchanger surface of an individual boiler Before commissioning all hydraulic pipes must N undergo a tightness test Test pressure on heating water side max 8 bar Prior to testing close the shut off valves in the heating circuit for the appliance because otherwise the safety valve accessory opens at 3 bar The appliance has already been tested at the factory for tightness at 6 bar If the appliance is not watertight there is a risk of leaks and resulting material losses The maximum flow rate must not exceed 6000 1001 min With a specific system volume of gt 50 I KW the total degree of hardness must be adjusted to 2 3 using a desalting process
14. is faulty Check lead a wins ictor Ec EE 20 Fault gas valve 1 A flame is recognised for 15 seconds after burner Replace the gas combination valve operation even though gas valve 1 has received a shutdown command Fault gas valve 2 A flame is recognised for 15 seconds after burner Replace the gas combination valve operation even though gas valve 2 has received a shutdown command speed fan Press reset fan Press reset fan Press reset NEM condensing boiler If unsuccessful replace the control unit PCB Edidi NI 17 If unsuccessful replace the control unit PCB Es e g short circuit 38 CRC fault default values The EEPROM record Master reset is invalid Replace the control unit PCB 2 3062555 201507 Wi Troubleshooting Fault Cause Remedy code CRC fault BCC Faulty boiler coding card Replace boiler coding card BCC missing Boiler coding card was removed Fit the correct boiler coding card CRC fault BCC Faulty boiler coding card Replace boiler coding card Incorrect BCC The boiler coding card is incompatible with the control Fit the correct boiler coding card unit PCB BCC no invalid Faulty boiler coding card Replace boiler coding card BCC system error Faulty boiler coding card Replace boiler coding card 41 Flow monitoring Return temperature Flow 25 K Vent heating system check system pressure Check heating circuit pump
15. is low enough With a specific system volume gt 10 I KW the next smaller value from the following table must be applied with gt 20 I KW the next but one smaller value and with V sys specific gt 40 I KW the smallest value With a specific system volume of gt 50 I KW the total degree of hardness must be adjusted to 2 3 using a desalting process This corresponds to a conductance of 60 100 uS cm If the boiler is integrated into the system without a low loss header the total hardness must be adjusted to 2 3 dH conductance 60 100 uS cm Limit values in relation to the specific system volume Vs system volume lowest individual power setting Conversion of total hardness 1 mol m 5 6 dH lt 10 I KW Total hardness Conduct total alkaline earths ance Total heating 2 16 8 0 36 3 0 60 500 2 112 0 36 2 0 60 300 0 36 0 54 60 100 2 50 200 2 11 2 0 36 2 0 60 300 0 36 1 5 60 200 200 600 2 8 4 0 36 1 5 60 200 0 36 0 54 60 100 0 36 0 54 60 100 4 0 60 100 0 36 0 54 60 100 0 36 0 54 60 100 0 36 0 54 Vsys gt 10 I kW and lt 40 1 gt 40 I KW Total hardness Conduct Total hardness Conduct total alkaline earths ance total alkaline earths ance mol m Cond dH mol m Cond dH mol m Cond uS cm uS cm uS cm 3 0 36 0 54 60 100 for circulating water
16. of the heating circuit pump accessory The pump modulates subject to burner load See diagrams for residual height Maintenance and design data CGB 75 100 residual head with pump assembly accessory 900 800 700 600 500 400 300 200 100 Residual head mbar 0 500 1000 1500 2000 2500 3000 3500 4000 4500 Water volume Hydraulic pressure drop in the boiler excluding pump CGB 75 100 pressure drop 300 280 260 240 220 200 180 160 140 120 Maximum 100 water volume 80 60 20 spread 40 20 Pressure drop mbar 0 500 1000 1500 2000 2500 3000 3500 04000 4500 5000 5500 6000 Water volume I h 3062555 201507 35 Wi Sensor resistances Maintenance and design data 100000 10000 1000 Resistance Ohm 100 20 10 0 10 20 30 40 50 60 70 80 90 100 110 120 Temperature pressure drop 0 16325 15 7857 30 4028 60 1244 5 12697 20 6247 40 2662 70 876 10 9952 25 C 5000 50 C 1800 80 C 628 Max spread Aheat exchanger protection function is integrated into the CGB 75 100 This prevents stresses in the material by limiting the maximum temperature differential between the flow and return As of 28 K the output is reduced If 38 K is nevertheless reached the burner shuts down briefly without a fault message This characteristic must be taken into account when selecting the components e g pumps
17. of the potable water e g from an analysis of the water supply Checking the specific system U KW VA specific Vsystem QBminimum volume specific greater less than 10 I kW Permissible total hardness Maximum permissible total hardness Cmax according to the table Proportion of desalinated potable 100 Cmax 0 1 dH water A Couw 0 1 x 100 Fill water to be treated Vireatment A X Vmax V treatment or V treatment X V system at stage 4 Commissioning filling and supplementary water Name of commissioning company Meter reading before initial filling in Meter Quantity of Total pH value of system di hard water after heating Date Explanation Abbreviation Znew in V Znew Zoa n in dH sufficient flushing Signature EN Desalted filling water NEM Untreated filling water EE Supplementary water mE Supplementary water MEM Supplementary water EN Supplementary water EN Supplementary water Supplementary water Supplementary water EE Supplementary water Supplementary water BENE Supplementary water Testing Water volume V gt Vmax Yes If the water volume V is greater than Vmax top up with desalinated water 3062555 201507 39 Design information Wi Balanced flue routing
18. power cable insulation Push the cable through the strain relief and secure the strain relief Terminate the appropriate cores at the Rast 5 plug Push the inserts back into the terminal box casing Push the Rast 5 plugs back into the correct positions Electrical connection The power supply terminals are live even when the ON OFF switch has been switched OFF LIN N 1 L1 N IN L1 11001 011010 Power supply Programmable Programmable Outside 230 V AC 50 H output input temperature 230 V AC 50 Hz zero volt sensor max 200 VA BUS External pump on site controller radio clock AF with radio 230 V 50 2 300 VA clock receiver outside radio sensor La Strain relief Terminal box factory set 18 3062555_201507 Wi Changing a fuse Isolate the condensing boiler from the power A N supply prior to changing a fuse The ON OFF switch on the boiler does not provide separation from the power supply Danger through live electrical components Never touch electrical components or contacts as long as the condensing boiler has not been isolated from the power supply Danger of death DHW cylinder sensor connection When a cylinder is to be connected the blue socket of the cylinder sensor must be connected to the blue plug of the control unit Observe the cylinder installation instructions Connection external heatin
19. restrictor must be replaced 4 4 X Screws SW8 Undo the gas combination valve from the mixing chamber for gas air four SW8 screws 5 Gas restrictor Remove the built in gas restrictor and replace it by a gas restrictor designed for the new type of gas according to the table on page 25 6 28 Undo the mixing chamber from the ventilator three Allen After assembly of the gas restrictor gas combination valve screws 5 mm and remove air inlet pipe where necessary and air inlet pipe push the O ring lubricated with silicone grease into the packing groove of the fan and refit the mixing chamber Reassemble in reverse order Note if you are converting from LPG to natural gas the gas combination valve and the flue gas orifice plate must be removed before assembly see pages 24 25 3062555 201507 23 Conversion to liquefied petroleum gas P G31 if necessary Wi Mixing chamber Gas restrictor Pull out the plug 9 undo the cross head screws first Threaded gas connector 4 off screws 8 AF Remove the four 8 AF screws from the threaded gas connector and remove the threaded connector from the gas combination valve Remove the gas combination valve and the gas restrictor Attach the protective labels on the inlet and outlet of the new gas combination valve to the openings of the removed valve Undo the threaded gas connection on the gas combination valve O ring 23 4
20. 10 can 25 Airinlet pipe 110 mm be routed in a duct 26 Air pipe 160 mm Ventilation air aperture in balanced flue operation 150 cm 2 x 75 cm 46 3062555 201507 Wi Eccentric balanced flue C53 B23 Install the balanced flue distributor 110 110 mm eccentrically Downstream of the support bend 19 the flue can be routed 26 for a separate balanced flue in DN 110 inside the duct When connecting a balanced flue certified acc to Building Regulations observe the permit of the relevant body Design information 16 16 Install the horizontal flue with a slope of 21 22 28 21 approx 3 6 cm m towards the boiler 4 Pain Route the horizontal air supply with 3 slope towards the outside install the air inlet with a cowl permissible wind pressure at the air inlet 90 Pa The appliance will not 27 operate with higher wind pressure Secondary ventilation 1 Gas condensing boiler 2 Gas condensing boiler connection DN 110 160 19 Support bend DN 110 20 Support rail 21 dios pus Maintain the following clearance dias between the internal duct wall and 1000 mm the flue 2000 mm Ventilation air aperture in balanced flue operation for circular ducts 3 in accordance with local regulations 150 cm 2 x 75 for rectangular ducts 2 cm 22 Bend 87 DN 110 23 Spacer 24 Cowl 27 Balanced flue distributor 110 110 mm 28 Tee 87 with inspect
21. 108 EU EMC Directive with electronic ignition and electronic flue gas temperature monitoring for low temperature heating and DHW production in heating systems with flow temperatures up to 95 and 6 bar permissible operating pressure in accordance with EN 12 828 The Wolf gas condensing boiler is also approved for installation in garages Open flue gas condensing boilers must only N be installed in a room which complies with the appropriate ventilation requirements Otherwise there is a risk of asphyxiation or poisoning Read these installation and maintenance instructions before installing the boiler Also take the technical engineering information into consideration Figure Wolf gas condensing boiler 51 622 is to be used for operation with LPG as otherwise there is a danger of malfunctions occurring with regard to the start up behaviour and the operation of the wall mounted gas boiler whereby there is a danger of damage to the appliance and personal injuries A poorly vented LPG tank may lead to ignition problems In this case consult the LPG tank filling company Exclusively propane in accordance with DIN To protect against limescale formation the hot water temperature may be set to maximally 50 from a total hardness of 15 2 5 mol m This corresponds to a maximum hot water rotary knob setting of 6 without accessory regulator From a total hardness of more than 20 dH the use of water treatment in th
22. 160 Balanced flue routing horizontal with cowl Connection to a flue gas chimney B33 length 250 mm with air apertures Support bend 87 DN 110 for connection to a flue in a duct Support rail Art C33x Gas condensing boiler with combustion air and flue gas routed vertically via the roof Please note Lubricate the pipe ends and gaskets for easier installation Check the required inspection piece 3 mat no 2651329 with your local flue gas inspector prior to installation Ventilation air aperture for balanced flue operation 3062555 201507 45 Wi Horizontal concentric balanced flue C13x C83x and B33 and flue on an external wall C53x examples Design information 180 15 _____ Dormer 7 onsite 116 NS O 5 4 17 ucl Horizontal balanced flue routing through a pitched roof 1 5 4 where required 120 mm opening in the chimney side Install the flue airtight into the chimney side 5 5 4 5 16 Flue pipe DN 110 Install the horizontal flue with a slope of approx 900 mm 3 6 cm m towards the boiler Route the 1000 mm horizontal air supply with a 3 slope towards 2000 mm the outside install the air inlet with a cowl 22 Bend 87 DN 100 permissible wind pressure at the air inlet 90 Pa 23 Spacer The appliance will not operate with higher wind 2 pressure Downstream of the support bend the flue 110 mm or the flexible flue DN 1
23. 7 x 2 62 Gas restrictor 6 7 3 Gas combination valve Threaded gas connector Screw the threaded gas connector with O ring 26 x 4 onto the new gas combination valve for LPG Insert the new gas restrictor with the ID 6 7 into the gas combination valve Screw the gas combination valve with O ring 23 4 x 2 6 Unscrew the mixing chamber from the fan 3 off hex socket onto the mixing chamber head screws 5 mm pull off the air inlet pipe if necessary O ring Gas combination Threaded gas connector 8 AF Adhere the O ring in the sealing groove of the fan with silicone grease and mount the mixing chamber with gas Unscrew the gas combination valve from the mixing combination valve on the burner fan chamber for gas air 4 screws 8 AF Tightly screw the threaded gas connector to the gas supply pipe 24 3062555 201507 Conversion to other gas types if required Note When converting from natural gas to LPG an flue gas orifice plate must additionally be installed in the condensate pan as follows When converting from LPG to natural gas the flue gas restrictor must be removed This assembly step takes place before the installation of the mixer chamber and the complete assembly After removing the upper casing cover undo the self Flue gas orifice plate tapping screw at the balanced flue locking mechanism Place the flue gas orifice plate 53 mm into the condensate pan and insert the flue
24. PG P Hi 12 8 kWh kg 46 1 MJ kg Gas supply pressure Natural gas LPG Flow temperature factory setting Maximum flow temperature Max overall pressure heating Heating water heat exchanger water content DHW temperature range adjustable Heating water pressure drop at 20 K spread Rated output Specification Flue gas mass flow rate Flue gas temperature 50 30 80 60 Available gas fan draught Lowest heat input Flue gas mass flow rate Flue gas temperature 50 30 80 60 Available gas fan draught 8 9 36 60 12 Flue gas group according to DVGW G 635 G52 NOx category 5 Electrical connection 230 50 230 50 Integral fuse medium slow A 3 15 3 15 Power consumption W 75 130 Condensate volume at 40 30 I h 7 1 9 8 Condensate pH value approx 4 approx 4 3062555 201507 5 Wi Any faults will be displayed as fault codes by Wolf controllers with eBUS capability To these faults cause and remedy may be allocated using the following table This table is designed to allow your local heating contractor to trace the fault more easily Troubleshooting Fault Cause Remedy code TBV excess temperature The flow temperature has exceeded the limit Check system pressure check heating for the TBV shutdown temperature or the circuit pump vent the system press reset heat exchanger is extremely dirty or the water button clean heat exchanger check TB Water pressure too low pressure switch switches off
25. The product described above conforms with the requirements of the following documents Article 6 1st BlmSchV 26 1 2010 BS EN 297 01 2005 BS EN 437 09 2009 BS EN 483 06 2000 BS EN 677 08 1998 BS EN 625 10 1995 BS EN 60335 1 02 2003 BS EN 50165 2001 BS EN 55014 1 06 2007 In accordance with the regulations contained in the following directives 90 396 EEC gas appliance directive 2004 108 EC EMC directive 2006 95 EC Low voltage directive 2009 125 EG ErP directive 2011 65 EU RoHS directive the product is marked as follows 0085 Mainburg 15 07 2015 Gerdewan Jacobs p p Klaus Grabmaier Technical Director Product Approvals Wolf GmbH Postfach 1380 84048 Mainburg Tel 08751 74 0 Fax 08751 741600 Internet www wolf heiztechnik de
26. al wall balanced flue DN 110 C83x Connection to the flue in a duct and DN 110 23 23 ventilation air through an external wall balanced flue DN 110 160 50 50 C83x Concentric connection to a moisture resistant flue gas chimney and Calculation according to EN 13384 combustion air through an external wall balanced flue balanced flue manufacturer Vertical flue for installation in a duct rigid flexible DN 110 14 14 with horizontal concentric connection line DN 110 160 45 39 Available fan draught CGB 75 145 Pa CGB 100 200 Pa The maximum length corresponds to the total length from the appliance to the flue terminal 2 Expansion in the duct from DN 110 to DN 160 Design information 23 50 23 3 50 Note Systems C33x and C83x are also suitable for installation in garages Where necessary adapt the installation examples to the relevant Building Regulations and requirements of your country region Discuss any questions relating to the installation of inspection covers and ventilation apertures with your local flue gas inspector The length dimensions for a concentric balanced flue and flues relate exclusively to original Wolf components 3062555 201507 41 Wi Minimum duct sizes applicable to open flue and balanced flue operation Design information KA 8 C93x balanced flue in a duct C33x balanced flue B33 open flue 4 DN 110 in a duct DN 110 160 in a duct DN 110 C93 x balanced f
27. and frost protection the burner is enabled Open contact enables the burner again Connection digital Wolf control accessories e g BM MM KM SM1 SM2 Only connect control units from the Wolf accessory range Each accessory is supplied with its own connection diagram Use a two core cable cross section gt 0 5 mm as the connecting cable between the control unit accessory and the condensing boiler Figure Digital Wolf control accessories connection eBUS interface Connection outside temperature sensor The outside temperature sensor for digital control accessory may be connected to the terminal strip of the boiler connection AF or the terminal strip of the control accessory Figure Connection outside temperature sensor 3062555 201507 21 Wi Fill the system and vent it properly to safeguard the perfect functioning of the condensing boiler Before connecting the gas condensing boiler flush the heating system to remove residues such as welding pearls hemp putty etc from the pipework Check the dirt filter The gas tap must be closed ON OFF switch Reset button Thermometer Filling the system The locking cap on the quick acting air vent valve should not be undone Open all radiator valves Open the return valves and the heat exchanger will then be filled steadily with water from below With the entire heating system and boiler in a cold condition slowly fill the system via the in
28. ced flue systems prior to installing the flue or the balanced flue connection The flue gas test ports must remain accessible for your local flue gas inspector even after fitting the ceiling bezels With low outside temperatures the water vapour contained in the flue gas may condense and freeze on the balanced flue Prevent ice from falling through on site measures e g the installation of a snow catcher grille 3062555 201507 Figure Example Balanced flue system Installation of the balanced flue system 17 Wi General notes The installation must be carried out by a licensed electrical contractor Observe electrical regulations and those of the local power supply utility Terminal box The control regulating and safety equipment are fully wired and tested Combi boiler power supply In the case of a permanent connection provide the power supply via a mains isolator e g fuse heating system emergency stop which ensures at least 3 mm contact separation for all poles Power cable flexible 3x1 0 mm or rigid max 3x1 5 mm Installation information electrical connection Isolate the system from the power supply before opening the casing Pivot the control unit to the side Unclip the terminal box from the holder The terminal box can be mounted on the wall to the right or left of the boiler Open the terminal box Insert the strain relief into the holes provided Strip approx 70 mm off the
29. d notice and affix to the inside of the casing Close the boiler again If any screws are not tightened there is a danger of gas escaping leading to a risk of explosion asphyxiation or poisoning 26 Checking the gas supply pressure Gas shut off valve 3062555 201507 Commissioning BUS address adjustment Wi Only qualified personnel must carry out the commissioning and initial start up of the boiler as well as instruct the user Check the boiler and system for leaks Normal operating pressure when system is cold Illuminated signal ring 1 5 2 0 bar prevent water leaks Figure Control unit overview Check location and seating of fitted parts Checkall connections and component unions for leaks Saving energy If tightness cannot be ensured then there is Instruct the customer about energy saving options a risk of water damage Refer your customer to section Information regarding energy efficient operation in the operating instructions Check the correct assembly of the flue gas accessories Open the feed and return shut off valves Open the gas shut off valve Turn the operating switch of the controller on Check the over ignition and regularity of the flame of the main burner If the wall mounted boiler goes properly into operation the illuminated ring for the status indication lights up yellow Check the condensate drain Familiarise customers with the ope
30. e cold water supply pipe is always required for the heating of potable water in order to extend the maintenance intervals Neglecting this can lead to premature formation of limescale in the appliance and to limited hot water comfort The local conditions should always be checked by the responsible tradesman 3062555 201507 5 Control Function Operation E xax A ut ON OFF switch Reset Thermometer button temperature selector Illuminated Heating water signal ring temperature selector 0 ON OFF switch The condensing boiler is OFF in position O Reset A fault is reset by pressing the reset button which will also restart the system Pressing the reset button reactivates the system if there was no fault Illuminated signal ring as status indicator Display Explanation Flashing green Standby power supply ON no heat demand Constant green light Heat demand Pump running burner OFF Flashing yellow Emissions test mode Constant yellow light Burner ON flame steady DHW temperature selection When gas condensing boilers are combined with a DHW cylinder setting 1 9 corresponds to a cylinder temperature of 15 65 The DHW temperature selector setting becomes ineffective when the system is combined with a digital room thermostat or a weather compensated controller The temperature will then be selected at the controller EN accessory UE gt 4 Heating water temperature selection
31. e recommend you remove the casing cover during the installation Release the casing cover with the h and r h screw Release the bottom of the casing cover and unhook at the top Seal the front casing tightly with screws after completing the service There is a risk of carbon ____ 2 monoxide poisoning if the flue system is faulty Screws Figure Undoing screws Mounting the boiler with a mounting bracket During installation of the gas condensing boiler N ensure that all fixings are strong enough to carry its weight Also consider the wall consistency otherwise gas or water may escape which could lead to explosions and flooding Initially determine the location for the installation of the gas condensing boiler In your deliberations consider the flue gas outlet the lateral clearances towards walls and ceilings and any existing connections for gas central heating DHW and electrics min 446 mm Figure Fixing holes for mounting bracket Mark the holes to be drilled for the mounting bracket taking into consideration the minimum clearances Insert the rawl plugs and fit the mounting bracket with the coach bolts and washers supplied Hang the gas condensing boiler with the mounting stays into the mounting bracket Mounting stays Figure Mounting brace on the condensing boiler 3062555 201507 11 Heating flow Heating return Condensate drain Gas connection Overpressure ca
32. eS 191 5 yonip JosseM vs jnepiong jnej40A ML Ls 9 191413 jne 10A ig HH ueyeuosjeA ayley ul Joueqnz sebqv ML es 18 UC eub _ __ _ _ LE QU 444 BY ZIN 2 13 uonesiuo 9 Josues eJnjeJeduue episinQ SO 9110889026 0J UOO 104 sng Sf ge indui L3 indino ejqeuuuueJ60Jd LV OV A OEZ euJ91X3 Z ZHOS OEZ SUIE N LE Ipuexiquioyse9 0A 3062555 201507 50 Wi Type Rated output at 80 60 C Rated output at 50 30 Rated heat input Lowest output modulating at 80 60 Lowest output modulating at 50 30 Lowest heat input modulating External diameter heating flow 172 172 External diameter heating return 12 172 Drain outlet condensate ds 1 Gas connection 3 4 Ya Balanced flue connection 110 160 110 160 Appliance dimensions HxWxD 1020x565x548 1020x565x548 Balanced flue routing B23 B33 B23 B33 C13 C13x C13 C13x C33 C33x C33 C33x C43 C43x C43 C43x C53 C53x C53 C53x C63 C63x C63 C63x C83 C83x C83 C83x C93 C93x C93 C93x Gas supply details Natural gas Hi 9 5 kWh m 34 2 MJ m L
33. ead to boiler damage and risk of injury Poorly vented LPG tanks can lead to ignition problems In such cases contact your local LPG supplier Standards and regulations Requirements The installation of the boiler must be in accordance with the relevant requirements of Gas Safety Installation and Use Regulations 1998 Health and Safety Document No 635 The Electricity at Work Regulations 1989 BS 7671 IEE Wiring Regulations and the Water Supply Water Fitting Regulations 1999 or The Water Bylaws 2000 Scotland It should also be in accordance with the relevant requirements of the Local Authority Building Regulations including amendments to the Approved Documents Part L and J 2002 The Building Regulations Scotland The Building Regulations Northern Ireland and the relevant recommendations of the following British Standards BS 5440 Flues and ventilation of gas fired boilers not exceeding 70 kW net Part 1 Flues Part 2 Ventilation 85 5449 Specification for forced circulation hot water for domestic premises BS 5546 Specification for forced circulation hot water for domestic premises BS 6700 Services supplying water for domestic use within buildings and their curtilages BS 6798 Specification for installation of gas fired boilers not exceeding 60 kW input BS 6891 Specification for installation of low pressure gas pipework up to 28 mm R1 in domestic premises 2 family gas BS 7593 Treatment of wate
34. eck the gas supply line and hydraulics for leaks 3062555 201507 CO adjustments Zero point adjusting screw Protective screw Gas flow adjusting screw Figure Gas combination valve Test port Flue gas mi Figure Flue gas test with a closed boiler Appliance closed Natural gas H 8 8 0 5 at upper load LPG P 10 3 0 5 Appliance closed Natural gas H 8 7 0 5 at lower load LPGP 9 0 0 596 33 Commissioning report 1 Gas type Natural gas H LPG Wobbe index Net calorific value 2 Gas supply pressure checked 3 Gas leak test carried out o D 4 Balanced flue system checked 5 Water connections checked for leaks 7 Boiler and system vented 8 System pressure 1 5 2 5 bar 10 Water treatment carried out according to the Water treatment planning notes pH value adjusted pH value dH Total hardness value adjusted 11 No chemical additives inhibitors antifreeze added 13 Function test carried out 14 Flue gas test Flue gas temperature gross Inlet air temperature Flue gas temperature net Carbon dioxide content CO or oxygen content O2 Carbon monoxide content CO 15 Casing fitted 244444444444122244 ppm 16 System user trained documentation handed over 17 Confirm commissioning 34 3062555 201507 Wi Residual head
35. em 38 Water treatment planning notes Example System power 170 KW System volume Vsystem 4000 I Volume of the supplementary water V supplement 1000 Total hardness of the potable water water 18 5 Maximum permissible total hardness Cmax 8 4 dH System power 170 KW System volume Vsystem 4000 Volume of the supplementary water Vsuppiement 1000 V sys specific 4000 17 170 KW 23 53 I KW Total hardness of the potable water Coot water 18 5 Maximum permissible total hardness Cmax 8 4 dH Proportion of the filling water to be treated A 100 8 4 0 1 18 5 0 1 x 100 54 9 54 9 of the filling and supplementary water must be desalted Vireated 54 9 4000 I 10001 2746 When filling the system 2 745 deionised water must be filled Subsequently the system can be topped up to Vmax with potable water When topping up it must be checked regularly that the maximum permissible total hardness is not exceeded 3062555 201507 Wi System log Location 20 mE Lowest boiler output Qnin Lowest boiler output for the system System output System volume Total volume expected during the system service life Maximum expected top up water volume V system Fill and top up water volume Moos Vmax Vsystem Vtop up lt c kW kW kW kW Qs tot oo Qs tot Total hardness
36. emperature selector anti clockwise and then back to In summer mode the circulation pump operates for approx 30 seconds after a maximum idle period of 24 hours The number of times the condensing boiler can be started in heating mode is limited electronically This limit can be bypassed by pressing the reset button Then the boiler starts immediately as soon as there is a heating demand Wi As delivered condition Gas condensing boiler Delivered condition standard delivery Accessories The standard delivery includes 1 Gas condensing boiler ready to connect with the casing The following accessories are required for installation of the gas condensing centre fitted Balanced flue accessories see design information 1 Mounting bracket for mounting on the wall with installation Room temperature dependent or weather compensated accessories control 1 Installation instructions 1 Operating instructions 1 Maintenance instructions 1 Siphon with hose 1 Maintenance tool Condensate drain outlet with hose retainer Gas ball valve with fire protection Fitting assembly for heating flow heating return and integral safety assembly Pump assembly with variable speed pump and integral safety assembly Low loss header set for one or two appliances in a cascade Dirt filter in the heating return Boiler connections Gas connection R 32 Condensate drain Heating flow G 1 Heating return G 17 Fi
37. eneral filling and supplementary water must be submitted to a desalization softening via a single stage ion exchanger is not permissible The permissible methods and limit values are to be taken from the section entitled Water treatment planning notes ATTENTION the limit values are plant specific nhibitors and anti freeze are not approved Asystem logbook is to be maintained see Water treatment planning notes After proper filling of the system the system must be heated to the maximum and the total hardness and pH value measured again or adjusted These values must be checked again and adjusted after 6 8 weeks 14 Installation Additional requirements for operation without low loss header Systems with only one CGB 75 100 Sludge separator in the appliance return of the CGB 75 100 Desalization of the heating water to 2 3 Control of the calorifier charging only via the MM module configurations 1 and 10 Charging pump at least DN 25 with a lifting height of at least 6 m The max inlet temperature must be set to 75 with the parameter HG08 The water treatment planning notes must be observed as otherwise damage to the system may occur leading to the escape of water The manufacturer cannot accept any liability for damage to the heat exchanger resulting from oxygen diffusion into the heating water In the case that oxygen can penetrate into the system we recommend a hydraulic separator by
38. esulting from incorrect pipe lengths excessive pressure drop premature wear with escaping flue gas and condensate or incorrect function e g through components working themselves loose are excluded from our warranty if non CE approved third party equipment is used Straight balanced flues must be no longer than 2 m when connecting the system to a combustion air supply and a separate flue In addition to the boiler connection bend up to two 90 diverters may be installed The chimney must be free from contamination if the combustion air is drawn from the chimney 49 iagram d iring W Wi enge Jexoeis sngae PO d 0894 ax 12250 5 lt 5 S 6X E 11 t YX lt X 2 2 w 2 353 ws 6 2 5 5 5 5 8 5 02228323 Sig Ose S Oye 5285 o OOL d 922 9588 om amp t esneuec uonesiuo e w 8 2 X ex lt N 5 70 E c 5 3 9 Q CJ pz e 8ue6sny p LEX WMd SM z CJIO Aq OWA 2 ZLX 96 0 Sa 4a YOeEMyONIpsey Joyaqnz SS uuaJg M 1
39. g circuit pump on site 230 V AC max 300 VA Insert the cable glands into the terminal box Insert and secure the connecting cable through the cable gland Connect the pump 230 V AC to terminals L1 and N and eT The pump is activated when there is demand in heating DHW or frost protection mode Connection output A1 230 V AC 200 VA Insert the cable glands into the terminal box Insert and secure the connecting cable through the cable gland Connect the connecting cable to terminals L1 N and The parameters for output 1 are described in the table on the following page 3062555 201507 Electrical connection Figure Terminal box cover open Blue plug Figure Blue plug cylinder sensor connection Netz Z Figure Connection heating circuit pump Nez Z Figure Connection output A1 19 Wi The functions of output A1 can be scanned and adjusted with Wolf control accessories with eBUS capability The following functions can be allocated to output A1 Explanation No function Output A1 is not activated Electrical connection DHW circulation pump 100 Output A1 is activated by control accessories timed if DHW has been enabled Output A1 is constantly activated when no accessory controller is installed DHW circulation pump 50 Output A1 is activated in cycles by control accessories timed if DHW has been enabled 5 minutes ON and 5 minutes
40. gas supply pressure Gas supply pressure Work on gas components must only be performed by a licenced gas fitter Work which is carried out incorrectly may lead to gas escaping resulting in a risk of explosion asphyxiation or poisoning The condensing boiler must be switched OFF open the gas shut off valve Release the casing cover with the I h and r h screw Release the bottom of the casing cover and unhook at the top Release the plug at test nipple D and vent the gas supply pipe Connectthe differential pressure meter or U tube manometer to the test nipple at with against atmosphere Switch ON the ON OFF switch After starting the boiler check the supply pressure at the differential pressure meter Natural gas If the supply pressure flow pressure is outside the 18 to 25 mbar range adjustments must not be carried out and the boiler must not be started There is a risk of faulty boiler functions LPG If the supply pressure flow pressure is outside the 25 to 45 mbar range supply pressure 37 mbar or 43 to 57 mbar range supply pressure 50 mbar adjustments must not be carried out and the boiler must not be started There is a risk of faulty boiler functions Switch OFF ON OFF switch close the gas shut off valve Remove the differential pressure meter and re seal the test nipple with plug Open the gas shut off valve Check the test nipple for gas tightness Complete the enclose
41. gure Connections with heating circuit connection set accessory Heating circuit pump assembly accessory Modulating pump Safety valve Pressure gauge BDF valve BDF valve Connection Expansion vessel 1 Heating flow G 2 G 2 Pump assembly accessory Heating return Figure 8 3062555 201507 Wi CGB 75 CGB 100 Layout Non return valve Ignition electrode Monitoring electrode Quick acting air vent valve Temperature limiter Combustion chamber cover Flash trap Temperature limiter flow Flow sensor Burner Displacement device Heating flow Heating return 3062555 201507 Ventilation air test point Flue gas test point Flue Combustion chamber casing Gas fan Gas air mixing chamber Gas restrictor Gas combination valve Inlet pipe Heating water heat exchanger Flow switch Return sensor Flue gas temperature limiter Gas supply pipe Condensate siphon Wi General notes Electrical connection must be made on site Please maintain the 350 mm clearance to the ceiling to enable inspection and maintenance work on the boiler to be carried out otherwise the necessary inspection and function tests on components cannot be ensured during maintenance The drain hoses must be secured with the retainer above the drain outlet siphon The drain must be able to be inspected The appliance may only be in
42. heaters lt 0 3 I KW and systems with electrical heating elements Gradual tightening of the specifications due to the specific system volume Vsys system volume lowest individual power setting and the total heating power The total filling quantity of water over the lifetime of the appliance may not exceed three times the nominal volume of the heat ing system Warning the total hardness may not fall below 2 3062555 201507 37 Wi Example System with a 170 KW boiler System volume Vsystem 4000 V sys specific 4000 170 KW 23 5 1 This is larger than 10 I KW hence stage 3 must be selected instead of stage 2 The filling and supplementary water must lie within the range of 2 to 8 4 If the total hardness of the untreated potable water is too high part of the filling and supplementary water must be desalted A 96 saline free water must be added 100 Cmax 0 1 dH Coot water 0 1 dH x 100 Cmax Maximum permissible total hardness in dH Coot water Total hardness of the untreated potable water in dH We recommend that you include the supplementary water expected for the initial filling in the calculation Untreated potable water can then be used for topping up later V treated A X Vsystem t V supplement In the case of large systems in stage 4 the supplementary water may not be included in the calculation for the initial filling V treated A X V syst
43. ing water temperature selector to the emissions test symbol illuminated ring of the status display flashes yellow Test the temperature and CO The balanced flue is not gas tight if the content is gt 0 296 rectify the leak After the test has been completed switch the boiler OFF remove the test probe and close the test port Ensure the screws are seated firmly Testing the flue gas parameters Flue gas can escape into the installation room if the test port is left open This results a risk of asphyxiation Remove the screw from the r h test port Open the gas shut off valve Start the gas condensing centre and turn the temperature selector to the emissions test symbol illuminated ring of the status display flashes yellow Insert the test probe Test the flue gas values After the test has been completed remove the test probe and close the test port Ensure the screws are seated firmly 3062555 201507 Testing the combustion parameters Test port Test port Inlet air Flue gas Figure Test ports ON OFF switch Temperature selector Figure Control unit overview 31 Wi Adjusting the gas air connection CO adjustments Carry out the adjustments in the following sequence At the factory the gas combination valve has been adjusted for the gas type stated on the type plate Only adjust the gas combination valve after the system has been changed to a different gas type or when se
44. ion aperture DN 110 29 Ventilation bezel 2 110 Secondary ventilation eer 23 Ventilation air in open flue operation in accordance with the local regulations 75 kW 200 m 100 kW 250 m 180 kW 350 m 200 kW 450 m 3062555 201507 47 Wi Supplementary installation notes Design information Flat roof Affix the ceiling outlet approx 170 mm 8 Install all horizontal balanced deep into the roof cover flues with gt 3 slope 6 cm m Pitched roof At 7 observe the installation instructions towards the boiler Any on the cowl regarding roof pitches condensate must be returned to the boiler Install the centring triangles near the end of the pipe Insert the roof outlet 9 from above through the roof and secure vertically with 6 to a rafter or brickwork Install the roof outlet only in its original condition Modifications are not permissible If required a flue pipe expansion piece in a duct from DN 110 to DN 160 can be fitted at the support bend 1750 2300 If an inspection aperture is required for the balanced flue insert a balanced flue with inspection aperture 3 200 mm length To check the balanced flue undo and remove the cover of the inspection piece 3 Distance A 5 Inspection piece 3 Distance A 5 Determine distance A Length of balanced flue 5 always approx 100 mm longer than distance A Always trim the flue on the smooth side never o
45. is corresponds to a conductance of 60 uS cm The max permissible total degree of hardness and the corresponding max conductance are system specific and must be calculated see also the Table maximum permissible total hardness To this end the saline free water conductance lt 30 uS cm must be mixed with untreated potable water The addition of chemical agents as well as lime elimination via single stage ion exchangers is not permissible since otherwise device damage can occur leading to the escape of water We recommend regular emptying of the sludge filter and the maintenance of a system logbook Permissible methods Deionisation mixed bed cartridges These are stage ion exchangers We recommend cartridges from the Gr nbeck or Judo companies for the initial filling and later if required Deionisation by reverse osmosis Topping up with distilled water Water treatment planning notes GB 75 Water treatment CGB 100 m Total hardness in Water treatment unnecessary 200 400 600 800 1000 1200 1400 1600 1800 2000 System volume in Diagram water treatment Treatment of the heating water based on VDI 2035 We recommend a pH value of between 8 2 and 8 5 for the heating water also in the case of combined installations of different materials A water analysis must be requested from the water supply company in order to check whether the total hardness
46. lue System DN 110 160 horizontal and DN 110 vertical Balanced flue rigid in a duct Min duct sizes B33 42 3062555 201507 Wi General notes Particularly for safety reasons use only original Wolf components for concentric balanced flues and for conventional flues Where necessary adapt the installation examples to the relevant Building Regulations and requirements of your country region Discuss any questions relating to the installation of inspection covers and ventilation apertures with your local flue gas inspector At low outside temperatures the water vapour N contained in the flue gas may condense and freeze on the balanced flue This ice may fall from the roof causing injuries or material losses Prevent ice from falling through on site measures e g the installation of a snow catcher grille If the balanced flue crosses different floors N route the pipes outside the installation room inside a duct with a fire resistance of at least 90 min and in low residential buildings with a resistance of at least 30 min Fire may spread if these instructions are not observed outlet above the roof may only be installed in attics or in rooms where the ceiling also forms the roof or where only the roof construction is located above the ceiling Gas condensing boilers with a balanced flue The following applies to gas boilers with a balanced flue above the roof where only the roof st
47. lue gas chimney must be inspected by the relevant authority and must be approved for condensing operation If necessary the flue outlet should be obtained from the chimney manufacturer The air vents to the boiler room must be free from obstruction Connection to a moisture resistant flue type B23 for open flue operation The straight horizontal flue must not be longer than 3 m In addition to the boiler connection bend up to two 90 diversions may be installed into the horizontal flue Forthis version observe the ventilation requirements for boiler rooms acc to local regulations 3062555 201507 Design information Connection to a moisture resistant flue type C53 C83x for balanced flue operation The straight horizontal flue must not be longer than 3 m For horizontal air supply pipes a maximum length of 3 m is recommended Observe special requirements for flues that are not surrounded by combustion air acc to local regulations or all locally applicable combustion orders Connection to a combustion air and flue system type C63x that is not tested together with the gas combustion equipment Original Wolf components are designed for long term use are designated with the DVGW quality seal and are matched for use with Wolf gas condensing boilers When using CE designated third party equipment the installer is responsible for the correct sizing and perfect function of such systems Faults material losses and injuries r
48. n the coupling side Chamfer the flue after trimming Please note Lubricate all balanced flue joints prior to installation e g with a soapy solution or coat lightly with suitable grease mat no 2651329 48 3062555 201507 Wi The following applies in accordance with local regulations Connection to a moisture resistant balanced flue chimney LAS flue gas chimney or flue gas system Chimneys and flue gas systems must be certified for combustion equipment in accordance with local Building Regulations CE certification Sizing via calculation tables subject to flue gas category In addition to the boiler connection bend or tee piece up to two 90 diversions may be installed Operation with positive pressure may require an appropriate permit Connection to a moisture resistant balanced flue chimney type C43x Straight balanced flues may be up to 2 0 m long when installing the system in a balanced flue chimney In addition to the boiler connection bend up to two 90 diverters may be installed The balanced flue chimney LAS must be inspected by the relevant authority and approved for pressurised condensing operation Connection to a moisture resistant flue gas chimney or a flue system type B33 for open flue operation Straight balanced flues must be no longer than 2 m when connecting the system to a flue gas chimney In addition to the boiler connection bend up to two 90 diverters may be installed The f
49. necting the condensing boiler particularly in older systems Prior to commissioning test all pipe and gas connections for leaks in accordance with local regulations Only approved foaming leak detection sprays should be used Inappropriate installation or using unsuitable components or assemblies may lead to gas escaping which results in a risk of poisoning and explosion in the gas supply line upstream of the Wolf condensing boiler Otherwise explosions may occur during a fire Size the gas supply line in accordance with details laid down in local regulations Install a gas ball valve with fire protection Gas fittings on the gas burner may be pressure N tested to 150 mbar Higher pressure may damage the gas train resulting in a risk of explosion asphyxiation or poisoning Close the gas ball valve on the gas condensing centre to pressure test the gas pipe Mount the gas ball valve in an easily accessible place Prior to installation ensure that the boiler corresponds to the gas type available See the following table for factory settings subject to type of gas 16 Installation Figure Straight through gas ball valve accessory LPGP Ws 20 2 21 3 kWh me 72 9 76 8 MJ m Table Factory settings subject to type of gas 3062555 201507 Wi For flues and concentric balanced flue systems use only original Wolf components Please observe the technical information regarding balan
50. ontrol parameters can be modified or displayed via control accessories with eBUS capability For procedures check the operating instructions of the relevant accessories Column 1 settings apply to control accessories ART AWT Column 2 settings apply to Wolf control system with BM programming module GB01 HG01 Burner switching differential K 8 HG02 Low end fan speed CGB 75 30 30 100 Minimum fan speed in 90 CGB 100 25 100 HG03 High end fan speed WW CGB 75 100 100 Maximum fan speed for DHW in CGB 100 100 100 CGB 75 100 CGB 100 100 GB04 HG04 High end fan speed HZ 100 2 8 25 30 25 30 25 Maximum fan speed for heating in 90 100 I GB05 A09 Frost protection outside temperature With connected outside temperature sensor and insufficient temperature pump ON HG06 Pump operating mode 0 gt Pump ON in winter mode 1 gt Pump ON during burner operation 1 GB07 HG07 Boiler circuit pumps run on time m Heating circuit pump run on time in minutes in heating mode GB08 HGO8or Maximum limit boiler circuit TV max HG22 Applicable to heating operation GB09 HG09 Burner cycle block mi Applicable to heating operation HG10 eBUS address Heat source BUS address HG11 DHW quick start Temperature of the plate heat exchanger in summer mode only applicable to combi boilers HG12 Gas type Not supported GB13 HG13 Programmable input E1 Various functions can be allocated to inpu
51. pipe again Note During conversion from LPG to natural gas the flue gas orifice plate must be removed Fit the mixing chamber as described under point 6 Re assemble in reverse order 10 Updating the type plate Cut out the relevant lines from the type plate supplied and affix them over the relevant lines on the appliance type plate Slide the balanced flue locking mechanism in the direction of the arrow Pull the flue pipe up out of the condensate pan DE ATILU 0085 Brennwert Kombi Wasserheizer Typ CGB 100 Bestimmungsland DE AT LU Kategorie I 2 ELL3 P Il2H3P 12 Art C13x C33x C43x 13 C33x B33 C13x C33x C63x C43x C43x C63x Eingestellt auf B P Anschlufsdruck 50 mba 1 6 2 0 kg h Eingestellt auf Erdgas E H A Anschlu druck 20 mbar Va Warmwasser 18 5 94 kW Heizen 19 5 94 kW Eingestellt auf Erdgas E H Leistungsbereich 0 OON Heizen 50 30 C 19 98 8 kW Heizen 80 60 18 91 5 kW Erdgas DE DE Max Vorlauftemperatur 90 C Anschlufsdruck f r GB CGB TGB TGK GU GG GU 1 GG 1 GU 2 GG 2 Conversion type plate Figure Updating the type plate Conversion sets for CGB 75 100 for conversion to other gas types Please state the corresponding part number when ordering Conversion to LPG P G31 Part no 86 12 714 ID 740 D imprinted on gas restrictor 3062555 201507 25 Wi Checking the
52. r in domestic hot water central heating systems Institute of Gas Engineers Publication IGE UP 7 1998 Guide for gas installations in timber framed housing Important The appliance must be installed and serviced by a competent person as stated in the Gas Safety Installation and Use Regulations 1998 In IE the installation must be in accordance with the current edition of 1 5 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ECI rules for electrical installation When tightening or loosening threaded connections always use suitable open ended spanners not pipe wrench or extensions etc Incorrect use and or unsuitable tools can lead to damage e g gas or water leaks modifications to the control unit or to the control components are excluded from our liability Incorrect use can lead to a risk to life and limb or to a risk of material losses Any damage or loss resulting from technical Note Please read these instructions carefully before the installation and keep them in a safe place Please also note the technical information in the appendix 3062555 201507 Wi Gas condensing boiler CGB Standards and regulations Gas condensing boiler in accordance with EN 297 EN 437 EN 483 EN 677 EN 625 pr EN 13203 and EU Directive 90 396 EEC Gas Consumer Equipment 92 42 EEC Efficiency guideline 2006 95 EU Low Voltage Directive and 2004
53. ration of the appliance using the operating manual and refer to possibly necessary water treatment for the filling and supplementary water Complete the commissioning protocol and hand over the manuals to the customer BUS address setting When operating several boilers number of boilers gt 1 in conjunction with a cascade module set the BUS address of each boiler in accordance with the table below Hold down the reset button after 5 seconds the corresponding flashing code will be displayed see table Select the corresponding address with the DHW temperature rotary selector then release the reset button again Boiler BUS address selector position Illuminated signal ring indication Boiler cascade 3062555 201507 27 Wi Displaying modifying control parameters Modifications must only the carried out by To prevent damage to the heating system cancel a recognised heating contractor or by Wolf night setback when outside temperatures fall customer service below 12 C If this rule is not observed ice may build up on the flue outlet which may cause Incorrect operation can lead to system faults injury or material losses Please note when adjusting parameter GB05 09 frost protection outside temperature that You can find the output data for the boiler on frost protection is no longer safeguarded if you the type plate set temperatures lower than 0 C This can lead to heating system damage The c
54. ructure lies above the ceiling If fire resistance is required for the ceiling the N pipes for combustion air supply and flue gas expulsion running between the top edge of the ceiling and the roof skin must be run inside a liner that provides the same fire resistance and is constructed from non combustible materials There is a risk of fire spreading if these requirements are ignored 3062555 201507 Design information If fire resistance is not required route the pipes N for combustion air supply and flue gas expulsion between the top edge of the ceiling and the roof skin inside a duct made from non combustible rigid materials or inside a protective metal pipe mechanical protection There is a risk of fire spreading if these requirements are ignored A clearance between the concentric balanced flue and combustible materials or components is not required as no temperatures higher than 85 will occur at the rated output If only a flue is installed maintain the clearances in accordance with local regulations Balanced flues without ducts must not be routed N through other installation rooms as there is a risk of fire spreading and mechanical protection 15 not ensured The combustion air must not be drawn from chimneys that used to carry flue gases from oil or solid fuel boilers Secure the balanced flue or flue outside ducts N with spacer brackets with a minimum clearance of 50 cm from the flue outlet or upstream
55. rvicing If too little heat is drawn off open some radiator valves A CO adjustment at the upper load emissions test mode Release the casing cover with the I h and r h screw Release the bottom of the casing cover and unhook at the top Remove the screw from the l h Flue gas test port Insert the test probe of the tester into the Flue gas test port approx 120 mm Turn the temperature selector to Emissions test Fi illuminated signal ring as status indicator flashes yellow Ensure that the boiler is not limited electronically Check the CO content at full load and compare the actual values with those in the table below Correct the adjustment if required using the gas flow adjusting screw on the gas combination valve in accordance with the table completing the service There is a risk of carbon monoxide poisoning if the flue system is faulty Seal the front casing tightly with screws after turn clockwise lowers CO content turn anti clockwise raises CO content Appliance open at upper load Natural gas H LPG P 8 6 0 2 10 1 0 2 Terminate the emissions test mode by turning the temperature selector back into its original position 32 Gas flow adjusting screw Figure Gas combination valve Test port Flue gas Figure Flue gas test with an open boiler 3062555 201507 Wi B CO adjustment at the lower load soft start Remove
56. scade DN 160 with low loss header set D 2 DONO 12 3062555_201507 Wi Heating circuit connection set Installation We recommend you connect the heating system with the aid of a heating circuit connection set Connection set comprising Connection to the appliance with flat gasket connection to heating flow return with ball valves 1 female thread Note Provide a BDF valve at the lowest system point Figure Heating circuit connection set accessory Safety equipment The CGB 75 and CGB 100 have not been fitted with an expansion vessel at the factory This must be fitted externally available from the Wolf accessories range Ensure the expansion vessel is correctly sized There must be no shut off valve between the expansion vessel and the condensing boiler otherwise the pressure build up would permanently damage the boiler during heating There is a risk of system components rupturing giving rise to a risk of scalding Exceptions are cap valves upstream of the expansion vessel The pump or fitting assembly includes a 3 bar safety valve 6 bar safety valve is available as an accessory Route the blow off line into a drain funnel The minimum system pressure is 1 0 bar The boilers are approved exclusively for sealed systems of up to 6 bar The maximum flow temperature is factory set to 80 and may be adjusted to 90 if required Figure Pump assembly accessory 3062555 201507 13 Wi
57. scaping gas may cause poisoning or an explosion Figure Gas connection Escaping gas may cause poisoning or an explosion Wi Obtain the permission of your mains gas supplier and flue gas inspector prior to the installation of Wolf gas fired boilers where appropriate Wolf gas fired boilers must only be installed by a recognised heating contractor This heating contractor will also be responsible for the correct installation and commissioning of the heating system The following regulations rules and guidelines must be observed during installation VDE 0722 EN50165 Electrical equipment of heat generators with non electrical heating systems DIN EN 12828 Heating systems in buildings designing hot water heating systems EN 60335 1 Safety of electrical equipment for domestic use and similar purposes VDE 0470 EN 60529 Protection through housings modifications to the control unit or to the control components are excluded from our liability Incorrect use can lead to a risk to life and limb or to a risk of material losses Any damage or loss resulting from technical Note Please read these instructions carefully before the installation and keep them in a safe place Please also note the technical information in the appendix Only use propane compliant with local regulations otherwise faults may arise through the starting characteristics and operation of the gas condensing boiler this in turn may l
58. space heater yeso If yes equipped with a yes no supplementary heater Combination heater yes no sf Rated heat output EE NN Useful heat output at rated heat kW 70 1 IM E 9 output and high temperature regime Useful heat output at 3096 of kW 0 7 6 rated heat output and low temperature regime Auxiliary electricity consumption elmax kW 0 075 0 109 at full load Auxiliary electricity consumption elmin kW 0 025 0 028 at part load Auxiliary electricity consumption Psp kW 0 003 0 003 in standby mode Seasonal space heating energy ns 93 93 efficiency Useful efficiency at rated heat n4 88 2 88 0 output and high temperature regime Useful efficiency at 3096 of rated n 97 4 97 4 heat output and low temperature regime Standby heat loss 0 086 0 085 Ignition burner power Ping kW 0 000 0 000 consumption Emissions of nitrogen oxides mg kWh Contact details Wolf GmbH Industriestra e 1 D 84048 Mainburg High temperature regime means 60 C return temperature at heater inlet and 80 C feed temperature at heater outlet Low temperature means for condensing boilers 30 C for low temperature boilers 37 C and for other heaters 50 C return temperature at heater inlet 3062555 201507 55 DECLARATION OF CONFORMITY according to ISO IEC 17050 1 Number 3062555 Drawn up by Wolf GmbH Address Industriestrake 1 D 84048 Mainburg Product Gas condensing boiler CGB 75 100
59. spection BDF valve at the return until 2 bar pressure is indicated Open the flow valves on the condensing boiler Fill the heating system to 2 bar pressure In operation the pressure gauge on site must indicate between 1 5 and 2 5 bar Check the entire system for water leaks Open the air vent valve Startthe condensing boiler set the heating water temperature selector to position 2 pump running illuminated signal ring status display constantly green Vent the pump for this briefly open and then retighten the air vent screw Ventthe heating circuit completely switching the condensing i i boiler ON for 5 seconds and OFF for 5 seconds at the Air vent valve heating ON OFF switch five times in succession circuit pump When the system pressure drops below 1 5 bar top up the water If the system pressure drops below 1 5 bar top up with supplementary water planning documents Open the gas ball valve Press the reset button Note n constant mode the heating circuit is automatically vented via the air vent valve At a system pressure below 1 0 bar the boiler will enter a fault state Fill siphon with water and fit it to the boiler 22 3062555 201507 Conversion to natural gas E LL G20 G25 if necessary Wi The gas condensing boilers CGB 75 CGB 100 are equipped as part of the standard delivery for operation with natural gas H G20 For operation with LPG G31 the gas
60. stalled in rooms that are safe from the risk of frost Clearance between the boiler and combustible N materials or components is not required as temperatures are limited to 85 C at the rated boiler output However explosive and easily combustible materials must not be used in the boiler room these would create a risk of fire or explosion During boiler installation ensure that no contaminants e g drilling swarf enter the gas boiler otherwise faults may develop First determine where the appliance is to be installed In your deliberations consider the flue gas outlet the lateral clearances towards walls and ceilings and any existing connections for gas central heating DHW and electrics 10 Installation instructions When using a low loss header set min 830 mm 27 The installation room and the combustion air N supplied to the appliance must be free from chemicals e g fluoride and chlorine or sulphur Such materials are contained in sprays paints adhesives solvents and cleaning agents Under the most unfavourable conditions these may lead to corrosion even in the flue gas system Sound insulation Under certain critical installation conditions e g installation on a drywall additional measures may be necessary to soundproof the boiler In this case use soundproof plugs and if necessary rubber mounts or insulation strips 3062555 201507 Wi Opening the casing cover Installation W
61. t E1 See chapter Connection input E1 7 5 in AG n 10 1 1 thermostat 5 GB14 HG14 6 Cylinder primary pump Programmable output A1 Output A1 230 V AC Various functions can be allocated to output A1 See chapter Connection output A1 HG15 Cylinder hysteresis Switching differential during cylinder re heating HG21 Minimum boiler water temperature TK min C GB15 5 Q2 ww ts 20 N 8 3062555_201507 Adjusting the modulating pump accessory Wi In heating mode The heating circuit pump accessory modulates in proportion to the burner output This means at maximum burner output the pump operates at the maximum pump speed for heating mode At minimum burner output the pump operates at the minimum pump speed for heating mode In other words the burner output and pump speed are regulated subject to the required heating load The power consumption is reduced by the pump modulation In DHW mode The heating circuit pump will not modulate but operates constantly at the selected pump speed In standby mode The heating circuit pump will not modulate but operates constantly at the selected pump speed Standby mode 20 Setting limits The speed limits for heating mode can be changed with the BM programming module The settings in column 1 apply to control accessories ART AWT The settings in column 2 apply to Wolf control s
62. t instructions concerning personal safety as well as operational reliability Safety instructions are instructions with which you must comply exactly to prevent risks and injuries to individuals and material losses Danger through live electrical components NB Switch OFF the ON OFF switch before removing the casing Never touch electrical components or contacts when the ON OFF switch is in the ON position This results in a risk of electrocution that may lead to injury or death The main supply terminals are live even when the ON OFF switch is in the OFF position Note indicates technical instructions that you must observe to prevent material losses and boiler malfunctions General notes Maintenance work must only be carried out by a N qualified heating contractor Regular maintenance and the exclusive use of original Wolf spare parts are necessary preconditions for trouble free operation and a long service life Wetherefore recommend you arrange a maintenance contract with a local heating contractor completing the service There is a risk of carbon monoxide poisoning if the flue system is faulty Seal the front casing tightly with screws after 3062555 201507 Safety instructions Figure Ignition transformer high voltage ignition electrode heat exchanger Danger from electrical voltage Risk of burning from hot components Figure Gas combination valve Danger from electrical voltage E
63. the protective screw over the zero point adjusting screw with a Torx screwdriver Restart the condensing boiler by pressing the Reset button Check and correct if required the CO content approx 20 s after the burner start with the CO tester by fine adjusting the zero point adjusting screw with Torx in accordance with the table This adjustment must be made within 180 s after the burner start If necessary press the Reset button to repeat the start phase for the adjustment During this adjustment there must be no DHW operation turn clockwise higher CO content turn anti clockwise lower CO content Appliance open at lower load Natural gas H LPG P 8 5 0 2 9 7 0 2 Retighten the protective screw C Checking the CO adjustment After completing the work refit the casing cover and check the CO value with the boiler closed Observe the CO emissions whilst making CO N adjustments The gas combination valve is incorrectly adjusted if the CO value is gt 300 ppm when the CO value is correct Take the following steps Fully insert the zero point adjusting screw Open the zero point adjusting screw 172 revolutions Repeat the adjusting process from section A The condensing boiler is correctly adjusted when the CO values correspond to those in the adjacent table D Completing the adjustments Shut down the boiler and close the test ports and hose connection nipples again Ch
64. ural gas and LPG Limiting the maximum output CGB 75 Heating output WW 18 22 25 2 o 55 66 7 Display vaue 30 35 40 45 so 56 6s 70 75 o 85 90 95 vo CGB 100 Heating w 18 23 28 3o o 55 6 8 86 Depsywaue 77 09 25 3o 36 41 s sr ee se 05 100 Table Output setting Limiting the maximum output relative to a flow return temperature of 80 60 C 95 90 85 21 pull LL Ll EL sr 80 75 70 65 co ES 2 En Lr uL LJ og Aq rp pe 241214 so _ NE roe a MN MN E 40 35 30 wi SNA E 1 y y 1 EBEN NEIN d _ _ __ _ 1 20 __ _ ___ _ 1 1 1 1 4 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Settings for parameter GB04 HG04 with Wolf connection accessories with eBUS capability in 96 25 2 Maximum output in kW 15 NO 30 3062555 201507 Wi Test the combustion parameters with the boiler closed Testing the combustion air Remove the screw from the l h test port Open the gas shut off valve Insert the test probe Start the gas condensing boiler and turn the heat
65. volt Connect the cable for input 1 at terminals E1 in accordance with the wiring diagram first remove the jumper between a and b from the respective terminals Figure Connection room thermostat The functions of input E1 can be scanned and adjusted with Wolf control accessories with eBUS capability The following functions can be allocated to input E1 Explanation No function Input E1 is not taken into consideration by the control unit Room thermostat factory setting With open input E1 heating operation will be blocked summer mode independent of any digital Wolf control accessories Maximum thermostat system pressure switch or condensate lifting system Connection option for a maximum thermostat system pressure switch or condensate lifting system To enable the burner input E1 must be closed As long as the contact is open the burner will remain blocked for DHW and central heating incl emissions test mode and frost protection Flow limiter Connection option for an additional water flow limiter After pump activation input E1 must be closed within 12 seconds Where this is not the case the burner will be switched OFF and fault 41 will be displayed Monitoring the ventilation air damper See parameters of output A1 no 7 Ventilation air damper Burner block BOB Operation without burner Closed contact burner blocked Heating circuit pump and cylinder primary pump run in standard mode In emissions test mode
66. ystems with programming module BM Parameter Unit Factory GB16 HG16 Pump minimum rate HK minimum 100 GB17 HG17 Heating circuit pump output maximum mr 100 This parameter must be set at least 5 higher than the parameter Heating circuit pump output minimum For the minimum pump speed for heating mode only settings in accordance with this table are permissible Otherwise there is a risk that the pump will not start In addition the Max pump speed for heating mode must be at least 5 higher than the Minimum pump speed for heating mode otherwise the pump would run at 100 Solution Problem Individual radiators are not getting properly warm See hydraulic balancing i e reduce the flow rate of hotter radiators In the spring and autumn average outside temperature Increase the set room temperature at the controller the required room temperature is not achieved e g from 20 C to 25 C When the outside temperature is extremely low the selected Select a steeper heating curve at the controller room temperature is not achieved e g from 1 0 to 1 2 3062555 201507 29 Wi CGB 75 100 Output setting parameter GB04 HG04 The output setting can be modified with Wolf control accessories with eBUS capability The heating output will be determined by the gas fan speed By reducing the gas fan speed in accordance with the table the maximum output will be matched at 80 60 to nat

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