Wolf FGB-K Series Installation And Maintenance Instructions For Contractors
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Wolf FGB-K Series Installation And Maintenance Instructions For Contractors

Wall mounted gas condensing/combi boiler
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Installation and maintenance instructions for contractors
Wall mounted gas
condensing boiler
FGB wall mounted gas condensing boiler
FGB-K wall mounted gas condensing combi boiler
FGB-28
FGB-35
FGB-K-28
FGB-K-35
Wolf GmbH / Postfach 1380 / D-84048 Mainburg / Tel. +49.0. 87 51 74- 0 / Fax +49.0.87 51 74- 16 00 / www.wolf.eu
Document no.: 3064458_201811
from FW 1.20
Subject to technical modifications
GB
IE

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  • Page 1 FGB wall mounted gas condensing boiler FGB-K wall mounted gas condensing combi boiler FGB-28 FGB-35 FGB-K-28 FGB-K-35 Wolf GmbH / Postfach 1380 / D-84048 Mainburg / Tel. +49.0. 87 51 74- 0 / Fax +49.0.87 51 74- 16 00 / www.wolf.eu Document no.: 3064458_201811 Subject to technical modifications...

  • Page 2: Table Of Contents

    Table of contents Information on documentation / standard delivery ......3 Safety instructions ................5 Dimensions ..................8 Specification ..................9 Set-up ..................... 10 Standards and regulations ............. 12 Installation Positioning ..................15 Installation dimensions ..............16 Opening the casing ................ 17 Installation ..................

  • Page 3: Information On Documentation / Standard Delivery

    1. Information on documentation / standard delivery Other applicable documents Operating instructions for users Also applicable are the instructions for all accessory modules and any further acces- sories used. Safekeeping of these documents The system user or operator should ensure the safekeeping of all instruction manuals and documents.
  • Page 4 1. Information on documentation / standard delivery Standard delivery 1 x gas condensing boiler, ready to connect, with casing 1 x suspension bracket for wall mounting 1 x installation and maintenance instructions for contractors 1 x operating instructions for users 1 x commissioning checklist 1 x power cable with standard plug, flexible, 3 x 0.75 mm²...

  • Page 5: Safety Instructions

    “OFF”. Only operate the gas condensing boiler within its output range, which is stated in the technical documentation supplied by WOLF. Intended use of the boiler includes the exclusive use for hot water heating systems in ac- Danger: if you smell flue gas cordance with DIN EN 12828.
  • Page 6 We recommend arranging a suitable maintenance con- tract. - The operator is responsible for the safety, environmental compatibility and energy quality of the heating system (German Immission Control Act/Energy Saving Ordi- nance) [Germany]. - Only use genuine WOLF spare parts. 3064458_201811...
  • Page 7 2. Safety instructions Fig: Terminal box: Danger through 'live' electrical components. Fig: Gas connection: Risk of poisoning or explosion in the event of gas escaping. Fig: Ignition transformer, high voltage ignition electrode, combustion Fig: Gas combination valve chamber, 3-way diverter valve, pump and fan Risk of poisoning or explosion in the event of gas escaping.

  • Page 8: Dimensions

    3. Dimensions Heating flow Heating return G 3/4 G 3/4 DHW connection Cold water G 1/2 connection G 1/2 3064458_201811...

  • Page 9: Specification

    4. Specification Type FGB-28 FGB-35 FGB-K-28 FGB-K-35 Rated heating output at 80/60 °C 24.4/27.3 31.1/34 24.4/27.3 31.1/34 Rated heating output at 50/30 °C 27.3 34.9 27.3 34.9 Rated heat input 25/28 32/35 25/28 32/35 Lowest heating output (modul.) at 80/60 °C Lowest heating output (modul.) at 50/30 °C Lowest heat input (modul.) Heating flow connection...

  • Page 10: Set-Up

    5. Set-up FGB wall mounted gas condensing boiler Flue pipe 13 Expansion vessel Burner 14 Pressure sensor Boiler water temperature sensor 15 Return temperature sensor Heating water heat exchanger 16 Flue gas temperature sensor Gas fan 17 3-way valve (motor) Mixing valve (venturi insert) 18 Heating circuit pump with air vent valve Gas valve...
  • Page 11 5. Set-up FGB-K wall mounted gas condensing combi boiler Flue pipe 15 Expansion vessel Burner 16 Pressure sensor Boiler water temperature sensor 17 Return temperature sensor Heating water heat exchanger 18 Flue gas temperature sensor Gas fan 19 3-way valve (motor) Mixing valve (venturi insert) 20 Heating circuit pump with air vent valve Gas valve...

  • Page 12: Standards And Regulations

    6. Standards and regulations Observe all standards and guidelines applicable to the installation and operation of this heating system in your country. Observe the information on the boiler type plate. The following local regulations must be complied with during installation and operation of the heating system: •...
  • Page 13 6. Standards and regulations The following also apply to installation and operation in Germany: • Technical Regulations for Gas Installations DVGW-TRGI 1986/1996 (DVGW Code of Practice G600 and TRF) • DIN 1988 Drinking water supply systems • DIN 18160 Chimneys •...
  • Page 14 DHW heating in heating systems with flow temperatures up to 90 °C and 2.5 bar permissible operating pressure to DIN EN 12828. This Wolf gas condensing boiler is also approved for installation in garages. Gas condensing boilers operated with an open flue may only be installed in rooms that comply with the appropriate ventilation requirements.

  • Page 15: Installation

    Operation in wet rooms In the delivered condition and for balanced flue operation, the Wolf gas condensing boiler has IP rating IPx4D. When installing it in wet rooms, the following conditions must be met:...

  • Page 16: Installation Dimensions

    8. Installation dimensions Securing the appliance, suspension bracket / flue gas system When installing the appliance, ensure that the fixings have sufficient load-bearing capacity. Also take into account the condition of the wall, to prevent gas or water from escaping, resulting in a risk of explosion and flooding.

  • Page 17: Opening The Casing

    9. Opening the casing • Undo the central screw at the bottom of the front casing. Screw • Push in the two locking hooks at the bottom left and right and pull the casing forwards. • Lift the front casing upwards to release it and remove it. 3064458_201811...

  • Page 18: Installation

    10. Installation Heating circuit We recommend installing a maintenance valve in both the heating flow and heating return – straight design for surface mounting. The return line to the appliance must have a dirt trap. A sludge separator with magnetite separator should be Please note used to protect the appliance and the high efficiency pump from dirt/sludge and magnetite.

  • Page 19: Gas Connection

    11. Gas connection Seite 16 Gaskugelhahn, Durchgangsform Connect the gas supply line at the gas connection or the expansion joint (recommended) using gas connection R½" and an approved sealant. Ensure the supply line is stress-free. Only a licensed gas fitter may route the gas pipe and make the gas connections.

  • Page 20: Fitting The Trap

    12. Fitting the trap Condensate drain connection Condensate pan connector Please note The trap must be fitted before commissioning the appliance. The trap included in the standard delivery must be fitted from underneath the appliance. Before installing, apply silicone grease to the sealing collar. After insertion, secure the screw fitting of the trap to the connector and check the connection is firm.

  • Page 21: Air/Flue Gas Routing

    13. Air/flue gas routing For concentric balanced flue systems, use only Please note original Wolf parts. Prior to installation, read the technical information regarding balanced flue systems. As regulations in the individual Federal States [Germany] differ, we recommend consulting the relevant authorities and local flue gas inspector prior to installation.

  • Page 22: Electrical Connection

    14. Electrical connection General information, The installation must be carried out by an approved electrical contractor. Observe VDE regulations and all local regulations of your electrical connection power supply utility company. The applicable national regulations and conditions, as well as those of the local utility company must be observed for electrical installation work.
  • Page 23 14. Electrical connection Opening the control unit Push the retaining bracket on the casing upwards and pivot the control unit forwards. Opening the control unit back Open the control unit cover using a screwdriver. Please note Cable glands M12 M12 M12 M16 M16 Only open the cable entries required.
  • Page 24 14. Electrical connection Terminal strip Power supply 230 V / 50 Hz Room thermostat input (jumper) Please note: No external voltage must be connected to input E1, as this would destroy the PCB. Outside temperature sensor T_Outside (5K NTC) Cylinder temperature sensor T_DHW (5K NTC) eBus 3064458_201811...
  • Page 25 14. Electrical connection Installation information, electrical connection - Isolate the system from the power supply before opening. - Check that the appliance is isolated from the power supply. - Remove the front casing. - Pivot the front of the control unit forwards. - Open the rear enclosure cover of the control unit.
  • Page 26 Connecting digital Wolf control accessories (e.g. BM-2, MM, KM, SM1, SM2, ISM7e) 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 > 0.5 mm²) as the connecting cable between the control unit accessory and the condensing boiler.
  • Page 27 Wolf portal server is established. The system is operated over the internet either by means of the Wolf portal user interface operated via internet browser or with the "Smartset" smartphone app, which can be downloaded and installed from the appropriate app store.

  • Page 28: Control Unit

    15. Control unit Key assignment If the appliance is connected to a BM-2, the display and setting function of keys 1, 2, 5, 6 and 7 is disabled. The BM-2 takes over these functions. Key 1 DHW key + Display/adjustment of set DHW temperature Press ▲(+) Hotter Contractor level...
  • Page 29 15. Control unit Display DHW mode (A flashing symbol indicates an active heat demand for DHW heating.) Only shown if DHW heating is available. Heating mode (A flashing symbol indicates an active heat demand for heating operation.) Changes are only possible when the heating curve is disabled. Shown when there are active fault codes.
  • Page 30 15. Control unit Operating modes Operating mode button (5) is used to select the boiler operating mode. (operating mode button) "Standby (OFF)", "Summer mode" or "Winter mode" If the appliance is connected to a BM-2 the operating mode button is disabled.
  • Page 31 15. Control unit Contractor level To navigate to the contractor level, press and hold reset button (4) for 10 s. Press buttons (1) and (2) to select one of the following 4 options. They are indicated by the following displays (flashing). The first menu shown is the parameter menu, indicated by a flashing "tS".
  • Page 32 15. Control unit Emissions test mode Emissions test mode is activated by simultaneously pressing and holding keys (6) and (7) for 5 s. This mode will now run for up to 15 min, i.e. it is automatically terminated after this time has elapsed. It can be terminated sooner by pressing key (4).

  • Page 33: Hg Control Parameters

    16. HG control parameters Modifications must only the carried out by a recognised heating contractor or by the Wolf customer service. Please note Incorrect operation can lead to system faults. To prevent damage to the entire heating system, cancel night setback when connecting a BM-2 module and outside temperatures fall below -12 °C. If this rule is not observed, ice may build up on the flue outlet which may cause personal injury or material losses. The control parameters can only be modified or displayed via the integral control unit.
  • Page 34 16. HG control parameters Factory settings 28 kW 35 kW No.: Description: Natural Natural Min. Max. eBUS feed Pump control type (constant = 0; spread ΔT = 1) Set spread, pump control °C Time, soft start 1 = Direct heating circuit 2 = Mixer module System configura- (no direct heating circuit)

  • Page 35: Parameter Description

    17. Parameter description Parameter H01 The burner switching hysteresis regulates the boiler water temperature within the set range by switching the burner on and off. The higher the start / stop temperature Switching hysteresis, burner differential is set, the greater the boiler water temperature fluctuation around the set value with concurrent longer burner runtimes and vice versa.
  • Page 36 17. Parameter description Parameter H09 Each time the burner is shut down in heating mode, it will be disabled for the duration of the burner cycle block. The burner cycle block is reset via power supply OFF – Burner cycle block power supply ON.
  • Page 37 17. Parameter description Parameter H17 In heating mode, the internal appliance pump does not regulate above this set value. With pump control type "constant", H17 is used as the set value for the pump speed HC pump rate, maximum in heating mode. Factory setting: see table Setting range: 15 to 100 % Individual setting:_____...
  • Page 38 17. Parameter description Parameter H37 For setting the type of pump speed control in heating mode and with cascade opera- tion. Pump control type 0: Constant = fixed pump speed (H17) Factory setting: see table 1: Spread ΔT = speed control between H16 and H17 to achieve flow/return Factory setting: 0 to 1 temperature spread (H38) Individual setting:_____...
  • Page 39 17. Parameter description System configuration 02 Direct heating circuit and one or more circuits with mixer via mixer modules (no direct heating circuit at the condensing boiler) • Burner starts subject to demand from the connected circuits with mixer • Internal appliance pump is enabled as a feed pump •...
  • Page 40 17. Parameter description Parameter H51 The DHW configuration is used to set the type of DHW heating.. DHW configuration If the configuration is modified, all parameters are returned to factory settings (except H12 and H40). Factory setting: see table Setting range: 1 to 4 Combi mode Configuration Combi mode + solar integration Configuration Individual setting:_____ Cylinder operation...
  • Page 41 17. Parameter description Parameter H54 If the heating curve is greater than 0, the heating flow temperature setting at Heating curve keys 6 and 7 is disabled. In this scenario, key 6 (-) and key 7 (+) serve to set the temperature correction (±4) for the heating circuit.
  • Page 42 17. Parameter description Temperature selection -4...+4 for heating circuit The flow temperature of the heating curve is changed with temperature selection -4...+4 as follows: Sample setting: Temperature correction: 0 H08 - (flow, max. heating operation) 75 °C H21 - (boiler, min. temperature) 20 °C H54 - (heating curve) 12 Outside temperature [°C] Sample setting:...
  • Page 43 17. Parameter description Parameter H55 In summer mode and outside the DHW switching times (in control accessories), DHW quick start the water in the plate heat exchanger can be maintained at a set temperature to increase DHW convenience. Factory setting: see table For this, the set DHW temperature selected with the DHW buttons applies.

  • Page 44: Filling The Heating System / Trap

    18. Filling the heating system / trap Hydraulics Before commissioning, carry out a leak test on all hydraulic pipework Note If the appliance is not watertight, there is a risk of leaks and resulting material damage. Test pressure on the heating water side max. 4 bar Prior to testing, close the shut-off valves in the heating circuit for the appliance, as otherwise, the safety valve (accessory) will open at 3 bar.
  • Page 45 18. Filling the heating system / trap Commissioning Vent the system completely at the maximum system temperature. The commissioning parameters must be recorded in the system log. This system log must be handed to the system operator following commissioning of the system. From that point onward, the operator is responsible for maintaining and keeping the system log.
  • Page 46 18. Filling the heating system / trap Filling the heating system Automatic To ensure correct function of the condensing boiler, fill air vent valve the system as instructed, vent it completely and fill the trap. We recommend using a sludge separator with integral magnetite separator in the boiler inlet to protect the high efficiency pump and the boiler.
  • Page 47 18. Filling the heating system / trap • Check the system pressure again (info key 3) and top up with water if required. Please note: During continuous operation, the heating circuit is automatically vented via the high efficiency pump. Info button Fig: Pressure indication on the control unit display Filling the heating system via the filling facility •...
  • Page 48 18. Filling the heating system / trap Filling the trap Prior to opening the gas ball valve and acknowledging the fault • Fill the trap from above through the inspection port in the flue pipe / bend. Fill only through the flue; do not fill water into the ventilation air aperture, as this could cause the burner to malfunction.
  • Page 49 18. Filling the heating system / trap Installing the condensate drain Connect the condensate hose provided to the safety valve drain/hydraulic separator. Please note: The condensate hose attached to the trap must not form a loop or roll up, as this could lead to impaired operation.

  • Page 50: Filling For Optional Appliance Versions

    19. Filling for optional appliance versions Optional boiler versions (subject to country-specific version): Equipped with heating system filling facility with system separation System separator CA Fill valve Fig: Filling facility integrated in the appliance on delivery Fig: Filling facility with system separation Applicable standards for filling facility with system separation (DIN) EN 1717 Protection against pollution of potable water installations (DIN) EN 14367 Non controllable backflow preventer - Family C, type A Also observe the country-specific standards and guidelines on installation and operation.

  • Page 51: Draining The Heating System

    20. Draining the heating system Draining the heating system: • Switch the boiler OFF at the control unit. Press the operating mode button until "OFF" shows in the display. The boiler then enters standby mode. If the appliance is connected to a BM-2, the operating mode key is disabled.

  • Page 52: Determining The Gas Type

    21. Determining the gas type Setting the gas/air mixture Carry out the adjustments in the order Please note described below. The gas combination Natural gas E/H 15,0: valve has been set at the factory to the gas = 11.4 - 15.2 kWh/m³ = 40.9 - 54.7 MJ/m³ type specified on the type plate.

  • Page 53: Checking The Gas Supply Pressure

    22. Checking the gas supply pressure Checking the gas supply pressure For permissible values, see table "Gas categories and supply pressures". Work on gas components must only be performed by a licensed gas fitter. Work that is carried out incorrectly may lead to gas escaping, resulting in a risk of explosion, suffocation or poisoning.
  • Page 54 23. Changing the gas type Changing the gas type (for operation with natural gas LL and LPG only) Change the gas type for operation with natural gas or LPG. 1. The gas boiler must be switched OFF. Close the gas ball valve. The boiler starts automatically when there is Please note a heat demand, even if the gas type has not...
  • Page 55 23. Changing the gas type setting at upper load When the test port is open, flue gas can Please note escape into the installation room. There is a risk of asphyxiation. 1. Remove screw B from the right hand test port. Flue gas test port 2.

  • Page 56: Adjusting The Maximum Heating Output

    24. Adjusting the maximum heating output Output setting (parameter H04) The output settings for the control parameters can only be adjusted via the integral control unit. The heating output is determined by the gas fan speed. By reducing the gas fan speed in accordance with the table, the maximum heating output at 80/60 °C is matched. 28 kW appliance Display value (%) Heating output (kW)

  • Page 57: Checking The Combustion Parameters

    25. Checking the combustion parameters A flue gas emissions test by a contractor is necessary after every modification of the components, including the Please control unit PCB, fan, mixing device, burner and gas valve. note Test the combustion parameters with the appliance closed. Checking the intake air Intake air test port 1.

  • Page 58: High Efficiency Pump Function Description

    26. High efficiency pump function description Residual head of the high efficiency pump (EEI ≤ 0,20) Overflow valve 450 mbar 100 % 90 % 80 % 70 % 60 % 50 % 40 % 1000 1200 1400 1600 Pump rate in [l/h] High efficiency pump function description (EEI ≤ 0,20) Possibilities Heating mode 2 operating modes are possible with the modulating heating circuit pump: 1. Spread control (ΔT) This type of control aims to utilise the condensing effect...
  • Page 59 26. High efficiency pump function de- scription Troubleshooting Problem Remedy Individual radiators do not warm up Carry out hydraulic balancing, properly. i.e. reduce the flow rate of hotter radiators. Increase the pump speed (H16). In the spring and autumn, the Increase the set room temperature required room temperature is not at the controller, e.g.

  • Page 60: Commissioning Report

    27. Commissioning report Commissioning steps Test values or confirmation 1.) Serial number on the type plate _______________________________________ 2.) Electrical wiring / connection / fuse protection checked in □ accordance with technical data of installation instructions and VDE regulations? 2.) System flushed? □ 3.) System filled and water treatment carried out? □...
  • Page 61 27. Commissioning report Commissioning steps Test values or confirmation 13.) Required heating output set in contractor parameter H04? □ 14.) Gas type set in contractor parameter H12? □ 1 = Natural gas = 28 kW 2 = LPG = 28 kW □ 3 = Natural gas = 35 kW □...

  • Page 62: Maintenance

    28.1. Maintenance – Fault messages Safety information for For maintenance, observe the safety instructions from page 4. maintenance Fault history Any faults that have occurred during operation can be called up on the contrac- tor level under "Fault history". To do this, press and hold reset (4) for 10 seconds (until ts appears). Using keys (1) and (2), access the fault history menu "Hi"...

  • Page 63: Maintenance - Spare Parts Maintenance Set

    28.2. Maintenance – Spare parts maintenance set Maintenance requires the following Maintenance set Part no. 8614950 Cleaning set Part no. 8614952 Measuring device for BImSch test No accessories Differential pressure tester No accessories FGB spare parts maintenance set DHW heat exchanger gasket Gasket, ignition and monitoring electrode...

  • Page 64: Preparing For Maintenance

    28.3. Preparing for maintenance Isolating the system from the power supply The mains terminals remain live even when the ON/OFF switch has been switched OFF. - Isolate the system from the power supply. Seite 16 Gaskugelhahn, Durchgangsform Closing the gas ball valve Removing the front casing - First undo the central screw at the bottom of the front casing.

  • Page 65: Determining The Soiling Level On The Heating Water Heat Exchanger (Flue Gas Side)

    28.4. Determining the soiling level on the heating water heat exchanger (flue gas side) Fitting the pressure test - Undo the M4 Allen screws on the ignition IO electrode connector - Fit the adapter plate with pressure test connector - The must be refitted after maintenance Ignition IO electrode - Connect the differential pressure tester between the adapter plate "+"...

  • Page 66: Burner Maintenance

    28.5. Burner maintenance Undoing the fitting on the gas combination valve Disconnecting the plug-in Disconnect the following plugs: connections - Fan - Gas combination valve - Ignition / IO electrode Pull off with small twisting movements. 3064458_201811...
  • Page 67 28.5. Burner maintenance Removing the - Pull off the inlet pipe combustion chamber - Undo 2 screws on the combustion chamber cover cover - Raise the combustion chamber cover, slide it back and lift it to remove. Burner maintenance The burner must be cleaned every time maintenance work is carried out. - Remove the burner - Visual inspection for damage - Replace if damaged...

  • Page 68: Checking The Ignition Ionisation Electrode

    28.6. Checking the ignition ionisation electrode Replacing the electrodes - Remove the electrode by releasing the two M4 screws. - The electrode, including gasket, must be replaced every time maintenance work is carried out (torque for fixing screws 3.0 ± 0.3 Nm). Electrode 3064458_201811...

  • Page 69: Cleaning The Trap / Checking The Expansion Vessel

    28.7. Cleaning the trap / checking the expansion vessel Cleaning the trap - Remove any residue from the trap - Place a drip pan under the trap - Open the cleaning aperture on the trap - Fill / flush the trap from above through the inspection port in the flue pipe/ bend Flush only through the flue;...

  • Page 70: Removing The Heat Exchanger

    28.8. Removing the heat exchanger Emptying the condensing - Close the flow and return maintenance shut-off valves boiler on the heating water side - Open the drain valve - Open the manual air vent valve Removing the flow and - Disconnect the plugs for the flow temperature sensor, high limit safety cut-out return pipes and flue gas temperature - Disconnect the return sensor and pressure sensor plugs...
  • Page 71 28.8. Removing the heat exchanger Removing the condensate pan - Remove the trap - Pressing together the retaining clips, pull them off downwards and place them in the casing Unhooking the heat exchanger - Lift the heat exchanger and remove it towards the front Cleaning the heat exchanger - Set the heat exchanger down on the burner flange - With the cleaning tool from the maintenance set, clean the pin rows diagonally.

  • Page 72: Assembling The Heat Exchanger

    28.9. Assembling the heat exchanger Assembling the heat exchanger - Replace the condensate pan gaskets and grease them with silicone grease - Insert the condensate pans into the casing - Hook the heat exchanger into place from above Fitting the condensate pan - Press together the retaining clips, guide them straight up and secure them on the heat exchanger - The flue pipe must be positioned in the condensate pan...
  • Page 73 28.9. Assembling the heat exchanger Filling the condensing boiler on - Close the drain valve the heating water side - For filling, see chapters 18 and 19 - Vent the condensing boiler - Open the flow and return maintenance shut-off valves Fitting the combustion chamber - Replace the burner gasket cover...
  • Page 74 28.9. Assembling the heat exchanger Tightening the fitting on the gas - Replace the threaded connection seals combination valve - Tighten the threaded connection on the gas combination valve and check for leaks. Filling the trap - Fill the trap from above through the inspection port in the flue pipe/bend. Fill only through the flue;...

  • Page 75: Checking The Dhw Heating

    29. Checking the DHW heating Checking the DHW heating - Shut off the cold water and depressurise the system. If the DHW output of a FGB-K is too low, take the following action: - On FGB-K units, check and clean the dirt filter. Plate heat exchanger PHE - Remove the plate heat exchanger of the FGB-K.

  • Page 76: Safety Devices

    30. Safety devices Temperature monitoring High limit safety cut-out (thermostat) The high limit safety cut-out shuts down the boiler when the temperature reaches 110 °C. This causes the burner to be shut down and results in a lockout fault Þ with fault code 01.
  • Page 77 31. Technical information, balanced flue Balanced flue system Provide ventilation for B23, B33, C53 Connection types Type Operating mode Can be connected to open flue balanced moisture-resistant room sealed balanced certified moisture- flue chimney balanced flue balanced resistant flue flue flue B23P, B33P, C13x, B33, C53, C83x C43x C13x C63x...
  • Page 78 - Concentric balanced flue (on external walls) DN80/125 components and ventilation apertures (ventilation generally - Flexible flue pipe DN83 required above 50 kW output) should be raised with your Wolf accessories are supplied with the relevant necessary local flue gas inspector prior to installation. identification labels. The specified lengths refer to concentric balanced...
  • Page 79 31. Technical information, balanced flue General information For reasons of operational safety, use only original Wolf If fire resistance is not required for the ceiling, route components for concentric balanced flues and standard the lines for the combustion air supply and the flue flues. gas from the top edge of the ceiling to the roof...
  • Page 80 31. Technical information, balanced flue Connection to balanced flue Ensure that the flues can be inspected regarding their free cross-section. For this, provide an appropriate inspection aperture in the installation room, in consultation with your local flue gas inspector. Connections on the flue gas side are made using female connections with gaskets. Always position female connections against the direction of the condensate flow.
  • Page 81 DVGW quality seal and are matched for use with Wolf gas condensing boilers. When using third Horizontal balanced flues must be no longer than 2 m when party equipment that is only DIBT certified or CD-designated, connecting the system to a flue gas chimney.
  • Page 82 31. Technical information, balanced flue Sizing table, flue system for cascade operation Wolf FGB Flue diameter Height, vertical* appliance combination in m Connection pipe Header Vertical 28 + 28 DN110 DN110 DN110 28 + 35 DN110 DN110 DN110 35 + 35 DN110 DN110 DN110 28 + 28 + 28 DN110...
  • Page 83 31. Technical information, balanced flue Tightness test on As part of the annual boiler test, the cascade damper on overpressure boiler systems must be tested for tightness, to ensure no CO can escape into the boiler room connections to (risk of poisoning or asphyxiation). adjacent appliances The check must be carried out with the appliance closed.
  • Page 84 31. Technical information, balanced flue Vertical balanced flue routing (examples) system DN 60/100 1 Gas condensing boiler 2 Balanced flue with inspection port (250 mm long) 3 Separator DN60/100 (slide coupling) if required 4 Balanced flue DN60/100 500 mm 1000 mm 2000 mm 5 Balanced flue, vertical DN60/100 (roof outlet for flat or pitched roofs) L = 1200 mm L = 1200 mm ...
  • Page 85 31. Technical information, balanced flue Horizontal balanced flue / connection to balanced flue chimney (examples) system DN60/100 1 Gas condensing boiler Dormer 2 Balanced flue with inspection port (250 mm long) 4 Balanced flue DN60/100 500 mm 1000 mm 2000 mm 9 Inspection bend 10 Bend 87 ° DN60/100 11 Pipe collar 12 Support rail 13 Support bend 87° DN60 to DN80 14 Spacer 15 PP flue pipe DN80...
  • Page 86 31. Technical information, balanced flue Balanced flue inside a shaft with horizontal connecting pipe DN60/100 1 Gas condensing boiler 3 Separator (slide coupling) if required 4 Balanced flue DN60/100 Installation example for balanced 500 mm flue / shaft 1000 mm 2000 mm 9 Inspection bend Please note Install horizontal 11 Pipe collar pipe with > 3° slope towards 12 Support rail boiler...
  • Page 87 Obtain the connection piece from the chimney manufacturer if re- quired, to safeguard the connection conditions. Connection to a moisture-resistant flue with two or multiple draught chimneys (shaft) Shaft cover from the Stainless steel shaft cover Wolf product range from the Wolf product range Chimney Polypropylene system up Chimney Polypropylene system up T400 to 120 °C, CE approved...
  • Page 88 31. Technical information, balanced flue Vertical concentric balanced flue C33x (examples) system DN80/125 1 Gas condensing boiler 2 Adaptor DN60/100 to DN80/125 3 Balanced flue with inspection port (250 mm long) 4 Balanced flue DN80/125 500 mm 1000 mm 2000 mm 5 Spacer bracket 6 Mounting bracket DN125 for roof outlet 7 Balanced flue, vertical DN80/125 (roof outlet for flat or pitched roofs) L = 1200 mm...
  • Page 89 31. Technical information, balanced flue Concentric balanced flue, horizontal C13x, C83x and B33 and flue on an external wall C53x (examples) DN80/125 Dormer 1 Gas condensing boiler 2 Adaptor DN60/100 to DN80/125 Horizontal balanced flue routed 3 Balanced flue with through pitched roof inspection port DN80/125 (250 mm long) 4 Balanced flue DN80/125 500 mm Flue routed along 1000 mm external wall 2000 mm 5 Spacer bracket 10 Inspection bend 87°...
  • Page 90 31. Technical information, balanced flue Connection to a concentric balanced flue inside a shaft (examples) DN80/125, C33x Connection to a flue inside a shaft, C93x 1 Gas condensing boiler 2 Adaptor DN60/100 to DN80/125 4 Balanced flue DN80/125 500 mm 1000 mm 2000 mm 5 Spacer bracket 8 Separator (slide coupling) if required 10 Inspection bend 87° DN 80/125 11 Support bend 87° DN80/125 16 Pipe collar 22 Support rail 26 Shaft cover with...
  • Page 91 31. Technical information, balanced flue Eccentric balanced flue Install the eccentric balanced flue distributor 80/80 mm (31) for separate air supply/flue gas routing downstream of the connection adaptor DN80/125 (2) with a test connector. When connecting a balanced flue certified acc. to Building Regulations, observe the permit of the relevant body.
  • Page 92 31. Technical information, balanced flue Supplementary installation instructions for balanced flue DN80/125 Flat roof: Affix ceiling outlet (14), approx. Ø 130 mm, to the roof cover. Pitched roof: For (12), observe the installation instructions on the cowl regarding roof pitches. Insert roof outlet (7) into the roof from above and secure vertically with (6) to a rafter or brickwork.

  • Page 93: Design Information, Underfloor Heating / Dhw Circulation

    32. Design information, underfloor heating / DHW circulation Underfloor heating system If pipes which are impermeable to oxygen are used, an underfloor heating system can be connected directly to a heat source with up to 10 kW heating output, depending on the system pressure drop. Always install a temperature limiter for the underfloor heating system to protect the pipes from overheating.

  • Page 94: Service Report

    33. Service report Step Report item Report item Report item Date Switch OFF boiler, set emergency stop switch to OFF Close gas supply valve Remove front casing Determine level of soiling of heating water heat exchanger (mbar) Check burner If necessary, clean burner and check ignition monitoring electrode Clean heating water heat exchanger Clean condensate pan Check gaskets, if necessary replace gaskets and apply silicone...

  • Page 95: Troubleshooting

    Any faults or damage which impact or might impact upon safety must be remedied immediately by a qualified contractor. Only replace faulty components and equipment with original Wolf spare parts. Faults are shown on the display of the control unit or the control accessory BM-2 programming unit and correspond to the messages listed in the following tables.
  • Page 96 34. Troubleshooting Fault Fault Possible causes Remedy code HLSC excess temp. The high limit safety cut-out (thermostat) High limit safety cut-out: has responded. - Check cables and plugs. - If electrical connection OK and The temperature at the heat exchanger no function: Replace HLSC.
  • Page 97 34. Troubleshooting Fault Fault Possible causes Remedy code Temp. limiter excess The flow sensor has exceeded the limit Check system pressure. temp. of the temperature limiter (95 °C) Vent heating circuit. Temperature limiter in the flow: System pressure - Check leads and plug-in connections. - If electrical connection OK and Air in heating circuit no function, replace temperature limiter.
  • Page 98 34. Troubleshooting Fault Fault Possible causes Remedy code DHW outlet sensor faulty DHW outlet sensor faulty. DHW outlet sensor: - Check cables and plug-in connections. Stratification sensor faulty. - If OK and no function, replace the sensor. CRC burner control unit Invalid EEPROM data.

  • Page 99: Fgb Wiring Diagram

    35. FGB wiring diagram X23:1 L HZ L WW FGB Control X22:1 L1 Venti N Venti’ L1 ZHP N ZHP X21:1 L1 N Netz eBUS ON/OFF switch 3064458_201811...

  • Page 100: Product Fiche According To Regulation (Eu) No. 811/2013

    Sound power level, indoors Any specific precautions that shall be taken See installation See installation when the space heater is assembled, installed instruction instruction or maintained Wolf GmbH, Postfach 1380, D-84048 Mainburg, Tel. +49-8751/74-0, Fax +49-8751/741600, Internet: www.wolf-heiztechnik.de 3064458_201811 Material number: 3021028 03/2015...
  • Page 101 Sound power level, indoors Any specific precautions that shall be taken See installation See installation when the space heater is assembled, installed instruction instruction or maintained Wolf GmbH, Postfach 1380, D-84048 Mainburg, Tel. +49-8751/74-0, Fax +49-8751/741600, Internet: www.wolf-heiztechnik.de 3064458_201811 Material number: 3021074 03/2015...

  • Page 102: Technical Parameters According To Eu Regulation No. 813/2013

    Qfuel Contact details Wolf GmbH, Industriestrasse 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 30 °C for condensing boilers, 37 °C for low-temperature boilers and for 50 °C return temperature (at heater inlet) other heaters.

  • Page 103: Eu Declaration Of Conformity

    EU DECLARATION OF CONFORMITY (to ISO/DIN 17050-1) Number: 3064219 Wolf GmbH Issued by: Address: Industriestrasse 1, D-84048 Mainburg Product: Gas condensing boiler FGB-28 FGB-K-28 FGB-35 FGB-K-35 The product described above conforms to the requirements specified in the following documents: §6, 1. BImSchV, 26.01.2010 DIN EN 437 : 2009 EN 437 : 2003 + A1 : 2009)
  • Page 104 WOLF GMBH POSTFACH 1380 / D-84048 MAINBURG / TEL. +49.0. 87 51 74- 0 / FAX +49.0.87 51 74- 16 00 www.WOLF.eu 3064458_201811 Document no.: Subject to technical modifications...

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