Wolf MGK-2-390 Installation Instructions Manual
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Wolf MGK-2-390 Installation Instructions Manual

Gas condensing boilers
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Installation instructions for contractors
Gas condensing boilers
MGK-2-390
MGK-2-470
MGK-2-550
MGK-2-630
Wolf GmbH • Postfach 1380 • D -84048 Mainburg • Tel. +49 (0)8751/74-0 • Fax +49 (0)8751/74-1600 • Internet: www.wolf-heiztechnik.de
Document no.: 3063772_201507
Subject to technical modifications
GB
(dt.)

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Summary of Contents for Wolf MGK-2-390

  • Page 1 Installation instructions for contractors Gas condensing boilers MGK-2-390 MGK-2-470 MGK-2-550 MGK-2-630 (dt.) Wolf GmbH • Postfach 1380 • D -84048 Mainburg • Tel. +49 (0)8751/74-0 • Fax +49 (0)8751/74-1600 • Internet: www.wolf-heiztechnik.de Document no.: 3063772_201507 Subject to technical modifications...

  • Page 2: Table Of Contents

    Table of contents Information about this document ................. 3 Safety instructions ..................4 - 5 Dimensions ......................6 Specification ......................8 Boiler layout ......................9 Casing ....................... 10 Standards and regulations ................. 11 - 12 Installation Handling / Installation instructions .............13 - 15 Safety equipment..................

  • Page 3: Information About This Document

    Within four weeks of commissioning of the burner the operator must notify the local flue gas inspector accordingly. Information about disposal We are happy to accept the return of your old Wolf boiler free of charge at one of our delivery depots. MGK-2 standard delivery...

  • Page 4: Safety Instructions

    Only operate the boiler within its output range, which is stated in the technical documentation supplied by WOLF. Intended use of the boiler refers to the exclusive use for hot water heating systems in accordance with DIN EN 12828. Never remove, bypass or otherwise disable any safety and monitoring equipment.
  • Page 5 Danger if you smell flue gas Information about disposal: - Switch OFF the boiler. We are happy to accept the return of your old Wolf boiler free - Open windows and doors. of charge at one of our delivery depots.

  • Page 6: Dimensions

    3. Dimensions 1180 1480 1700 A = ventilation air pipe DN 200 B = gas pipe 2" C = safety assembly connection 2" D = flow pipe DN 80 E = return pipe DN 80 F = BDF valve connection G = flue pipe DN 250 H = condensate drain 3063772_201507...
  • Page 7 4. Specification Type MGK-2 Rated heating output at 80/60 °C 366.7 434.7 511.6 584.4 Rated heating output at 50/30 °C 392.0 467.1 549.3 626.6 Rated heat input 371.2 443.6 521.0 593.9 Low boiler output (modul.) at 80/60 °C 58.5 70.7 84.5 96.7 Low boiler output (modul.) at 50/30 °C...

  • Page 8: Specification

    This characteristic must be taken into account when selecting the components (e.g. pumps, heat exchanger and cylinder). Flow rate Excessive flow velocities may lead to erosion. Maximum flow rate (volume flow) at Q MGK-2-390: 28.5 m³/h MGK-2-470: 34.4 m³/h MGK-2-550: 39.8 m³/h MGK-2-630: 45.5 m³/h 3063772_201507...

  • Page 9: Boiler Layout

    5. Boiler layout Wolf MGK-2-390/470/550/630 gas condensing boilers are adjusted at the factory for natural gas E and LL. The high performance heat exchanger is made from robust aluminium-silicon alloy with a high resistance to corrosion. The gas premix burner with...

  • Page 10: Casing

    6. Casing Remove burner hood - Remove 3 screws on the top of the boiler. (e.g. for servicing the gas-air mixing unit) - Lift burner hood slightly and remove from boiler. Re-assemble in reverse order. Open side casing - Remove 2 screws on the right side casing of the boiler. (e.g.

  • Page 11: Standards And Regulations

    7. 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 for installation and operation: •...

  • Page 12: Standards And Regulations

    7. Standards and regulations For installation and operation in Austria, the following apply: • ÖVE regulations • Provisions of the ÖVGW and the corresponding Austrian standards • ÖVGV TR-Gas (G1), ÖVGW-RTF (G2) • Provisions of ÖVGW guideline G41 for condensate drainage •...

  • Page 13: Handling / Installation Instructions

    8. Handling / Installation instructions Handling • With ground conveyor vehicle: With or without a pallet, the boiler can be handled easily using a pallet truck or forklift, as it can be lifted from any side. Example: 3063772_201507...
  • Page 14 8. Handling / Installation instructions • Can be lowered into the basement with a cable winch or chain hoist, secured to prevent it from sliding down on its own. Example: Dimensions after separating: The gas condensing boiler can be separated into a gas-air mixing unit and heat exchanger unit measuring 790 mm x 1295 mm for easier handling.

  • Page 15: Installation Instructions

    8. Installation instructions Installation instructions • The boiler should be installed on a level surface which is substantial enough to carry its weight. • The boiler must be level (level with adjustable feet). The boiler must only be installed in a room that is protected from frost. Caution If there is a risk of frost while the system is shut down, drain the boiler and the system components that are at risk to prevent pipes from bursting.

  • Page 16: Safety Equipment

    Two can be installed as permissible operating pressure 2nd maximum pressure limiter accessories in MGK-2 safety being exceeded that can be integrated in Wolf assembly accessory safety assembly (accessory) Flash trap Facility to prevent permissible Near safety valve or replaced...

  • Page 17: Information About Water Treatment

    / d i r t t r a p We recommend a heating water pH value of between 8.2 and (e.g. Wolf accessory, <500 μm = 0.5 mm mesh width MW) 8.5, also in mixed installations with various materials.

  • Page 18: Boiler System Pipework

    11. Boiler system pipework Heating flow and return are on the right-hand side of the boiler. Always provide shut-off valves for the flow and the return. Install a check valve downstream of the boiler circuit pump(s) to prevent incorrect circulation. For new systems we recommend installing a blow-down tank (or alternatively a dirt filter) into the return.

  • Page 19: Selection Of Circulation Pumps

    12. Selection of circulation pumps The MGK-2 is supplied without a circulation pump. The pump rate of the pump to be supplied by the customer must be determined depending on the system and boiler pressure drop. The fan's power supply and speed control are via the MGK-2 (see electrical connection).

  • Page 20: Gas Connection

    Install a gas ball valve with fire protection 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 DVGW-TRGI regulations.

  • Page 21: Fitting The Siphons

    14. Fitting the siphons The standard delivery includes: 1 x condensate trap (under the burner hood on the ventilation air pipe) 2 x siphons with 3 condensate hoses and 1 tee (on the condensate trap) Condensate connection: Install condensate trap in the flue outlet of the condensate pan. Check tightness of the connections.

  • Page 22: Neutralising System (Accessory)

    The Neutrakon neutralising system type 08/BGN with booster pump for intensive pH regeneration, which is available as a Wolf accessory, can be slid under the boiler. Firstly remove the wooden slats for boiler transport. The booster pump can be mounted on the boiler crossbar.

  • Page 23: Neutralising System / Condensate Pump (Accessories)

    9 Hose clip, cover Condensate lifting system (accessory) 10 Hose clip, connection The Wolf condensate lifting system is fully wired and can be 11 Pipe spout with strainer integrated into the MGK-2. The power supply and the alarm output of the condensate lifting system are connected to the cable set.

  • Page 24: Air/Flue Gas Routing

    17. Air/flue gas routing Air/flue gas routing Connection types Operating mode Can be connected to Boiler type Gas boiler type Category Open flue Room Moisture- Balanced Balanced Building Moisture- sealed resistant flue flue regulation resistant flue chimney chimney system approved pipe flue pipe C33, C53, C63 B23, C53, MGK-2 B23, B23P,...
  • Page 25 Discuss any questions relating to the installation of inspection covers and ventilation air supplies with your local flue gas inspector. • The length dimensions refer to concentric balanced flue systems and flues, specifically only to original Wolf components. • The following balanced flues or flues with CE-0036-CPD-9169003 certification may be used:...

  • Page 26: Control Unit

    Either an AM display module or a BM2 programming module can be installed in the front panel for operating the boiler. The ON/OFF switch (integrated in the Wolf logo) switches the appliance OFF at all poles. Front panel with integral...
  • Page 27 18. Electrical connection Remove the cover of the control Remove the front casing (see "Casing" chapter), then remove the 4 screws on the control unit with a screwdriver. unit Remove the HCM-2 casing cover Overview of components in the control unit Terminals Cable conduit Fine-wire fuse...
  • Page 28 18. Electrical connection Connections in the control unit Power cable inlet 230 V or 400 V Cable inlet 0-10 V eBUS T_DHW (5kNTC cylinder sensor) T_outside (5kNTC outside temperature sensor) E2 (5kNTC header sensor = low loss header; alternatively 0-10 V control e.g. 8 V = 80 % heating output) E1 (programmable input e.g.
  • Page 29 18. Electrical connection Boiler connection (230 V/400 V): The control, regulating and safety equipment are fully wired and tested. You only need to connect the power supply, the heating circuit pump and the external accessories. Create a permanent connection for the power supply. Provide the power supply via a mains isolator (e.g.
  • Page 30 18. Electrical connection Connection output Z1 (230 V AC; max. 1.5 A) * Insert and secure the connecting cable through the cable gland. Connect the connecting cable to terminals L1, N and * Max. 1.5 A / 345 VA per output, no more than 600 VA in total for all outputs Fig: Connection output Z1 Connection output primary pump...
  • Page 31 Fig: Connection, outside temperature sensor Connection, digital Wolf control accessories (e.g. TM2, 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 > 0.5 mm²) as the connecting cable between the control unit accessory and the condensing boiler.

  • Page 32: Display/Programming Module / Installation

    Remove the front panel of the MGK-2 and refit it after installation of the module. Insert the AM or BM2 in the slot above the ON/OFF switch (Wolf logo). Both modules can be plugged into this slot. Further commissioning or address assignment measures specific to the BM2 can be found in the BM2 installation instructions.
  • Page 33 20. AM display module Overview AM Note: If your Wolf heating appliance does not have an AM display module, ignore this page. Other functions and descriptions can be found in the installation instructions for contractors or the user operating instructions for the AM display module.

  • Page 34: Am Display Module Menu Structure

    21. AM display module menu structure AM control unit menu structure Notification Heating appliance Status Display of Boiler temperature Operating mode faults or System pressure Burner status notifications (see chapter 10) Main menu Back Displays Default settings Emissions test Contractor Back Displays Default settings...

  • Page 35: Operating Mode / Heating Appliance Burner Status

    22. Operating mode / Heating appliance burner status Heating appliance operating mode Display indication Function Start Start the appliance Standby No heating or DHW demand Heating mode Heating mode, at least one heating circuit demands heat DHW mode DHW heating with cylinder, cylinder temperature is below set value Emissions test Emissions test mode active, heating appliance running at maximum power Antifreeze HC...

  • Page 36: Bm2 Programming Module

    23. BM-2 programming module Overview BM2 Note: Other functions and descriptions can be found in the installation instructions for contractors or the user operating instructions for the BM2 programming module. Operating mode Page heading Burner status Quick start buttons Status display Button 1 Heating appliance Heating mode...

  • Page 37: Hg Control Parameters

    24. HG control parameters Modifications must only be carried out by a recognised heating contractor or by Wolf customer Caution service. Incorrect operation can lead to system faults. On the AM display module or the BM2 programming module, the factory setting for the HG parameters Caution can be reinstated in the Contractor menu.

  • Page 38: Parameter Description

    25. Parameter description Parameter HG01 The burner switching hysteresis regulates the boiler water temperature within Burner switching hysteresis a set range by switching the burner ON and OFF. The higher the hysteresis, the higher the boiler water temperature fluctuation around the set value, resulting Factory setting: in longer burner runtimes and vice versa.
  • Page 39 25. Parameter description Parameter HG07 If there is no more heat demand from the heating circuit, the feed/heating circuit Run-on time, heating circuit pump pump ZHP will run on in accordance with the set time to prevent a boiler safety shutdown at high temperatures.
  • Page 40 With open input E1, heating operation will be blocked (summer mode) and frost protection mode and emissions test mode will not be blocked, independent of any digital Wolf control accessories. DHW blocking/enabling With open input E1, DHW heating will be blocked, independent of any digital Wolf control accessories.
  • Page 41 25. Parameter description Parameter HG14 The functions of the output A1 can only be read and set directly on the boiler Function output A1 under parameter HG14 using the AM display module or BM2 programming module. Display Description none none (factory setting) Output A1 is not taken into consideration by the control unit.
  • Page 42 25. Parameter description Parameter HG15 The cylinder hysteresis regulates the start point for cylinder heating. The higher Cylinder hysteresis the setting, the lower the start point for cylinder heating. Factory setting: Example: Set cylinder temperature 60 °C see table chap. 24 Cylinder hysteresis 5 K Control unit parameters Cylinder heating commences at 55 °C and ends at 60 °C.
  • Page 43 25. Parameter description Parameter HG20 Cylinder heating commences as soon as the cylinder temperature sensor Max. cylinder heating time demands heat. The heating circuit pumps would be constantly switched off if the boiler was undersized, the cylinder was scaled up or if DHW was constantly Factory setting: drawn off during DHW priority mode.
  • Page 44 25. Parameter description Parameter HG33 When starting the burner or changing to heating mode, the burner hysteresis Burner hysteresis runtime is set to the parameter "Burner switching differential" HG01. Based on this set value, the burner hysteresis within the set "Runtime burner hysteresis" HG33 Factory setting: is reduced to the minimum burner hysteresis of 7 K.
  • Page 45 25. Parameter description The MGK-2 is fine-tuned to the heating system by selecting from 6 Parameter HG40 preconfigured system configurations that can only be read and set directly System configuration on the boiler under parameter HG40 using the AM display module or BM2 programming module.
  • Page 46 25. Parameter description System configuration 51 BMS burner output Burner is activated subject to demand from the external controller BMS% • Feed/heating circuit pump (ZHP) activated as feed pump from 2 V upwards • No temperature control • Input E2: Control 0-10 V by external controller 0-2 V burner OFF, 2-10 V burner output min.
  • Page 47 25. Parameter description Parameter HG41 In DHW mode, the pump runs at this set value. Independent of pump control Speed ZHP DHW type set in HG37. Factory setting: see table chap. 24 Control unit parameters Individual settings: ________ Parameter HG42 The header hysteresis regulates the header temperature within the set range Header hysteresis by switching the heat source ON and OFF.

  • Page 48: Flue Gas Damper Power Supply

    26. Flue gas damper power supply Flue gas damper power supply Note: - Isolate the system from the power supply before opening. The contractor parameter - Check that appliance is isolated from the power supply. HG13 (input 1) must be set to Fl gas damp - Open the front casing and the cover of the control unit.

  • Page 49: Cascade Operation

    * Calculation and design to EN 13384-2 – kit on request A maximum back pressure up to 50 Pa must be maintained in the connection to the header line and must not be exceeded. Only use DIBt approved flue pipes. In cascade operation, a Wolf cascade controller is required. 3063772_201507...

  • Page 50: Cascade Operation

    KM10 KM11 Pump speed setting If the circulation and feed pump (ZHP) are controlled by the Wolf boiler control unit during operation with low loss header, the flow rates of the primary and secondary circuits may differ from each other.
  • Page 51 27. Cascade operation Installation instructions For general information on positioning, see also information on installation of individual system. Different minimum clearances must be observed when installing the boilers in the installation room. Fig: 2 - 4 boilers in the installation room, side by side Flue gas damper installation Motor-controlled flue gas damper to DIN 3388 Part 2 and DVGW G 635.

  • Page 52: Filling / Draining The Heating System

    28. Filling / draining the heating system Filling the heating system Fill the system correctly in line with the information on water treatment and the system and operator's log, and vent it completely to ensure the smooth running of the condensing boiler. Before connecting the gas condensing boiler, flush the heating Caution system to remove residues such as welding pearls, hemp, putty,...

  • Page 53: Commissioning

    29. Commissioning Only qualified personnel must carry out the commissioning and operation of the boiler and instruct the user. • Check that the power supply has been switched OFF. • Check the boiler and system for leaks. Prevent water leaks. •...

  • Page 54: Checking The Gas Supply Pressure

    30. Checking the gas supply pressure Countries, gas categories and connection Country Appliance Supply pressure pressures in mbar category Natural Natural gas If the supply pressure is outside the specified range, Caution Nom. Min. Max. adjustments must not be carried out and the boiler I2ELL must not be started.

  • Page 55: Settings

    31. Changing the gas type, CO setting Carry out the adjustments in the following sequence. At the factory, the gas combination valve has been set up for natural gas E (G20). A) CO setting at the upper load (emissions test mode) - Release the screws on the burner hood (top).
  • Page 56 31. Changing the gas type, CO setting B) CO setting at the lower load (soft start) - Restart the gas condensing boiler. - Approx. 30 seconds after burner start, check the CO content with the CO measuring instrument. This should be 9.1 % ± 0.3 % for natural gas E/H/LL and can be corrected with a 2.5 mm Allen button at the gas combination valve as shown in the picture.

  • Page 57: Commissioning Report

    32. Commissioning report Commissioning steps Test values or confirmation □ 1.) Gas type Natural gas E/H □ Natural gas LL Wobbe index _____________ kWh/m³ Calorific value, heating _________ kWh/m³ □ 2.) Gas supply pressure checked? □ 3.) Gas leak test carried out? □ 4.) Balanced flue system checked? □...

  • Page 58: Design Information Air/Flue Gas Routing

    Original Wolf components have been optimised country/region. Discuss any questions relating to the over many years and are designed for use with Wolf installation of inspection covers and ventilation apertures condensing boilers. If using third party equipment that with your local flue gas inspector.

  • Page 59: Wiring Diagram Hcm2 /Gbc-P

    34. HCM2 wiring diagram Booster Mains filter Heating circuit Incoming Mounting plate Booster Pump contactor Mains contactor pump ZHP 230 V AC supply front panel fuse 230 V AC/ 230 V AC/ 400 V AC 400 V AC max. 4 A 3063772_201507...
  • Page 60 34. GBC-P wiring diagram 3063772_201507...

  • Page 61: Troubleshooting

    Only replace faulty components and equipment with original Wolf spare parts. Faults and warnings are shown in plain text on the display of the control accessories – AM display module or BM2 programming module –...
  • Page 62 35. Troubleshooting Fault The following faults are in the system: Fault Fault Cause Remedy code HLSC excess temp. The high limit safety cut-out (thermostat) has Test heating circuit pump, vent responded system, press reset, clean heat The boiler water temperature has exceeded exchanger 107 °C TL excess temp.
  • Page 63 35. Troubleshooting Fault Fault Cause Remedy code Fan speed > The fan does not stop Test the fan's PWM and power cable, test fan, press reset, test flue system for strong draught CRC burner control unit The EEPROM record is invalid Switch the power supply OFF and ON.

  • Page 64: Troubleshooting

    35. Troubleshooting Fault Fault Cause Remedy code HC pressure Water pressure too low, water pressure too Test system pressure, test cable, high press reset, test water pressure sensor Button Button Boiler chip card Cyclic redundancy check EEPROM Rewritable memory Burner control unit Gas combination valve Ionisation signal HLSC...

  • Page 65: Troubleshooting Warning Messages

    36. Troubleshooting warning messages Warning messages The following warnings are in the system: Number Fault Description Cause and remedy BCU replaced The control PCB has detected that the burner Insert boiler chip card that control unit has been replaced corresponds to appliance output; if necessary, reinsert boiler chip card HC pressure The water pressure has fallen below the...

  • Page 66: Sensor Resistance Table

    37. Sensor resistance table NTC sensor resistances Boiler sensor, cylinder sensor, outside temperature sensor, return sensor, eHLSC sensor, header sensor Temp. °C Resist. Ω Temp. °C Resist. Ω Temp. °C Resist. Ω Temp. °C Resist. Ω 51393 8233 1870 48487 7857 1800 45762...

  • Page 67: Technical Parameters According To Eu Regulation No. 813/2013

    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 for condensing boilers 30°C, for low-temperature boilers 37°C and for other heaters 50°C return temperature (at heater inlet).

  • Page 68: Declaration Of Conformity

    DECLARATION OF CONFORMITY (to ISO/IEC 17050-1) Number: 3063772 Issued by: Wolf GmbH Address: Industriestrasse 1, D-84048 Mainburg Product: MGK-2 gas condensing boiler The product described above conforms to the requirements specified in the following documents: § 6, 1.BImSchV, 26/01/2010 DIN EN 437, 09/2009 DIN EN 483, 06/2000 DIN EN 677, 08/1998 DIN EN 60335-1, 10/2012...

This manual is also suitable for:

Mgk-2-550Mgk-2-470Mgk-2-630

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