Wolf CGU-2-18 Installation And Maintenance Instructions Manual
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Wolf CGU-2-18 Installation And Maintenance Instructions Manual

Wall mounted gas fired combi boilers and wall mounted gas fired boilers with integral cylinder connection
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Installation and

maintenance instructions

Wall mounted gas fired combi boilers
and wall mounted gas fired boilers
with integral cylinder connection
CGU-2-18/24
CGG-2-18/24
CGU-2 K-18/24
CGG-2 K-18/24
Wolf GmbH · Postfach 1380 · D-84048 mainburg · Tel. +49-8751/74-0 · Fax +49-8751/741600 · Internet: www.wolf-heiztechnik.de
Part no. 30 62 347
Subject to modifications
Illustration:
Wall mounted gas fired boiler with auxiliary equipment BM
03/09
GB

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Summary of Contents for Wolf CGU-2-18

  • Page 1: Maintenance Instructions

    CGU-2 K-18/24 CGG-2 K-18/24 Illustration: Wall mounted gas fired boiler with auxiliary equipment BM Wolf GmbH · Postfach 1380 · D-84048 mainburg · Tel. +49-8751/74-0 · Fax +49-8751/741600 · Internet: www.wolf-heiztechnik.de Part no. 30 62 347 Subject to modifications 03/09...

  • Page 2: Table Of Contents

    Contents General information Safety instructions / Standards and regulations ..... 3-5 Installation and commissioning Dimensions ...............6 Layout / Equipment code ..........7-9 Positioning information / Installation dimensions ..10-11 Installation on finished walls / Installation on unfinished walls ........12 General boiler installation ..........13 Electrical connection ..........

  • Page 3: Safety Instructions / Standards And Regulations

    Safety instructions / Standards and regulations The following symbols and reference symbols are used in this description. These important instructions concern 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.
  • Page 4 3 mm contact separation. - It is not permitted to carry out repairs on parts that fulfil a safety function. - Use only original WOLF replacement parts or those that are equivalent and that have been approved by the manufacturer.
  • Page 5 - Obtain the permission of your mains gas supplier and all relevant authorities prior to the installation of Wolf gas fired combi boilers. - Open flue gas fired boilers must only be installed in a room that complies with the appropriate ventilation requirements.

  • Page 6: Dimensions

    Dimensions (CGG-2) (CGU-2) Gas fired combi Gas fired boilers boilers Heating flow Heating flow DHW flow Cold water DHW return Heating return Heating return Gas connection Gas connection Installation inside a cupboard For installation of the gas fired boiler inside a cupboard note the following: Never install the gas fired boiler on the back wall >25...
  • Page 7 Layout CGU-2(K) 18/24 Flue gas temperature limiter Draught hood Limit thermostat Flow sensor 2 Heating water heat exchanger Combustion chamber Flow sensor 1 Ignition electrode Monitoring electrode Gas burner Expansion vessel Safety valve Air vent Heating circuit Three-way strainer diverter valve Gas combination valve Heating circuit...
  • Page 8 Layout CGG-2(K) 18/24 LAF connection Differential pressure switch Flue gas fan with speed regulation Flue gas Limit thermostat collector Flow sensor 2 Heating water heat exchanger Combustion chamber Flow sensor 1 Ignition electrode Gas burner Monitoring Expansion vessel electrode Safety valve Air vent Heating circuit Three-way...

  • Page 9: Layout / Equipment Code

    Balanced flue gas fired boiler with integrated cylinder connection CGG-2 K - 18/24 Balanced flue gas fired combi boiler Wolf Low NOx unit with hydro tec system (plug-in technology for quick installation) compactly designed for low emissions, high energy efficiency. Flue gas...

  • Page 10: Positioning Information / Installation Dimensions

    - Hang the gas fired boiler with the hook-in brace on the back of the boiler onto the mounting bracket. (CGU-2-18) Ø110 (CGU-2-24) Ø130 (CGG-2-18) l.h. turnbuckle r.h.
  • Page 11 Positioning information / Installation dimensions Installation dimensions of the boiler with freestanding cylinder SW-120 / CSW-120 Installation on unfinished walls Installation dimensions of the boiler with freestanding cylinder SW-120 / CSW-120 Installation on finished walls 3062347_0309...

  • Page 12: Installation On Finished Walls

    Installation on finished / unfinished walls Installation on finished walls (accessory) Installation on unfinished walls (accessory)   Heating flow Rp ¾" Heating flow R ¾"   DHW Rp ¾" (gas combi boilers) DHW R ¾" (gas combi boilers) ...

  • Page 13: General Boiler Installation

    As the cold water strainer may need to be cleaned, provide a facility for its removal in site. Hydraulic connections - Wolf connection sets (accessories) are available for Otherwise there is a risk of faults. Note installation on fi nished and unfi nished walls. The connection pipes are Cu 18x1.

  • Page 14: Electrical Connection

    Electrical connection CGU-2(K) / CGG-2(K) General notes The installation must be carried out by a licensed electrical contractor. Observe the regulations of the relevant authorities and the local regulations of the power supply company. The power supply terminals are 'live' even when the ON/OFF switch has been switched OFF.
  • Page 15 Flue gas damper connection - Push the inserts back into the terminal box casing. Programmable input E1 zero volt - Push the Rast-5 plugs back into the correct 2-wire eBUS connection, digital Wolf control positions. accessories Outside temperature sensor Changing a fuse 230 V <...
  • Page 16 - Push the inserts back into the terminal box casing. programmable input E1 zero volt - Push the Rast-5 plugs back into the correct 2-wire eBUS positions. connection, digital Wolf control accessories Outside temperature sensor Changing a fuse Isolate the boiler from the main supply prior 230 V <...

  • Page 17: Electrical Connection

    Fig.: Connection, programmable input capability. Connection of digital Wolf control accessories (e.g. BM, MM, SM1, SM2, KM) Note Only connect control units from the Wolf accessory Pay attention range. Each accessory is supplied with its own + , - connection diagram.

  • Page 18: Fill / Vent The System

    - Open all radiator valves and the shut-off valves on the heating water side of the boiler. - Fill the entire heating system and boiler via the fill & drain valves (Wolf accessory) up to approx. 0.5 bar, whilst simultaneously venting the heating system.

  • Page 19: Guidelines For Commissioning

    Otherwise there is a risk of faults. Note - Flush and vent boiler (use shut-off valve with fill & drain valve from Wolf Step 1 accessory range), fill boiler and system and test for tightness. Normal operating pressure when system is cold 1.5 bar.

  • Page 20: Control / Function / Commissioning

    Control / Function / Commissioning ON / OFF switch Reset Thermometer button temperature selector Pressure Illuminated Heating water gauge signal ring temperature selector Signal ring as Display Explanation status display Flashing green Standby (power supply ON, burner OFF) Constant green light Heat demand: pump running, burner OFF Flashing yellow Emissions test mode...

  • Page 21: Control / Function / Commissioning

    Control / Function / Commissioning Setting Winter mode (position 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.

  • Page 22: Displaying / Modifying Control Parameters

    Displaying / modifying control parameters with Wolf control accessories The control parameters can only be modified or displayed via Wolf control accessories with eBUS capability. For installation and procedures, check the operating instructions of the relevant accessories. BM programming module...
  • Page 23 Displaying / modifying control parameters with Wolf control accessories Contractor level Press the r.h. rotary selector to change to control level 2. Turn the r.h. rotary selector clockwise to select the menu level Contractor and confi rm the selection expert by pressing the r.h.
  • Page 24 Displaying / modifying control parameters with Wolf control accessories Upper burner output DHW The higher burner output in DHW mode can be adjusted within the modulation Parameter HG03 range. The setting relates to the maximum heating output in kW (see table "Limiting maximum heating output").
  • Page 25 Displaying / modifying control parameters with Wolf control accessories Pump operating mode 2: Buffer cylinder primary pump Boiler pump becomes the buffer primary pump. The manifold sensor (buffer) only affects the heating operation. In case of DHW heating, the reference temperature is provided by the internal boiler sensor.
  • Page 26 Displaying / modifying control parameters with Wolf control accessories Burner cycle block Each time the burner is shut down in heating mode, it will be blocked for the Parameter HG09 duration of the burner cycle block. The burner cycle block is reset by switching the ON / OFF switch OFF and ON HG09 or by briefl y pressing the reset button.
  • Page 27 Displaying / modifying control parameters with Wolf control accessories Programmable The functions of input E1 can only be scanned and adjusted with Wolf control Input E1 accessories with eBUS capability. Parameter HG13 The following functions can be allocated to input E1: HG13 The electrical control to input E1 must be made with a zero volt contact.
  • Page 28 Displaying / modifying control parameters with Wolf control accessories Programmable The functions of output A1 can only be scanned and adjusted with Wolf control Output A1 accessories with eBUS capability. Parameter HG14 The following functions can be allocated to output A1:...
  • Page 29 Displaying / modifying control parameters with Wolf control accessories Cylinder hysteresis The cylinder hysteresis regulates the start point for cylinder heating. The greater Parameter HG15 the hysteresis, the lower the start temperature. Example: Set cylinder temperature 60 °C HG15 Cylinder hysteresis 5 K Cylinder heating commences at 55 °C and ends at 60 °C.
  • Page 30 Displaying / modifying control parameters with Wolf control accessories Boiler overtemperature during The excess temperature differential between the cylinder temperature and the DHW cylinder heating boiler water temperature during cylinder heating is selected with parameter Parameter HG25 HG25. This ensures that, even in spring and autumn, the boiler water...

  • Page 31: Dhw Connection Versions / Resetting Control Unit

    DHW connection versions / Resetting control unit With boilers CGU-2 / CGG-2 there are 3 possible boiler versions. Legend VL sensor 2 VL sensor 1 Boiler pump Three-way valve Flow rate sensor Cylinder sensor Boiler The DHW circuit is bridged and is not used Combination When drawing DHW the flow rate sensor boiler...

  • Page 32: Setting The Ebus Address For Cascade Mode

    Setting the eBUS address for cascade mode When operating several boilers (up to 4 control units) in conjunction with a cascade controller KM, adjust the eBUS address of the boilers in accordance with the table, below. ON / OFF switch Reset DHW temperature Thermometer...

  • Page 33: Commissioning Gas Connection

    Start-up gas connection Only qualified personnel must carry out the - Connect the hose to the pressure test appliance at commissioning and boiler operation as well test nipple  and check against atmosphere. as the user instruction to prevent dangers Gas type Nominal supply pressure, and injuries as well as material losses.

  • Page 34: Conversion To Other Gas Types / Nozzle Change

    Conversion to other gas types CGU-2(K) / CGG-2(K) The conversion to other gas types is made in four steps: 1. Nozzle replacement 2. Adjusting the control unit after converting the gas type 3. Checking and adjusting the nozzle pressure Identification Carry out all steps, otherwise there is a risk of Note incorrect functions or system damage.

  • Page 35: Setting The Control Unit After Converting The Gas Type

    Check the nozzle pressure after converting the gas type, otherwise material losses and Note incorrect functions can occur. Note: The adjustment of the gas type can also be done with the BM accessory controller (Contractor parameter HG12, description see chapter "Displaying / modifying control parameters with Wolf control accessories"). 3062347_0309...

  • Page 36: Checking Nozzle Pressure

    Check nozzle pressure 3. Checking and adjusting the nozzle pressure: - The gas fired boiler must be switched OFF. - Open the gas shut-off valve. - Remove boiler casing cover and move the control unit to the front. - Undo the plug at the test nipple [2]. - (+) Connect the differential pressure tester with a hose at test nipple [2].
  • Page 37 Check nozzle pressure Gas throughput table for gas volume adjustment according to the volume flow method Gas fired Thermal Rated Gas throughput in l/min (1013 mbar; 15 °C) boilers output thermal Natural gas H (gas fired load with an operational net calorific value of H in MJ/m³...

  • Page 38: Resetting Gas Valve / Setting Nozzle Pressure

    Readjust the gas valve Checking / adjusting the nozzle pressure Readjusting the gas valve: Carry out the nozzle pressure adjustment in the following order: - Remove transparent plastic cap [4] from the gas combination valve. - Operate the boiler in emissions test mode (P - Adjust the maximum pressure at nut [5] (spanner size 10).

  • Page 39: Adjusting The Flue Lengths Cgg-2(K)

    * Operation only with condensate drain pipe in the balanced flue routing (see accessories) Note: The adjustment of the flue pipe length can also be done with the BM accessory controller (Contractor parameter HG12, description see chapter "Displaying / modifying control parameters with Wolf control accessories"). 3062347_0309...

  • Page 40: Flue Gas Test Cgu-2(K) Cgg-2(K)

    Flue gas test CGU-2(K) / CGG-2(K) The flue gas emissions must be tested with the boiler closed. Testing the combustion air CGG-2 - Remove the screw from the test port "inlet air". - Insert the test probe until it bottoms out. - Start the boiler and turn the heating water temperature selector to emissions test [chimney sweep symbol].

  • Page 41: Limiting The Maximum Output

    Limiting the maximum output The output setting can be modified with Wolf control accessories with eBUS capability via parameter HG 02, 03, 04. The heating output will be determined by the modulation current of the gas valve. By reducing the modulation current in accordance with the table, the maximum output will be matched at 80/60 °C to natural gas H and LPG.

  • Page 42: Selecting The Pump Stage / Bypass

    Selecting the pump stage / bypass The boiler is equipped with a three-stage pump that is set to stage 2 in the delivered condition. Stage 1 Stage 2 Stage 3 Fig.: Pump rate stages at the heating circuit pump The minimum circulation volume is ensured by a connection line between the flow and return.

  • Page 43: Selecting The Pump Stage / Bypass

    Selecting the pump stage / bypass Bypass valve CGU-2(K)-18 / CGG-2(K)-18 completely open (delivered condition) Pump stage Pump rate [l/h] Bypass valve CGU-2(K)-18 / CGG-2(K)-18 closed Pump stage Pump rate [l/h] Bypass valve CGU-2(K)-24 / CGG-2(K)-24 completely open (delivered condition) Pump stage Pump rate [l/h] Bypass valve CGU-2(K)-24 / CGG-2(K)-24 closed...

  • Page 44: Checking The Flue Gas Monitoring Cgu-2(K)

    Checking the flue gas monitoring CGU-2(K) Checking the flue gas monitoring CGU-2(K) The electronic flue gas monitoring switches off the gas boiler CGU-2(K) at the flue outlet on the draught hood. The boiler restarts automatically after approx. 15 mins. A regular check must be carried out on the function of the flue gas monitoring.

  • Page 45: Notes On Planning Ventilation / Flue Gas System Cgu-2(K)

    Wolf boilers are certified as one unit with the original Wolf balanced flue system. Use only original Wolf balanced flue systems. Using alternative accessories can lead to incorrect functions.
  • Page 46 If the balanced flue routing is longer than 2.5 m and the heating demands are very low, a condensate trap is recommended, to avoid moisture damage to the gas boiler (see Wolf accessories). Vertical balanced flue system (LAF) horizontal CGG-2(K)
  • Page 47 Engineering information – balanced flue system Vertical balanced flue system (LAF) vertical CGG-2(K) Gas fired boiler Boiler connection (straight) 2b Boiler connection bend 90°, for connection to the gas fired boiler Sliding coupling 3b Condensate trap horizontal or vertical Balanced flue incl. inspection aperture 250 mm Lengths of straight balanced flue: 500 mm, 1 000 mm Bend 45°, for connecting two balanced flues Bend 90°, for connecting two balanced flues...

  • Page 48: Installation Information

    Engineering information – balanced flue system Connection to room sealed balanced flue and flue gas chimney 19/20 19/20 e.g. System Plewa e.g. System Schiedel Connector for flue gas chimney B32 The flue gas chimney connection (17) must be installed directly to the flue gas chimney in accordance with the figure shown (no extension piece between flue gas chimney and flue outlet).
  • Page 49 With thermal flue dampers only Diermayer dampers of type GWR-T from the Wolf product range may be used, as only these meet the approval requirements and are checked for functionality. When other thermal flue gas dampers are used approval of the gas boiler is invalidated.

  • Page 50: Commissioning Report

    Commissioning report Commissioning CGU-2(K) / CGG-2(K) Actual value or confirmation Gas type Natural gas H Wobbe Index_____________________kWh/m³ Net calorific value_________________kWh/m³ Calculated flue length _______________________________________ m No.____________________ /_______________ mm Gas supply pressure checked? ______________________________________ mbar Nozzle pressures checked? (only complete when changing the gas type): Gas leak test carried out? Balanced flue system, tightness of condensate trap (optional), checked?

  • Page 51: Inspection And Maintenance Steps

    Inspection and maintenance steps / Service report Advise the system user that an approved contractor should clean and check the heating system Note annually, to safeguard the reliable and economic function of his heating system and to avoid risks to individuals and prevent material losses. Report about the inspection and service work No.

  • Page 52: Service Report

    Inspection and maintenance steps / Service report to copy Report about the inspection and service work to be implemented Maintenance Maintenance Maintenance Maintenance Maintenance always if required We recommend users arrange a service contract 3062347_0309...

  • Page 53: Maintenance

    Maintenance Cleaning the gas burner: - Switch OFF the boiler at the ON / OFF switch, isolate it from the power supply and close the gas valve - Remove the casing lid of the gas fired boiler. For this, pivot the control unit lid down, hook in the r.h. and l.h.
  • Page 54 Maintenance Cleaning the heating water heat exchanger: - Detach cable from ventilator (only CGG-2(K)) - Undo the fan fixing screw [6] and remove the fan Flue gas (only CGG-2(K)). temperature - After undoing both fixing screws, remove the front limiter [8] wall of the combustion chamber [7].
  • Page 55 Maintenance Cleaning the DHW heat exchanger Subject to the water quality it may be advisable to regularly descale the DHW heat exchanger on the DHW side. For this the disassembly of the hydraulic group is required. Take the hydraulic assembly apart as follows: Hydraulically depressurise the system, collecting water in a suitable container.
  • Page 56 Maintenance - Remove the heat exchanger and treat with a commercially available descaler Please note: When reinstalling make sure the four rubber gaskets are in the right position and the mounting position is correct When reinstalling pay attention to the inscription on the heating water heat exchanger.

  • Page 57: Maintenance

    Maintenance Cleaning the strainer in the cold water inlet - Close the cold water inlet on the system side. Note: As standard, a combined cold water strainer with throughput controller [16] is fitted at the - Remove the cold water inlet shut-off valve on the cold water connection [15] of the boiler (see equipment side.

  • Page 58: Wiring Diagram Cgu-2(K)

    Wiring diagram CGU-2(K) 3062347_0309...

  • Page 59: Wiring Diagram Cgg-2(K)

    Wiring diagram CGG-2(K) 3062347_0309...

  • Page 60: Specification

    Specification Type CGU-2(K) 18 CGU-2(K) 24 Rated output Rated thermal load 20.2 26.5 Lowest output (modulating) 10.9 Lowest thermal load (modulating) 12.0 Standard efficiency at 75/60 °C (Hi/Hs) 93/85 94/85 Outside diameter, heating flow ¾" ¾" Outside diameter, heating return ¾"...
  • Page 61 Specification Type CGG-2(K) 18 CGG-2(K) 24 Rated output Rated thermal load 19.7 26.5 Lowest output (modulating) 10.9 Lowest thermal load (modulating) 11.7 Standard efficiency at 75/60 °C (Hi/Hs) >94/85 >94/85 Outside diameter, heating flow ¾" ¾" Outside diameter, heating return ¾"...

  • Page 62: Fault / Cause / Remedy

    Troubleshooting Any faults will be displayed as fault code 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.

  • Page 63: Resistance Table

    Sensor resistances Boiler sensor, cylinder sensor, solar cylinder sensor, outside Sensor resistances temperature sensor, return sensor, flow sensor, manifold 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 64: Notes

    Notes 3062347_0309...

  • Page 65: Keyword Index

    Commissioning gas connection ........................33 Commissioning guidelines ..........................19 Commissioning report........................... 50 Connection of digital Wolf control accessories (e.g. BM, MM, SM1, SM2, KM) ........... 17 Contractor level ............................23 Conversion to other gas types ........................34 Cylinder hysteresis ............................29 DHW connection versions ..........................
  • Page 66 Keyword index Gas connection............................. 13 Gas throughput table ............................ 37 Guidelines for commissioning........................19 Heating water temperature selector ......................20 Illuminated signal ring as status indicator ..................... 20 Input E1 (24 V) connection ........................... 17 Installation dimensions ..........................10 Installation dimensions with cylinder ......................11 Installation inside a cupboard ........................

  • Page 67: Keyword Index

    Keyword index Parameter overview / setting report......................22 Programmable input E1 ..........................27 Programmable output A1 ..........................28 Pump operating mode / boiler pump ......................24 Readjust the gas valve ..........................38 Replacing expansion vessel ......................... 56 Reset ..............................20, 31 Safety instructions ............................

  • Page 68: Ec Declaration Of Conformity

    Dichiarazione di conformita campione di costruzione - EG Con la presente dichiariamo che le nostre caldaie Murali a Gas Wolf e le caldaie a Gas Wolf corrispondono al e campioni di costruzione, come sono descritte nel certificato di collaudo EG "campione di costruzione"...

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