Wolf CGB-35 Maintenance Instructions Manual
Gas fired condensing boiler
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Also See for CGB-35:
- Operating instructions manual (8 pages) ,
- Installation instructions manual (60 pages)
Related Manuals for Wolf CGB-35
Summary of Contents for Wolf CGB-35
- Page 1 Maintenance instructions Gas fired condensing boiler CGB-35 Boiler CGB-50 Boiler Wolf GmbH · PO Box 1380 · 84048 Mainburg · Tel. +49 8751/74-0 · Fax +49 8751/741600 · Internet: www.wolf-heiztechnik.de Document no.: 3061491_0805 Subject to technical modifications.
- Page 2 Index Index ........................ Page Safety instructions ....................3 Maintenance steps .................... 4-13 List of required components ..................14 Overview of the steps to be taken and the maintenance report ...... 15-16 With innovative maintenance technology Maintenance position 1 Maintenance position 2 3061491_0805...
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Page 3: Safety Instructions
OFF switch is turned off. "NB" indicates technical instructions which you must observe to prevent material losses and boiler malfunc- tions. Fig.: Gas combination valve Danger from electric current Escaping gas may cause poisoning or the risk of explosion General notes Maintenance work must only be carried out by a qualified heating contractor. Regular maintenance and the exclusi- ve use of original Wolf spare parts are necessary preconditions for trouble-free operation and a long service life. We therefore recommend you arrange a maintenance contract with a local heating Fig.: Gas connection: Escaping gas may cause poisoning or contractor. the risk of explosion 3061491_0805... -
Page 4: Maintenance Steps
Maintenance steps • Pivot the control unit lid down. Switch OFF the condensing boiler at the ON/OFF switch. The mains terminals are 'live' even when the ON/OFF switch has been switched OFF. • Disconnect the system from the power supply. Close the gas tap. • Unlock the casing lid with the l.h. and r.h. rotating bolts. Release the bottom of the casing lid and unhook at the top. L.h. rotating bolt R.h. rotating bolt 3061491_0805... - Page 5 Maintenance steps Danger of burning Several components may be hot. Let these cool down for approx. half an hour or wear gloves. • Crack open the gas supply connection and remove the gasket. • Release the heat exchanger locking spring. • Pivot the heat exchanger into the mainte- nance position 1. • Release the electrical cable (6x). 3061491_0805...
- Page 6 Maintenance steps • Open the retaining tab. • Remove the burner unit upwards. • Visual burner unit inspection. Monitoring Replace the monitoring electrode. electrode Check and replace the ignition electrode, if necessary. Ignition electrode • Pull the multi-purpose bag over the heat ex- changer. 3061491_0805...
- Page 7 Maintenance steps • Release the retainer and pivot the heat exchanger into the maintenance position 2. • Hook the multi-purpose bag into the heat exchanger. • Remove the clamp. • Remove the displacer segments one after the other. Clamp Lower displacer section Seal ring Upper displacer section 3061491_0805...
- Page 8 Maintenance steps • Clean the heat exchanger with a brush. • Visual flue pipe inspection. • Clean the condensate pan. • Remove the multi-purpose bag. 3061491_0805...
- Page 9 Maintenance steps • Replace the heat exchanger gasket at the top and bottom. Never stretch gaskets. • Lubricate the heat exchanger gaskets at the top and bottom with silicone grease. • Lubricate the heat exchanger seat. 3061491_0805...
- Page 10 Maintenance steps Assembly • Pivot the heat exchanger into the mainte- nance position 1, insert the burner unit and thread in the rear retaining spring. Position the front retaining spring with a key into its position. • Tip the heat exchanger (forward) to return it to maintenance position 2. Insert the upper displacer section as far as it will go into the burner. • Replace the seal ring and the lower dis- placer section. • Insert the displacer clamp. 3061491_0805...
- Page 11 Maintenance steps • Pivot the heat exchanger back into the main- tenance position 1 and plug in the cables (6x). • Release the retainer and pivot the heat ex- changer fully back into the boiler. Check the lower heat exchanger gasket. • Click the heat exchanger locking spring back into place. • Install the gas restrictor and gasket. CGB-35 Gas type Colour Diameter yellow CGB-50 Gas type Colour Diameter light grey lilac 3061491_0805...
- Page 12 Maintenance steps • Check the balanced flue system. Checking the siphon If required, clean and re-fill. Check for tight fit, prevent flue gas from escaping. • If you notice a loss of water, check the ex- pansion vessel inlet pressure and increase it, if required, to 0.75 bar. The heating circuit must be at zero pressure. Then fill the system. 3061491_0805...
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Page 13: Maintenance Steps
Maintenance steps Completion Check gas train for soundness and water connections for leaks. • Fit the casing. Test run • Reset the MCBs. • Open the gas tap. • Switch the boiler ON. • Set the program selector to emissions test mode. Emissions test mode position Carrying out a ventilation test Check LAF for soundness, if the CO > 0.2%. "Flue gas“ "Air supply" test port test port Carrying out a flue gas test In emissions test mode, enter the captured values in the maintenance report. -
Page 14: List Of Required Components
List of required components Checking control accessories Fig.: DWT Fig.: AWT • The display must show BUS connection . BUS connection Maintenance requires the following: Maintenance set CGB-35/50 Part no. 86 11 173 Cleaning set - supplementary set Part no. 24 82 875 Cleaning brush Part no. 24 40 053 Test equipment for BImSch test [Germany] We recommend you have the following as part of your service kit: Gasket set, flue pipe DN 80 Part no. 86 11 184 Silicone grease 10 g tube part no. 86 02 264 or 400 g tube part no. 35 00 103... -
Page 15: Overview Of The Steps To Be Taken And The Maintenance Report
Overview of the steps to be taken and the maintenance report Step Report item Switch OFF the boiler, switch OFF the emergency stop switch Close the gas supply valve, Remove the casing and the combustion chamber housing Undo the gas fitting Pull the electrical cables off the fan, sensors and electrodes Remove the heat exchanger lid Visual inspection of the burner unit Check the ignition electrodes and replace if required Clean the heating water heat exchanger Clean the condensate pan Check and replace gaskets, if required and lubricate the replace- ments with silicone grease Refill granulate, if a neutralising system is installed Check the protective anode every 2 years on enamelled cylinders and replace, if necessary Assemble the boiler Clean and fill the siphon, install and check for tight fit Check the expansion vessel in case of water loss Open the gas supply valve and start the boiler Gas soundness test Flue gas system soundness test Check the ignition Check the interaction with control accessories Flue gas test in emissions test mode Gross flue gas temperature °C Air supply temperature °C Net flue gas temperature... -
Page 16: Overview Of The Steps To Be Taken And The Maintenance Report
Overview of the steps to be taken and the maintenance report Step Report item Switch OFF the boiler, switch OFF the emergency stop switch Close the gas supply valve, Remove the casing and the combustion chamber housing Undo the gas fitting Pull the electrical cables off the fan, sensors and electrodes Remove the heat exchanger lid Visual inspection of the burner unit Check the ignition electrodes and replace if required Clean the heating water heat exchanger Clean the condensate pan Check and replace gaskets, if required and lubricate the replace- ments with silicone grease Refill granulate, if a neutralising system is installed Check the protective anode every 2 years on enamelled cylinders and replace, if necessary Assemble the boiler Clean and fill the siphon, install and check for tight fit Check the expansion vessel in case of water loss Open the gas supply valve and start the boiler Gas soundness test Flue gas system soundness test Check the ignition Check the interaction with control accessories Flue gas test in emissions test mode Gross flue gas temperature °C Air supply temperature °C Net flue gas temperature...
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