Wolf CGB-2 Series Installation Instructions For Contractors

Wall mounted gas condensing boiler/gas condensing combi boiler

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Page 1 Wall mounted gas condensing boiler CGB-2 wall mounted gas condensing boiler CGB-2K wall mounted gas condensing combi boiler CGB-2-14 CGB-2(K)-20 CGB-2(K)-24 WOLF GMBH / POSTFACH 1380 / D-84048 MAINBURG / TEL. +49.0.875174-0 / FAX +49.0.875174-1600 / www.WOLF.eu Art.-Nr.: 3064810_201804 Subject to technical modifications...
Page 2: Table Of Contents
Table of contents Information on documentation/standard delivery ....... 3 Safety instructions ................5 Dimensions ..................8 Specification ..................10 Layout ....................11 Electronic gas/air mixture ..............13 Casing ..................... 14 Standards and regulations ............... 15 Installation Positioning ..................18 10. Installation dimensions ..............19 11.
Page 3: Information On Documentation/Standard Delivery
1. Information on documentation/ standard delivery 1.1 Other applicable documents - Operating instructions for the user - Maintenance instructions - System and operating log The instructions for all accessory modules and other accessories also apply where relevant. 1.2 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, in casing 1 x Suspension bracket for wall mounting 1 x Installation instructions for contractors 1 x Operating instructions for users 1 x Service instructions 1 x Commissioning checklist 1 x Label "G31/G30"...
Page 5: Safety Instructions
[Germany/Austria]. Operate the gas condensing boiler only within its output Danger: if you smell flue gas range, which is stated in the technical documentation - Switch OFF the appliance. supplied by WOLF. Intended use of the boiler includes exclusive use for hot water heating systems in accordance - Open windows and doors with DIN EN 12828. - Notify an approved contractor.
Page 6 We recommend arranging a suitable maintenance contract. - 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. 3064810_201804...
Page 7 2. Safety instructions Fig: Terminal box: Danger from electrical voltage Fig: Gas connection: Risk of poisoning or explosion in the event of gas escaping Gaskombiventil Fig: Ignition transformer, high voltage ignition electrode, combustion Fig: Gas combination valve chamber Danger from 'live' electrical components Danger from 'live' electrical components, risk of burning from hot Risk of poisoning or explosion in the event of gas escaping components...
Page 8: Dimensions
3. Dimensions 3 4 4 3 4 4 CGB-2 Wall mounted gas condensing boiler 3 4 4 1 9 0 1 9 0 Ø 80/125 Ø 60/100 1 9 0 1 0 0 1 0 0 1 0 0 1 0 0 3 7 8 3 7 8 4 4 0 4 4 0...
Page 9 3 4 4 3 4 4 3. Dimensions CGB-2K Wall mounted gas condensing combi boiler 3 4 4 1 9 0 1 9 0 Ø 80/125 Ø 60/100 1 9 0 3 7 8 3 7 8 1 0 0 1 0 0 1 0 0 1 0 0 4 4 0 4 4 0 3 7 8...
Page 10: Specification
4. Specification Type CGB-2 CGB-2K Rated heating output at 80/60 °C 13.5 18.9/22.2 23.8/27.1 18.9/22.2 23.8/27.1 (23.8 (23.8 Rated heating output at 50/30 °C 15.2 20.4 25.8 20.4 25.8 Rated heat input 14.0 19.6/23.0 24.6/28.0 19.6/23.0 24.6/28.0 (24.6 (24.6 Lowest heating output (modulating) at 80/60 °C 1.8/4.6 3.8/6.8 4.8/6.8...
Page 11: Layout
5. Layout CGB-2 Wall mounted gas condensing boiler 1 Gas fan 11 Burner 2 Expansion vessel 12 Heating water heat exchanger 3 Mixing valve 13 Flue gas temperature sensor 4 Gas valve 14 Pressure sensor 5 Trap 15 Return temperature sensor 6 3-way valve 16 Boiler water temperature sensor 7 Control unit enclosure 17 Heating circuit pump with air vent valve...
Page 12 5. Layout CGB-2K Wall mounted gas condensing combi boiler 1 Gas fan 13 Flue gas temperature sensor 2 Expansion vessel 14 Pressure sensor 3 Mixing valve 15 Return temperature sensor 4 Gas valve 16 Boiler water temperature sensor 5 Trap 17 Heating circuit pump with air vent valve 6 3-way valve 18 Plate heat exchanger 7 Control unit enclosure...
Page 13: Electronic Gas/Air Mixture
6. Electronic gas/air mixture Gas-adaptive combustion air control Principle: The relationship between the actual ionisation current and excess air is used for combustion control. The system carries out a continuous set/actual comparison for the ionisation current. The control unit adjusts the gas throughput via the electronic gas valve to match the actual ionisation current to the set value.
Page 14: Casing
7. Casing Casing First, grip the control unit cover on the r.h. side and swivel to the side. Then undo the two screws on the r.h. and l.h. sides of the front casing. The front casing can then be released at the top and removed.
Page 15: Standards And Regulations
8. Standards and regulations Observe all standards and guidelines applicable to the installation and opera- tion 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: • Siting conditions • Ventilation and exhaust air facilities and connection to a chimney • Electrical connection to the power supply • Technical regulations of the gas supply utility company regarding the connection of the gas appliance to the local gas mains •...
Page 16 8. Standards and regulations The following general regulations, rules and guidelines must be observed for installation in particular: • (DIN) EN 806 Specifications for installations inside buildings conveying water for human consumption • (DIN) EN 1717 Protection against pollution of potable water installations • (DIN) EN 12831 Heating systems in buildings – Method for calculation of the de- sign heat load • (DIN) EN 12828 Heating systems in buildings – Design of water-based heating systems • (DIN) EN 13384 Chimneys - Thermal and fluid dynamic calculation methods •...
Page 17 (EU) No 811/2013 / Commission Delegated Regulation (EU) No 813/2013, with electronic ignition and electronic flue gas temperature monitoring, for low temperature heating and DHW heating in heating systems with flow temperatures up to 90 °C and 3 bar permissible operating pressure in accordance with EN 12828.This Wolf gas condensing boiler is also approved for installation in garages. Gas condensing boilers operated with an open flue may be installed only in rooms that comply with the appropriate ventilation requirements.
Page 18: Positioning
Operation in wet rooms In the delivered condition and for room-sealed opera- tion, the Wolf gas condensing boiler has IP rating IPx4D. When installing it in wet rooms, the following conditions must be met: - Balanced flue operation - Compliance with IP rating IP 4D - All outgoing and incoming cables must be routed through the strain relief cable glands and secured.
Page 19: Installation Dimensions
10. Installation dimensions Flue system component 80/125 Flue system component 60/100 Connection panel for surface mounting Suspension bracket Installation template Installation panel for Cold water unfinished walls Heating flow Heating return Trap connection Gas connection 3064810_201804...
Page 20 10. Installation dimensions Bild: Bohrlöcher für Einhängewinkel Bild: Bohrlöcher für Einhängewinkel Seite 12 Seite 12 Securing the appliance with the suspension Ceiling bracket When installing the appliance, ensure that the fixings have sufficient load-bearing capacity. Also take into account the condition of the wall,as an escape of gas or water might result in a risk of explosion and flooding. 1. Mark the Ø12 holes to be drilled for the suspension bracket, taking into account the minimum clearances.
Page 21: Installation
11. Installation Supply lines on unfinished walls Seite 15 Bild: Montageschablone Unterputz If supply lines for cold water and DHW, heating, gas and safety Seite 15 valve drain are routed on unfinished walls, the connections Bild: Montageschablone Unterputz can be determined using the installation template for unfin- ished walls.
Page 22 If the cold water supply pressure is above the maximum permissible operating pressure of 10 bar, install a tested and certified pressure reducer in accordance with Wolf accessories. If mixer taps are used, provide a centralised pressure reducer. Observe the regulations of DIN 1988 [Germany] as well as those of your local water supply utility when connecting cold water and DHW.
Page 23: Gas Connection
12. Gas connection Seite 16 Gaskugelhahn, Durchgangsform Connect the gas supply line at the gas connection or the ex- pansion 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. Remove all residues from the heating pipework and the gas line prior to connecting the con- densing boiler, particularly in older systems.
Page 24: Fitting The Trap
Bild 2: Anschlussset für Überputzinstallation Connection to Wolf cylinder Bild 1: Anschlussset für Unterputzinstallation A detailed description is included with the connection set (accessories). Fig: Fig: Connection set for Wolf cylin- Connection set for Wolf cylinder der CSW-120 CSW-120 Installation on unfinished walls Installation on finished walls (accessories) (accessories)
Page 25: Air/Flue Gas Routing
14. Air/flue gas routing For concentric balanced flue systems, use only Please original Wolf parts. note Prior to installation, read the technical information regarding air/flue gas routing. As regulations in the individual Federal States [Germany] differ, we recommend consulting the relevant authorities and local flue gas inspector prior to installation.
Page 26: Electrical Connection
Either an AM display module or a BM-2 programming module can be installed in the front panel for operating the appliance. The ON/OFF switch (integrated in the Wolf logo) switches the appliance off across all poles. Front panel with integral...
Page 27 15. Electrical connection Removing the front casing See chapter "Casing". Removing the HCM-2 casing cover Control unit component overview Burner control unit GBC-e HCM-2 control unit Netz eBUS Fig: Control unit component overview 3064810_201804...
Page 28 15. Electrical connection Connections inside the control unit eBUS 1 (+), 2 (-) WOLF control accessories T_DHW (5kNTC cylinder sensor) T_outside (5kNTC outside temperature sensor) E2 (5kNTC common sensor = low loss header; alternatively 0-10 V switching, e.g. 8 V = 80 % heating output) E1 (programmable input e.g. flue gas damper or room thermo-...
Page 29 15. Electrical connection 230 V mains connection The control and safety equipment is fully wired and tested. You only need to connect the power supply and the external accessories. Create a permanent connection for the power supply. Provide the power supply via a mains isolator (e.g. heating system emergency stop switch) that ensures at least 3 mm contact separation for all poles.
Page 30 15. Electrical connection Connecting output A1 (230 V AC; max. 1.5 A) * Insert and secure the power cable through the cable gland. Connect the power cable to terminals L1, N and The parameters for output A1 are described in the table. * Max. 1.5 A/345 VA per output, sum of all outputs no more than 600 VA Fig: Connection of A1 output Changing a fuse...
Page 31 Fig: Cylinder sensor connection Connecting digital WOLF control accessories (e.g. BM-2, MM-2, KM-2, SM1-2, SM2-2) Only control units from the Wolf range of accessories may be connected. Each accessory is supplied with its own connection diagram. Use a two-core cable (cross-section > 0.5 mm²) as the con- necting cable between the control unit accessory and the condensing boiler.
Page 32: Flue Gas Damper/Ventilation Air Damper Electrical Connection
16 Flue gas damper/ventilation air damper electrical connection Flue gas damper/ventilation air damper electrical connection Note: The contractor parameter - Isolate the system from the power supply before opening. HG13 (input 1) must be set to Fl. gas damper - Check that the appliance is isolated from the power supply. - Swivel the front panel to one side.
Page 33: Display/Programming Module Installation
• AM is always in the boiler Insert the AM or BM-2 in the slot above the ON/OFF Status switch (Wolf logo). Betriebsart Heizbetrieb Brennerstatus Softstart Both modules can be plugged into this slot. Further...
Page 34: Removing The Display Module/Programming Unit
18. Removing the display module/ programming unit Removing the BM-2 programming unit or AM display module 3064810_201804...
Page 35: Am Display Module
19. AM display module AM overview Note: If your Wolf boiler is not equipped with an AM display module, ignore this page. Further functions and descriptions can be found in the installation instructions for contractors or the user operating instructions for the AM display module. Status display Quick start keys Key 1 Status Rotary selector with Operating mode Key 2 pushbutton function Heating mode Key 3 Burner status Key 4 Burner ON Boiler in heating mode Boiler pump ON Set boiler temperature (if BM-2 used as remote control – no function) Key 1...
Page 36: Am Display Module Menu Structure
Extend time T_DHW outl. in °C Parameter reset DHW DFL (flow rate) in l/min Message history Input E1 Modulation level in % Back IO set value (Wolf service) ZHP speed Burner starts Burner hours run Hours run on mains power Power ON count HCM-2 FW Back...
Page 37: Operating Mode/Boiler Burner Status
21. Operating mode/Boiler burner status Boiler operating mode Display shows Meaning Start Appliance starting Standby No heating or DHW demand Combi mode DHW heating with heat exchanger active, water tap is open 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, boiler running at maximum output Frost HC...
Page 38: Programming Unit
22. BM-2 programming unit BM-2 overview Note: Further functions and descriptions can be found in the installation instructions for contractors or the user operating instructions for the BM-2 programming unit. Operating mode Screen header Burner status Quick start keys Status display Key 1 Boiler Rotary selector with Heating mode pushbutton function Key 2 Burner ON 25.2 Key 3 °C Pressure Boiler water tem- System data display perature Key 4 (content varies) 14:12 20.01.15...
Page 39: Hg Control Parameters
23. HG control parameters Modifications must only be carried out by a recognised heating contractor or by Wolf customer service. Incorrect Please operation can lead to system faults. note On the AM display module or the BM-2 programming unit, the factory setting for the HG parameters can be Please reinstated in the contractor menu. note To prevent damage to the heating system, cancel night setback when outside temperatures fall below -12 °C. If this requirement is not observed, ice may form on the flue outlet which may cause injury or material losses. The control parameters can only be modified or displayed using the AM display module or BM-2 programming module on the boiler. For procedures, check the operating instructions of the relevant accessories. Designation: Unit Factory setting Min: Max: Condensing boiler 14 kW 20 kW 24 kW HG01 Burner switching hysteresis °C...
Page 40: Parameter Description
24. Parameter description Parameter HG01 The burner switching hysteresis regulates the boiler water temperature within Burner switching hysteresis the set range by switching the burner on and off. The higher the start/stop temperature differential is set, the greater will be the fluctuation in boiler water Factory setting: see table temperature around the set value with corresponding longer burner runtimes, Setting range: 7 to 30 °C and vice versa.
Page 41 24. Parameter description Parameter HG07 If there is no longer a heat demand from the heating circuit, the internal appliance Run-on time, heating circuit pump pump runs on for the set amount of time, to prevent a boiler safety shutdown due to high temperatures. Factory setting: see table Setting range: 0 to 30 min Individual setting:_____...
Page 42 With input E1 open, DHW heating will be disabled, regardless of any digital Wolf control accessories. RT/DHW Heating and DHW disabled/enabled With input E1 open, heating mode and DHW heating will be disabled, regardless of any digital Wolf control accessories*. Zirkomat Zirkomat (DHW circulation remote control) When input E1 is configured as the DHW circulation remote control, output A1 is automatically set to "DHW circulation pump" and is blocked for further settings.
Page 43 24. Parameter description Parameter HG14 The functions of output A1 can only be checked and set directly on the boiler under Function output A1 parameter HG14 using the AM display module or BM-2 programming module. Display Designation: none none (factory setting) Output A1 is ignored by the control unit. Circ 100 DHW circulation pump 100 % Output A1 is switched by the time program in the control accessory if...
Page 44 24. Parameter description Parameter HG15 The cylinder hysteresis regulates the start point for cylinder heating. Cylinder hysteresis The higher the setting, the lower the start point for cylinder heating. Factory setting: see table Example: Set cylinder temperature 60 °C Setting range: 1 to 30 K Cylinder hysteresis 5 K Cylinder heating commences at 55 °C and ends at 60 °C.
Page 45 24. 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 appliance were undersized, the cylinder were scaled up or if DHW were Factory setting: see table constantly drawn off during DHW priority mode.
Page 46 24. Parameter description Parameter HG33 When the burner starts or when the boiler switches to heating mode, the burner Burner hysteresis runtime hysteresis is set to the parameter "Burner switching differential" HG01. Based on this set value, the burner hysteresis within the set "Runtime burner hysteresis" HG60 is reduced to the minimum burner hysteresis of 7 K.
Page 47 24. Parameter description System configuration 01 Direct heating circuit on the condensing boiler + optional additional mixer circuits via mixer modules (factory setting) • Burner is enabled subject to demand from the direct heating circuit or optionally connected mixer circuits • Internal appliance pump is enabled as a heating circuit pump • Thermostatic boiler control Set value is specified by the heating circuit or mixer circuits •...
Page 48 24. Parameter description System configuration 51 BMS burner output BMS % • Burner is enabled subject to demand from the external controller • Internal appliance pump is enabled as a feed pump from 2 V • No temperature control • Input E2: 0-10 V control from the external controller 0-2 V burner OFF 2-10 V burner output min.
Page 49 24. Parameter description Parameter HG41 In DHW mode, the pump runs at this set value. Independent of pump control ZHP speed DHW type set in HG37. Factory setting: see table Setting range: 15 to 100 % Individual setting:_____ Parameter HG42 The header hysteresis regulates the header temperature within the set range by Hysteresis, header switching the heat generator ON and OFF.
Page 50 24. Parameter description Parameter HG45 The setting range of the flue length compensation is from 0 to 7.5 % and can Flue length compensation be enabled in increments of 2.5 %. Flue length compensation compensates for the pressure drop which increases with the length of the balanced flue system, Factory setting: see table thus ensuring optimum operation. Setting range: 0 to 7.5 % Individual setting:_____ There is a separate setting table for each model of the CGB-2: CGB-2-14 HG45 Flue system/DN...
Page 51 24. Parameter description Parameter HG46 The excess temperature differential between the header temperature and the Excess boiler temperature, header boiler water temperature during header heating is selected with parameter HG46. The boiler water temperature continues to be limited by the maximum Factory setting: see table boiler water temperature (parameter HG22).
Page 52: Filling The Heating System/Trap
25. Filling the heating system/trap Hydraulics Before commissioning, carry out a leak test on all hydraulic pipework Please If the appliance is not watertight, there is a risk of leaks and resulting note 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) opens at 3 bar. The appliance has already been leak tested at the factory at 4.5 bar. Treatment of heating water in accordance with VDI 2035: Filling Potable water may be used as filling and top-up water if the limits in table 1 are not exceeded. Otherwise, the water must be treated using a desalinisation process. If the water quality does not meet the required values, the warranty for components on the water side becomes void. The only permissible water treatment process is desalinisation! Please note...
Page 53 25. 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 54 If leak-tightness cannot be ensured, there is a risk of water damage. Pressure gauge • Switch ON the condensing boiler at the red ON/OFF Fig: Pressure gauge switch in the WOLF logo (pump will run). Slightly open the • Briefly open the manual air vent valve until all air has manual air vent valve escaped and then close it again.
Page 55 • Fill the trap with water up to the mark. • Refit the trap. • Open the gas ball valve and acknowledge the fault. • Switch ON the condensing boiler at the red ON/OFF switch in the WOLF logo. Note: Trap The condensate hose attached to the trap must not form Fig: Trap a loop or roll up, as this could lead to impaired operation.
Page 56: Filling Of Optional Appliance Versions
26. Filling of optional appliance versions Optional boiler versions (subject to country-specific versions): Two versions are available equipped with heating system filling facility. Hand wheel Hand wheel Hydraulic separator CA Hydraulic separator CA Fig: Filling facility integrated in the appliance on delivery Fig: Filling facility that can be integrated into the appliance as a retrofit kit Applicable standards for the filling facility: (DIN) EN 1717 Protection against pollution of potable water installations (DIN) EN 14367 Non controllable backflow preventer - Family C, type A DIN 1988-100 (for Germany) Codes of practice for drinking water installations Also observe the country-specific standards and guidelines on installation and operation.
Page 57: Draining The Heating System
27. Draining the heating system Draining the heating system: • Switch OFF the condensing boiler at the red ON/OFF switch in the WOLF logo. • Close the gas ball valve. • Allow the temperature in the heating circuit to cool to at least 40 °C. (Risk of scalding) •...
Page 58: Determining/Changing The Gas Type
28. Determining/changing the gas type Determining the gas type The condensing boiler is equipped with electronic com- Natural gas E/H 15.0: bustion control which regulates the gas-air-ratio in ac- = 11.4 - 15.2 kWh/m³ = 40.9 - 54.7 MJ/m³ cordance with the prevailing gas quality and so provides Natural gas LL 12.4: optimum combustion. = 9.5 - 12.1 kWh/m³...
Page 59 28. Determining/changing the gas type Seite 19 gas type (only for operation with LPG) Changing the Change the gas type for operation with LPG 1. The gas boiler must be switched OFF. Close the gas ball valve. The boiler starts automatically when there is a heat Please demand, even if the gas type has not yet been note correctly set.
Page 60: Checking The Gas Supply Pressure
29. Checking the gas supply pressure Seite 19 Checking the gas supply pressure For permissible values, see table "Gas catego- ries and supply pressures". Work on gas components must only be per- formed by a licensed gas fitter. Work that is carried out incorrectly may lead to gas escap- ing, resulting in a risk of explosion, suffocation or poisoning. 1. The gas boiler must be switched OFF. Close the gas ball valve. 2. Loosen screw B on the gas test connector of the gas combination valve with a screwdriver.
Page 61: Adjusting The Maximum Heating Output
30. Adjusting the maximum heating output Output setting (parameter HG04) The output setting can be modified with Wolf control accessories with eBUS capability. 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. 14 kW appliance Display value (%) Heating output (kW) 11.3...
Page 62: Checking The Combustion Parameters
31. Checking the combustion parameters The condensing boiler is equipped with electronic combustion control which ensures optimum combustion quality. During commissioning and maintenance, only a check of CO, CO or O is required. Test the combustion parameters with the boiler closed. Please A flue gas emissions test by a contractor is necessary after every modification of the GBC-e PCB, mixing device, note burner and gas valve.
Page 63 31. Checking the combustion parameters If the actual CO or O values lie outside their respective ranges, proceed as follows 1. Check the ionisation electrode and supply line. 2. Check the electrode gaps. Bild: Abstand Zündelektrode Bild: Abstand Ionisationselektrode Check the electrodes for wear and contamination. Clean the electrodes with a small brush (not with a wire brush) or sandpaper. Check the electrode gaps.
Page 64: Converting From Combi Boiler To Boiler With Cylinder
(does not apply to CGB-2-14). This requires the If changes have previously been made to control parameters appropriate conversion kit from the Wolf accessories range. to adjust the system, make sure to record these first and then set them again after the master reset. Carry out the following steps: To carry out a parameter reset: •...
Page 65: Setting The Flow Limiter
33. Setting the flow limiter The combi boiler is fitted with an adjustable flow Seite 26 limiter (DHW draw-off rate). The flow limiter is shipped with a flow rate set at the factory to 8 l/min. The flow rate can be changed via the green rotary selector on the flow limiter. The flow limiter can be adjusted between 5 and 13 l/min. Procedure: • Manually pull out the green rotary selector forwards. • Increase flow rate Þ rotate counter clockwise in + direction. • Reduce flow rate Þ rotate clockwise in - direction.
Page 66: High Efficiency Pump Function Description
34. High efficiency pump function description Residual head of the high efficiency pump (EEI ≤ 0.23) 20 % 30 % 60 % 40 % 80 % 100 % 90 % 2,8 W 4,5 W 10 W 14,5 W 6,5 W 21,1W 29,5 W 46,6 W 40,6 W 1000 Fördermenge in [l/h] Pump rate in [l/h] High efficiency pump function Heating mode 3 operating modes are possible with the modulating heating description (EEI ≤ 0.23)
Page 67 34. High efficiency pump function description Factory settings for pump speeds Appliance Heating mode Standby output heating mode maximum minimum 14 kW 70 % 45 % 55 % 30 % 20 kW 70 % 45 % 75 % 30 % 24 kW 70 % 45 % 85 % 30 % Troubleshooting Problem...
Page 68: Commissioning Report
35. 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 from installation instructions and VDE regulations? 2.) System flushed? □ 3.) System filled and water treatment carried out in line with □ "Technical information, water treatment"? pH value set _______________ pH value Total hardness set _______________...
Page 69 35. Commissioning report Commissioning steps Test values or confirmation 12.) Standard setting set on control unit? □ 13.) Required heating output set in contractor parameter HG04? □ 14.) Gas type set in contractor parameter HG12? Natural gas □ □ 15.) Check system configuration and modify if required □ Contractor parameter HG40 □ 16.) Flue length compensation set according to "Flue length compensation table"...
Page 70: Safety Devices
36. Safety devices Temperature monitoring Combustion chamber temperature sensor (eHLSC) The combustion chamber temperature sensor is a contact sensor on the indirect coil. It consists of 2 sensor beads which together act as a high limit safety cut-out (eHLSC). At the same time, the combustion chamber temperature sensor acts as a temperature monitor (TM).
Page 71: Technical Information, Air/Flue Gas Routing
37. Technical information, air/flue gas routing Balanced flue system C43x C33x C13x C33x C53x C13x C43x C93x C83x C93x C33x C83x Provide ventilation for B23, B33, C53 Information about multiple connections: Point Safe differential pressure in accordance with DIN EN 15502-2-1 CGB-2-14 CGB-2-20 CGB-2-24 The maximum safe differential pressure at the lowest thermal load (Δpmax, saf(max)) The maximum safe differential pressure at the highest thermal load (Δpmax, saf(min)) The maximum safe differential pressure at start (Δpmax, saf(start))
Page 72 - 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 Please also observe the installation information supplied flues and standard flues, and apply to original Wolf with the accessories.
Page 73 37. Technical information, air/flue gas routing General information For reasons of operational safety, use only original Wolf If fire resistance is not required for the ceiling, components for concentric balanced flues and standard route the lines for the combustion air supply and flues. the flue gas from the top edge of the ceiling to the roof skin in a duct made from non-combustible, rigid Where necessary, adapt the installation examples to the rel-...
Page 74 37. Technical information, air/flue gas routing If the gas condensing boiler is installed with a balanced flue routed over an external wall (type C13x), the rated boiler output in heating mode must be reduced to below 11 kW (for appropriate measures, see chapter "Limiting the maximum output"). Connection to the balanced flue It must be possible to inspect the entire cross-section of the flues. Therefore, install an appropriate cleaning and/or inspection aperture inside the boiler room; agree suitable arrangements with your local flue gas inspector.
Page 75 Original Wolf components are designed for long-term use, flue system type B33 for open flue operation are designated with the DVGW quality seal and are designed 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 CE-designated, connecting the system to a chimney. In addition to the boiler the installer himself is responsible for the correct sizing and connection bend, no more than two 90°...
Page 76 37. Technical information, air/flue gas routing 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 (risk connections to of poisoning or asphyxiation). adjacent appliances The check must be carried out with the appliance closed. We recommend proceeding as follows: Tightness test on connections to adjacent appliances - Select the mixer circuit via the right hand rotary selector.
Page 77 37. Technical information, air/flue gas routing Vertical balanced flue routing (examples) system DN 60/100 1 Gas condensing boiler 2 Balanced flue pipe with inspection port (250 mm long) 3 Separator DN60/100 (slide coupling) if required 4 Balanced flue pipe 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 ... 1700 mm 6 Universal tile for pitched roof 25/45°...
Page 78 37. Technical information, air/flue gas routing Horizontal balanced flue/connection to balanced flue chimney (examples) system DN60/100 1 Gas condensing boiler Dormer 2 Balanced flue pipe 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 500 mm...
Page 79 37. Technical information, air/flue gas routing Balanced flue inside a duct with horizontal connecting pipe DN60/100 1 Gas condensing boiler 3 Separator (slide coupling) if required 4 Balanced flue DN60/100 500 mm Installation example for bal- 1000 mm anced flue/duct 2000 mm 9 Inspection bend Please 11 Pipe collar note Install horizontal pipe with > 3° 12 Support rail slope towards 13 Support bend 87° DN60/100 boiler 14 Spacer 16 Duct cover with...
Page 80 The flue gas chimney must be tested for suitability. Apply 0 Pa draught when calculating the chimney draught. Obtain the connection piece from the chimney manufacturer if required, to safeguard the connection conditions. Connection to a moisture-resistant flue with two or multiple draught chimneys (duct) Stainless steel duct Duct cover from cover from the Wolf the Wolf product product range range Chimney Polypropylene system up...
Page 81 37. Technical information, air/flue gas routing 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 L = 1800 mm 8 Separator (slide coupling) if required...
Page 82 37. Technical information, air/flue gas routing 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 pipe with inspec- through pitched roof tion port DN80/125 (250 mm long) 4 Balanced flue pipe DN80/125 500 mm 1000 mm Flue routed along external wall 2000 mm 5 Spacer bracket 10 Inspection bend 87° DN 80/125 11 Bend 87°...
Page 83 37. Technical information, air/flue gas routing Connection to a concentric balanced flue inside a duct (examples) DN80/125, C33x Connection to a flue inside a duct, C93x 1 Gas condensing boiler 2 Adaptor DN60/100 to DN80/125 4 Balanced flue pipe 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 Duct cover with UV resistant terminal C33x...
Page 84 37. Technical information, air/flue gas routing Eccentric balanced flue Install eccentric balanced flue distributor 80/80 mm (31) for separate air supply/flue gas routing downstream of 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. Install the horizontal flue pipe with a slope of approx. 3° (6 cm/m) towards the boiler. Route the horizontal air supply with a 3° slope towards the outside – fit the air inlet with a wind protector; permissible wind pressure at the air inlet 90 Pa. The burner will not start if the wind pressure is higher. 1 Gas condensing boiler 2 Adaptor DN60/100 to DN80/125...
Page 85 37. Technical information, air/flue gas routing 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. When installing, slide the separator (8) fully into the female Install the roof outlet only in its original condition. Modifica- connection. Push the next balanced flue pipe (4) 50 mm...
Page 86: Technical Information, Underfloor Heating/Dhw Circulation
38. Technical information, underfloor heating/DHW circulation Underfloor heating system When using pipes impermeable to oxygen, an underfloor heating system can be connected directly to a heat source with up to 10 kW heating output, subject to system pressure drop. Always install a temperature limiter for the underfloor heating system to protect the pipes from overheating. The output of the integrated pump should be increased if un- derfloor heating is connected (parameters HG16 and HG17).
Page 87: Reset
39. Reset Reset Parameter Reset A parameter reset returns all parameters to their Status factory settings. See Parameter settings. Operating mode Heating mode Burner status Main menu Back Displays Standard settings Flue gas inspector Contractor Back Password Contractor Authorisation Contractor code required 1111 Back - - - - Relay test System Parameter...
Page 88: Technical Maintenance And Design Data
40. Technical maintenance and design data Boiler water temperature sensor, cylinder temperature sensor, DHW outlet temperature sensor, outside temperature sensor, return temperature sensor, eHLSC sensor, flue gas Sensor resistances temperature sensor, header temperature sensor. Temp. °C Resist. Ω Temp. °C Resist. Ω Temp. °C Resist. Ω Temp. °C Resist. Ω 40,810 7162 1733 38,560 6841 1669 36,447 6536 1608 34,463 6247 1549...
Page 89: Troubleshooting
Any faults or damage which impact or might impact upon safety must be remedied immediately by a qualified contractor. Replace faulty components and equipment only with original Wolf spare parts. Faults and warnings are shown in plain text on the display of the control accessories – AM display module or BM-2 programming module –...
Page 90 41. Troubleshooting Fault Fault Possible causes Remedy code HLSC excess temp. High limit safety cut-out (thermostat) has High limit safety cut-out: responded - Check cables and plugs - If electrical connection OK and no func- Temperature at the heat exchanger tion: Replace HLSC cover has exceeded 185 °C Combustion chamber: Combustion chamber contaminated...
Page 91 41. Troubleshooting Fault Fault Possible causes Remedy code Flame failure Flame failure during flame stabilisation Gas type setting: after flame detection - Check gas type setting on the gas valve and the AM/BM. Monitoring electrode faulty Gas pressure: Flue path blocked - Check the gas supply pressure (flow pres- sure).
Page 92 41. Troubleshooting Fault Fault Possible causes Remedy code Boiler sensor faulty Excess temperature in the flow Pump: Boiler sensor > 100 °C Check if pump is running. If not, check cables and plugs. If electrical connection Boiler sensor or sensor lead has short OK and no function, replace pump. circuit or break Excess flow temperature: Increase the minimum pump speed.
Page 93 41. Troubleshooting Fault Fault Possible causes Remedy code CRC burner control unit The EEPROM record is invalid EEProm record invalid: - Switch power supply OFF/ON. - If fault persists, call out a contractor 23 V AC supply 23 V AC supply outside the permissible Power supply unit: range (e.g.
Page 94 41. Troubleshooting Fault Fault Possible causes Remedy code Max. cylinder heating Cylinder heating takes longer than Check DHW sensor (cylinder sensor) and time permitted. sensor lead. Check cylinder increase HG25 parameter. Press reset button. Check primary pump. IO control deviation Gas valve faulty Gas valve: - Check cables, plugs, power supply and Gas supply pressure outside set range...
Page 95 41. Troubleshooting Fault Fault Possible causes Remedy code Calibration factory limit Calibration factory limit (minimum) not Flue gas recirculation: reached - Check the flue path inside and outside the appliance (leaking, blocked). Flue gas recirculation Have customer service set IO default value to factory setting.
Page 96 41. Troubleshooting Fault Fault Possible causes Remedy code Header sensor faulty Sammlerfühler oder Fühlerleitung hat Header sensor: Kurzschluss oder Unterbruch - Check leads and plug-in connections. - If OK and no function, replace the sensor. - Press reset button BCU communication Communication between control unit Press reset button.
Page 97: Troubleshooting Warning Messages
42. Troubleshooting warning messages Fault Warning Possible causes Remedy code Burner control unit The PCB has detected that the burner Ensure that the correct boiler coding card has control unit has been replaced been inserted. replaced Check appliance parameter settings. Heating circuit pressure Water pressure has fallen Check the system pressure, below warning limit...
Page 98 42. Troubleshooting warning messages Fault Warning Possible causes Remedy code GLV actuators Flue gas recirculation Flue gas recirculation: - Check the flue path inside and outside the Incorrect gas type setting appliance (leaking, blocked). Incorrect gas restrictor - Check wind effect. Gas type setting Gas valve faulty - Check gas type setting on the gas valve and the AM/BM.
Page 99: Wiring Diagram
43. HCM-2 wiring diagram eBUS Netz Front panel Reset ON/OFF switch AM/BM-2 contact PCB ISM7i (optional) 3064810_201804...
Page 100 43. GBC-e wiring diagram 3064810_201804...
Page 101: Product Fiche According To Regulation (Eu) No. 811/2013
Any specific precautions that shall be taken See installation See installation See installation when the space heater is assembled, installed instruction instruction instruction or maintained 3064810_201804 Wolf GmbH, Postfach 1380, D-84048 Mainburg, Tel. +49-8751/74-0, Fax +49-8751/741600, Internet: www.wolf-heiztechnik.de Material number: 3020248 03/2015...
Page 102 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 3064810_201804 Wolf GmbH, Postfach 1380, D-84048 Mainburg, Tel. +49-8751/74-0, Fax +49-8751/741600, Internet: www.wolf-heiztechnik.de Material number: 3020317 03/2015...
Page 103: Technical Parameters According To Eu Regulation No. 813/2013
23,006 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 104: Notes
46. Notes 3064810_201804...
Page 105 46. Notes 3064810_201804...
Page 106 46. Notes 3064810_201804...
Page 107: Eu Declaration Of Conformity
EU DECLARATION OF CONFORMITY (to ISO/IEC 17050-1) Number: 3063421 Issued by: Wolf GmbH Address: Industriestrasse 1, D-84048 Mainburg Product: Gas condensing boiler CGB-2-14 CGB-2(K)-20 CGB-2(K)-24 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 108 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 3064810_201804 Document no.: Subject to technical modifications...

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