Wolf CGS-2-14/120L Installation Instructions Manual
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Wolf CGS-2-14/120L Installation Instructions Manual

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Installation instructions for contractors
Gas condensing centre
CGS-2 gas condensing centre
CGS-2-14/120L
CGS-2-20/160L
CGS-2-24/200L
CGS-2-14/150R
CGS-2-20/150R
CGS-2-24/150R
WOLF GMBH / POSTFACH 1380 / D-84048 MAINBURG / TEL. +49.0.875174-0 / FAX +49.0.875174-1600 / www.WOLF.eu
Art.-Nr.: 3064816_201804
Subject to technical modifications
GB
IE

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Summary of Contents for Wolf CGS-2-14/120L

  • Page 1 Installation instructions for contractors Gas condensing centre CGS-2 gas condensing centre CGS-2-14/120L CGS-2-20/160L CGS-2-24/200L CGS-2-14/150R CGS-2-20/150R CGS-2-24/150R WOLF GMBH / POSTFACH 1380 / D-84048 MAINBURG / TEL. +49.0.875174-0 / FAX +49.0.875174-1600 / www.WOLF.eu Art.-Nr.: 3064816_201804 Subject to technical modifications...

  • Page 2: Table Of Contents

    Table of contents Information on documentation/standard delivery ....... 3 Safety instructions ................5 Dimensions/installation dimensions ........... 8 Specification ..................10 CGS-2L layout ................. 12 Electronic gas/air mixture ..............14 Casing ..................... 15 Standards and regulations ............... 16 Installation Siting ....................19 10. Installation/separation ..............20 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 with integral stratification cylinder (CGS-2L) or cylinder with internal indirect coil (CGS-2R), fully wired, in casing 1 x Suspension bracket for wall mounting 1 x Installation instructions for contractors 1 x Operating instructions for users 1 x Maintenance instructions 1 x Commissioning checklist 1 x Label "G31/G30"...

  • Page 5: Safety Instructions

    Only operate the gas condensing boiler 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 EN 12828. - Notify an approved contractor. Never remove, bypass or otherwise disable any safety or monitoring equipment. Only operate the appliance if it is...
  • Page 6 We recommend arranging a suitable maintenance con- tract. - The operator is responsible for the safety, environmental compatibility and energy quality of the heating system (German Immission Control Act/Energy Saving Ordi- nance) [Germany]. - Only use genuine WOLF spare parts. 3064816_201804...
  • Page 7 2. Safety instructions Fig.: Terminal box: Danger through live electrical components Fig.: Gas connection: Risk of poisoning or explosion in the event of gas escaping Gaskombiventil Fig.: Ignition transformer, high voltage ignition electrode, combustion Fig.: Gas combination valve chamber Danger through live electrical components Danger through live electrical components, risk of burning from hot Escaping gas may cause poisoning or an explosion components...

  • Page 8: Dimensions/Installation Dimensions

    3. Dimensions/installation dimensions CGS-2L Gas condensing centre with stratification cylinder Ø 80/125 Ø 80/125 Ø 60/100 Ø 60/100 2 6 2 1 9 0 4 1 . 5 4 1 . 5 1 0 9 6 0 0 5 6 3 6 3 5 4 5 4 DHW circulation 4 0 0 connection...
  • Page 9 3. Dimensions/installation dimensions CGS-2R Gas condensing centre with cylinder with internal indirect coil Ø 80/125 Ø 80/125 Ø 60/100 Ø 60/100 1 9 0 2 6 2 1 0 9 4 1 . 5 4 1 . 5 6 0 0 5 6 3 6 3 5 4 5 4 DHW circulation DHW connection 4 0 0...

  • Page 10: Specification

    4. Specification Type CGS-2-14/120L CGS-2-20/160L CGS-2-24/200L Rated heating output at 80/60 °C 13.5 18.9/22.2 23.8/27.1 (23.8 Rated heating output at 50/30 °C 15.2 20.4 25.8 Rated heat input 14.0 19.6/23.0 24.6/28.0 (24.6 Lowest heating output (modulating) at 80/60 °C 1.8/4.6 3.8/6.8...
  • Page 11 4. Specification Type CGS-2-14/150R CGS-2-20/150R CGS-2-24/150R Rated heating output at 80/60 °C 13.5 18.9/22.2 23.8/27.1 (23.8 Rated heating output at 50/30 °C 15.2 20.4 25.8 Rated heat input 14.0 19.6/23.0 24.6/28.0 (24.6 Lowest heating output (modulating) at 80/60 °C 1.8/4.6 3.8/6.8 4.8/6.8 Lowest heating output (modulating) at 50/30 °C...

  • Page 12: Cgs-2L Layout

    5. CGS-2L layout CGS-2L Gas condensing centre with stratification cylinder 1 Gas fan 16 Combustion chamber temperature sensor (eHLSC sensor) 2 Expansion vessel 17 Burner 3 Mixing valve 18 Heating water heat exchanger 4 Gas valve 19 Flue gas temperature sensor 5 Trap 20 Pressure sensor 6 3-way valve 21 Return temperature sensor 7 Control unit enclosure...
  • Page 13 5. CGS-2R layout CGS-2R Gas condensing centre with cylinder with internal indirect coil 1 Gas fan 15 Combustion chamber temperature sensor (eHLSC sensor) 2 Expansion vessel 16 Burner 3 Mixing valve 17 Heating water heat exchanger 4 Gas valve 18 Flue gas temperature sensor 5 3-way valve 19 Pressure sensor 6 Trap 20 Return temperature sensor...

  • Page 14: 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 15: 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 16: 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 for installation and oper- ation of the heating system: • Siting conditions • Ventilation and extract air facilities and connection to a chimney • Electrical connection to the power supply • The technical regulations of the gas supply utility regarding the connection of the gas appliance to the local gas mains •...
  • Page 17 8. Standards and regulations The following apply to installation and operation in Austria in particular: • ÖVE regulations • Provisions of the ÖVGW and the corresponding Austrian standards • ÖVGV TR-Gas (G1), ÖVGW-TRF (G2) • Provisions of ÖVGW guideline G41 for condensate drainage • Local regulations of building and industry regulatory agencies (usually represented by the flue gas inspector [Germany]) •...
  • Page 18 (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 19: Siting

    Operation in wet rooms In the delivered condition and for room sealed operation, the Wolf gas condensing boiler has IP rating IPx4D. When installing it in wet rooms, the following conditions must be met: - Room sealed operation - Compliance with IP rating IPx4D - All outgoing and incoming cables must be routed through the strain relief cable glands and secured.

  • Page 20: Installation/Separation

    10. Installation/separation Handling The gas condensing centre is secured to the transportation pallet at 4 points. Transportation The front cylinder casing has to be removed in order to trans- handles port the gas condensing centre. This reveals the transportation screws on the floor panel of the cylinder and the two transportation handles on the cylinder. SW 10 Fig.: Front transportation handles/locking screws Remove the transportation screws at the back of the cylinder.
  • Page 21 10. Installation/separation Dismantling the CGS-2L/R side cylinder casing: Fig.: Dismantling the CGS-2L/R side cylinder casing Separation For simpler transportation, the heating module (A) can be separated from the cylinder (B) - Open control unit flap (1) - Remove both front panels from A + B (2) (also see chap- ter 7) - Release union nut G3/4"...

  • Page 22: Installation

    11. Installation Supply lines for flush mounting Fixing holes If supply lines for cold water and DHW, heating flow and return and gas are routed on unfinished walls, the concealed mount- ing bracket (accessory) can facilitate the on-site pre-installation of connections. Fit the concealed mounting bracket for flush mounting to the wall using the fixing holes. Installation dimensions approx. 1100 mm above the installation Htg flow Htg rtn DHW circulation area. Route lines for gas, heating and DHW to the concealed Fig.: Concealed mounting bracket for flush mounting (accessory) mounting bracket on unfinished walls.
  • Page 23 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 24: Gas Connection

    12. Gas connection Seite 16 Gaskugelhahn, Durchgangsform With the power supply disconnected, connect the gas supply pipe to the gas connection at a 90° angle and connect the flexible gas hose to gas connection R½". Use an approved sealant. 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 25: Fitting The Trap

    13. Fitting the trap Condensate connection 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 upwards. Fill the supplied trap with water and connect it to the conden- sate pan connector.

  • Page 26: Balanced Flue

    14. Balanced flue For concentric balanced flues and standard flues, Please use only original Wolf parts. note Prior to installation, read the technical information regarding the balanced flue. As regulations in the individual German Federal States differ, we recommend consulting the rele- vant authorities and local flue gas inspector prior to installation. Fig.: Example: Balanced flue The flue gas test connectors must remain acces- Please sible for your local flue gas inspector, even after note fitting the ceiling bezels.

  • Page 27: Electrical Connection

    Either an AM display module or a BM-2 programming unit 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 28 15. Electrical connection Removing 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 3064816_201804...
  • Page 29 15. Electrical connection Connections inside the control unit eBus 1(+), 2(-) WOLF control accessories T_DHW (5 kNTC cylinder sensor) T_outside (5 kNTC outside sensor) E2 (5 kNTC 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 30 15. Electrical connection 230 V mains connection The control and safety devices are 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 an omnipolar isolator (e.g. heating system emergency stop switch) with at least 3 mm contact separation.
  • Page 31 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.: Connecting output A1 Changing the fuse...
  • Page 32 Fig.: Cylinder sensor connection Connecting digital Wolf control accessories (e.g. BM-2, MM-2, KM-2, SM1-2, SM2-2) Only controllers 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 connecting cable between the control accessory and the condensing boiler.

  • Page 33: Flue Gas/Ventilation Air Damper Electrical Connection

    16. Flue gas/ventilation air damper electrical connection Flue gas/ventilation air damper electrical connection Note: Contractor parameter HG13 (input 1) must be set to Fl. gas - Isolate the system from the power supply before opening. damper - Check that the appliance is isolated from the power supply. HG14 (output 1) must be set to Fl. gas - Swivel the front panel to one side.

  • Page 34: Display Module/Programming Unit/Installation

    • AM is always in the heating appliance 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 35: Display Module/Programming Unit/Dismantling

    18. Display module/programming unit/ dismantling Removing the BM-2 programming unit or AM display module 3064816_201804...

  • Page 36: Am Display Module/Description

    19. AM display module/description AM overview Note: If your Wolf heating appliance is not equipped with an AM display mod- ule, 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 Operating mode Key 2 Rotary selector Heating mode with pushbutton Key 3 Burner status function Key 4 Burner ON Heating appliance in heating mode Heating appliance pump ON Set heating appliance temperature (if BM-2 as remote control - no function) Key 1...

  • Page 37: Am Display Module Menu Structure

    T_DHW outlet in °C Parameter reset Finish DHW DFL (flow rate) in l/min Message history Input E1 Back Modulation level in % IO actual value (Wolf service only) DHW CP speed Burner starts Burner hours run Mains hours Power ON count HCM-2 FW Back 3064816_201804...

  • Page 38: Heating Appliance Operating Mode/Burner Status

    21. Heating appliance operating mode/ burner status Heating appliance operating mode Display shows Meaning Start Appliance start 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, heating appliance running at maximum output Frost prot htg...

  • Page 39: 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 Screen header mode Burner status Quick start keys Status display Key 1 Heating appliance Heating mode Rotary selector Key 2 Burner ON with pushbutton function 25.2 Key 3 °C Pressure Boiler water tem- perature Display of system data Key 4 14:12 20.01.15...

  • Page 40: 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 if 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 unit on the heat generator. For procedures, check the operating instructions of the relevant accessories. No.: Designation: Unit Factory setting Min: Max: Condensing boiler 14 kW 20 kW 24 kW HG01 Burner switching hysteresis °C HG02 Lower burner output, heat generator, in % (fan control)

  • Page 41: Parameter Description

    24. Parameter description Parameter HG01 The burner switching hysteresis regulates the boiler water temperature within Burner switching hysteresis the set range by starting/stopping the burner. The higher the set start/stop temperature differential, the greater the fluctuation in boiler water temperature Factory setting: See table around the set value with correspondingly longer burner runtimes, and vice Setting range: 7 to 30 °C versa.
  • Page 42 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 43 Input E1 is ignored by the control unit. Room thermostat With input E1 open, heating mode will be disabled (summer mode), regardless of any digital Wolf control accessories*. DHW disabled/enabled With input E1 open, DHW heating will be disabled, regardless of any digital Wolf control accessories.
  • Page 44 24. Parameter description Parameter HG14 The functions of output A1 can only be checked and set directly on the boiler Function output A1 under parameter HG14 using the AM display module or BM-2 programming unit. Display Designation: None None (factory setting) Output A1 is ignored by the control unit. Timer DHW circulation pump 100 % Output A1 is switched by the time program in the control accessory if...
  • Page 45 24. 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. Example: Set cylinder temperature 60 °C Factory setting: See table Cylinder hysteresis 5 K Setting range: 1 to 30 K Cylinder heating commences at 55 °C and ends at 60 °C.
  • Page 46 24. Parameter description Parameter HG20 Cylinder heating commences as soon as the cylinder temperature sensor de- Max. cylinder heating time mands heat. The heating circuit pumps would be constantly off if the appliance were undersized, the cylinder were scaled up or if DHW were constantly drawn Factory setting: See table off during DHW priority mode.
  • Page 47 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" HG33 is reduced to the minimum burner hysteresis of HG60.
  • Page 48 24. Parameter description System configuration 01 Direct heating circuit on the condensing boiler + optional additional circuits with mixer via mixer modules (factory setting) • Burner starts subject to demand from the direct heating circuit or optionally connected circuits with mixer • Internal appliance pump is enabled as a heating circuit pump • Boiler water temperature control; set value is specified by heating circuit or mixer circuits • Input E2: not assigned System configuration 02 One or more circuits with mixer via mixer modules (no direct heating circuit on the condensing boiler)
  • Page 49 24. Parameter description System configuration 51 BMS burner output BMS % • Burner is started 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 50 24. Parameter description Parameter HG41 In DHW mode, the pump runs at this set value. Regardless of pump control DHW circ. pump speed 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 51 24. Parameter description There is a separate setting table for each model of the CGS-2: CGS-2-14/120L HG45 Flue gas system/DN 2.5 % C33x / DN 60/100 0 m - 4 m 4.25 m - 16 m C33x / DN 80/125 0 m - 4.25 m 4.25 m - 17 m...

  • 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 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. Trap Note: Fig.: Trap The condensate hose attached to the trap must not form 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 appliance versions (subject to country-specific version): Equipped with heating system filling facility, with two versions available. 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) Drinking water supply systems For installation and operation, observe country-specific standards and directives.

  • 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 Natural gas E/H 15.0: = 11.4 - 15.2 kWh/m³ = 40.9 - 54.7 MJ/m³ The condensing boiler is equipped with electronic combustion Natural gas LL 12.4: control which regulates the gas/air ratio in accordance with the = 9.5 - 12.1 kWh/m³ = 34.1 - 43.6 MJ/m³ prevailing gas quality and so provides optimum combustion.
  • Page 59 28. Determining/changing the gas type Seite 19 gas type (only for operation with LPG) Changing the For operation with LPG, it is necessary to change the gas type. 1. The gas condensing boiler must be 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: Commissioning

    - Switch ON the condensing boiler at the red ON/OFF switch in the WOLF logo. - If the system water pressure falls below 1.5 bar, top up with water until a pressure of 2.0 to max. 2.5 bar is reached.

  • Page 61: Checking The Gas Supply Pressure

    30. 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 car- ried out incorrectly may lead to gas escaping, resulting in a risk of explosion, asphyxiation or poisoning. 1. The gas condensing boiler must be off. Close the gas ball valve. 2. Loosen screw B on the gas test connector of the gas combination valve with a screwdriver.

  • Page 62: Adjusting The Maximum Heating Output

    31. 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 adjusted. 14 kW appliance Display value (%) Heating output (kW) 11.3...

  • Page 63: Testing The Combustion Parameters

    32. Testing the combustion parameters The condensing boiler is equipped with electronic combustion control which ensures optimum combustion quality. For a detailed description of combustion control, see chapter "Combustion air control". During commissioning and maintenance, only a check of the CO, CO and O is required.
  • Page 64 32. Testing the combustion parameters If the actual CO or O values lie outside their respective ranges, proceed as follows 1. Check the ionisation electrode and connecting cable 2. Check the electrode gaps Fig.: Ignition electrode gap Fig.: Ionisation electrode gap Check the electrodes for wear and contamination. Clean the electrodes with a small brush (not a wire brush) or sandpaper. Check the electrode gaps.

  • Page 65: Heating Circuit Pump Function Description

    33. Heating circuit 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 40,6 W 46,6 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 description (EEI ≤ 0.23)
  • Page 66 33. Heating circuit pump function de- scription 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 67: Commissioning Report

    34. 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 specification from installation instructions and VDE regulations? 2.) System flushed? □ 3.) System filled and water treatment carried out in accordance □ with "Technical information, water treatment"? pH value set ________________ pH value Total hardness set ________________ °dH 4.) Appliance and system vented?
  • Page 68 34. Commissioning report Commissioning steps Test values or confirmation 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 69: Safety Devices

    35. Safety devices Temperaturüberwachung Brennkammertemperaturfühler (eSTB) Der Brennkammerfühler ist ein Anlegefühler an der Rohrwendel. Er besteht aus 2 Fühlerperlen, die zusammen die Funktion eines Sicherheitstemperaturbegrenzers (eSTB) erfüllen. Zugleich erfüllt der Brennkammertemperaturfühler die Funktion eines Temperaturwächters (TW). Die TW Abschalttemperatur liegt bei > 102°C. Diese führt zum Abschalten des Bren- ners, ohne dass dieser das Gerät verriegelt.

  • Page 70: Technical Information, Balanced Flue

    36. Technical information, balanced flue Balanced flue 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 71 - Concentric balanced flue (on external walls) DN 80/125 components and ventilation apertures (ventilation generally - Flexible flue DN 83 required above 50 kW output) should be raised with your Wolf accessories are supplied with the 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 72 36. Technical information, balanced flue General information For reasons of operational safety, use only original Wolf If fire resistance is not required for the ceiling, components for balanced flues and standard flues. route the lines for the combustion air supply and the flue gas from the top edge of the ceiling to the Where necessary, adapt the installation examples to the rel- roof skin in a duct made from non-combustible, rigid...
  • Page 73 36. Technical information, balanced flue If a gas condensing boiler is installed with a balanced flue routed over an external wall (type C13x), the rated output in heating mode must be reduced to below 11 kW (for procedure, see chapter "Limiting the maximum heating 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 port inside the boiler room; agree suitable arrangements with your local flue gas inspector.
  • Page 74 Connection to moisture-resistant flue gas chimney or a Original Wolf components are designed for long term use, flue gas 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 not be more than 2 m long party equipment that is only DIBT certified or CE-designated, when connecting the system to a flue gas chimney. In addition installers themselves are responsible for the correct sizing to the boiler connection bend, up to two 90°...
  • Page 75 36. Technical information, balanced flue Tightness test on As part of the annual heating appliance inspection, the cascade damper on overpressure boiler systems must be tested for tightness, to ensure no CO connections to escape into the boiler room (risk 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 circuit with mixer via the right hand rotary selector.
  • Page 76 36. Technical information, balanced flue Vertical balanced flue routing (examples) system DN 60/100 1 Gas condensing boiler 2 Balanced flue with inspection port (250 mm long) 3 Separator DN 60/100 (sliding socket) if required 4 Balanced flue DN 60/100 500 mm 1000 mm 2000 mm 5 Balanced flue, vertical DN 60/100 (roof outlet for flat or pitched roofs) L = 1200 mm L = 1200 mm ... 1700 mm 6 Universal tile for pitched roof 25/45°...
  • Page 77 36. Technical information, balanced flue Horizontal balanced flue/connection to balanced flue chimney (examples) system DN 60/100 1 Gas condensing boiler Dormer 2 Balanced flue with inspection port (250 mm long) 4 Balanced flue DN 60/100 500 mm 1000 mm 2000 mm 9 Inspection bend 10 Bend 87° DN 60/100 11 Pipe collar 12 Support rail 13 Support bend 87° DN 60 to DN 80 14 Spacer 15 PP flue DN 80 500 mm...
  • Page 78 36. Technical information, balanced flue Balanced flue in a duct with horizontal connection pipe DN 60/100 Installation example for room sealed operation/duct 1 Gas condensing boiler Please Install horizon- 3 Separator note tal pipe with > (sliding socket) 3° fall towards if required boiler 4 Balanced flue DN 60/100 500 mm 1000 mm 2000 mm 9 Inspection bend 11 Pipe collar 12 Support rail 13 Support bend 87°...
  • Page 79 The flue gas chimney must be tested for suitability. Apply 0 Pa when calculating the chimney draught. Obtain the connection piece from the chimney manufacturer if required, to safeguard the connection conditions. Connection to moisture-resistant flue with two or multiple draught chimneys (duct) Stainless steel duct cover Duct cover from from the Wolf product the Wolf product range range Chimney Polypropylene system up Chimney...
  • Page 80 36. Technical information, balanced flue Luft-/Abgasführung senkrecht konzentrisch C33x (Beispiele) System DN80/125 1 Gasbrennwertgerät 2 Übergang DN60/100 auf DN80/125 3 Luft-/Abgasrohr mit Revisionsöffnung (250mm lang) 4 Luft-/Abgasrohr DN80/125 500 mm 1000 mm 2000 mm 5 Abstandschelle 6 Befestigungsbügel DN125 für Dachdurchführung 7 Luft-/ Abgasführung senkrecht DN80/125 (Dachdurchführung für Flachdach oder Schrägdach) L = 1200 mm L = 1800 mm 8 Trennvorrichtung (Schiebemuffe) falls erforderlich 9 Bogen 45° DN 80/125...
  • Page 81 36. Technical information, balanced flue Luft-/Abgasführung waagerecht konzentrisch C13x, C83x und B33 und Abgasleitung an der Fassade C53x (Beispiele) DN80/125 Dachgaube 1 Gasbrennwertgerät 2 Übergang DN60/100 auf DN80/125 Horizontale Luft-/Abgasführung 3 Luft-/Abgasrohr mit Revi- durch Schrägdach sionsöffnung DN80/125 (250mm lang) 4 Luft-/Abgasrohr DN80/125 500 mm 1000 mm Abgasleitung an der Fassade 2000 mm 5 Abstandschelle 10 Revisionsbogen 87° DN80/125 11 Bogen 87° DN80/125 15 Luft-/Abgasrohr waagerecht mit Windschutz 16 Rosette 17 Außenwandkonsole 87° DN80/125 (nur bei Bedarf)
  • Page 82 36. Technical information, balanced flue Connection to a concentric balanced flue in a duct (examples) DN 80/125, C33x Connection to a flue in a duct, C93x 1 Gas condensing boiler 2 Adaptor DN 60/100 to DN 80/125 4 Balanced flue DN 80/125 500 mm 1000 mm 2000 mm 5 Spacer clip 8 Separator (sliding socket) if required 10 Inspection bend 87° DN 80/125 11 Support bend 87° DN 80/125 16 Pipe collar 22 Support rail 26 Duct cover with UV-resistant terminal...
  • Page 83 36. Technical information, balanced flue Eccentric balanced flue Install eccentric balanced flue distributor 80/80 mm (31) for separate air supply/flue gas routing with a test connector downstream of connection adaptor DN 80/125 (2). When connecting a balanced flue certified according to Building Regulations, observe the permit of the relevant body. Install the horizontal flue with a fall of approx. 3° (6 cm/m) towards the boiler. Route the horizontal air supply with a 3° fall towards the outside – fit the air intake with a wind protector; permissible wind pressure at the air inlet 90 Pa. The burner will not start if the wind pressure is higher.
  • Page 84 36. Technical information, balanced flue Supplementary installation instructions for balanced flue DN 80/125 Install all horizontal balanced flues with > 3° fall (6 cm/m) Flat roof: Affix ceiling outlet (14), approx. Ø 130 mm, to the roof cover. towards the boiler. Any con- Pitched roof: For (12), observe the installation instructions on the densate must be returned to cowl regarding roof pitches. the appliance.

  • Page 85: Technical Information, Underfloor Heating System/Dhw Circulation

    37. Technical information, underfloor heating system/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 monitor 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 86: Reset

    38. 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 87: Technical Maintenance And Design Data

    39 Technical maintenance and design data Boiler water temperature sensor, cylinder temperature sensor, DHW outlet temperature Sensor resistances sensor, outside temperature sensor, return temperature sensor, eHLSC sensor, flue gas temperature sensor, header temperature sensor. Temp. °C Resist. Ω Temp. °C Resist. Ω Temp. °C Resist. Ω Temp. °C Resist. Ω 40810 7162 1733 38560 6841 1669 36447 6536 1608...

  • Page 88: 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 unit –...
  • Page 89 40. Troubleshooting Fault Fault Possible causes Remedy code HLSC excess temp. The high limit safety cut-out (thermostat) High limit safety cut-out: has responded - Check cables and plugs - If electrical connection OK but no function: Temperature at the heat exchanger Replace HLSC cover has exceeded 185 °C Combustion chamber: Combustion chamber contaminated...
  • Page 90 40. 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 91 40. 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 but no function, replace the pump. circuit or lead break Excess flow temperature: - Increase the minimum pump speed.
  • Page 92 40. Troubleshooting Fault Fault Possible causes Remedy code 23 V AC supply 23 V AC supply outside the permissible Power supply unit: range (e.g. short circuit) - Switch power supply OFF/ON. - Press reset button. - If the fault cannot be acknowledged, call out a contractor.
  • Page 93 40. 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 94 40. Troubleshooting Fault Fault Possible causes Remedy code Calibration factory limit Calibration factory limit (minimum) not Flue gas recirculation: reached - Check flue path inside and outside the appliance (leaking, blocked). Flue gas recirculation Have customer service set the IO default value to Ionisation electrode corroded/bent factory setting.
  • Page 95 40. Troubleshooting Fault Fault Possible causes Remedy code BCU communication Communication between control unit Press reset button. PCB and burner control unit disrupted Connection between GBC-e and HCM-2: - Check engagement of the two PCB enclo- sures. - If OK and fault persists: Check PCB plug on HCM-2.

  • Page 96: Troubleshooting Warning Messages

    41. Troubleshooting warning messages Warning Possible causes Remedy Fault 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 97 41. Troubleshooting warning messages Warning Possible causes Remedy Fault code GLV actuators Flue gas recirculation Flue gas recirculation: - Check flue path inside and outside the appli- Incorrect gas type setting ance (leaking, blocked). - Check wind effect. Incorrect gas restrictor Gas type setting Gas valve faulty - Check gas type setting on the gas valve and the AM/BM.

  • Page 98: Wiring Diagram

    42. HCM-2 wiring diagram eBUS Netz Front panel Reset ON/OFF switch AM/BM-2 contact PCB ISM7i (optional) 3064816_201804...
  • Page 99 42. GBC-e wiring diagram 3064816_201804...

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

    Sound power level, indoors Any specific precautions that shall be taken See installation See installation when the space heater is assembled, installed instruction instruction or maintained 3064816_201804 Wolf GmbH, Postfach 1380, D-84048 Mainburg, Tel. +49-8751/74-0, Fax +49-8751/741600, Internet: www.wolf-heiztechnik.de Material number: 3020363 03/2015...

  • Page 101: Technical Parameters According To Eu Regulation No. 813/2013

    23,452 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 102 23,772 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 103: Eu Declaration Of Conformity

    (to ISO/IEC 17050-1) Number: 3063612 Issued by: Wolf GmbH Address: Industriestrasse 1, D-84048 Mainburg Product: Gas condensing centre CGS-2-14/120L CGS-2-14/150R CGS-2-20/160L CGS-2-20/150R CGS-2-24/200L CGS-2-24/150R The product described above conforms to the requirements specified in the following documents: §6, 1. BImSchV, 26.01.2010 DIN EN 437 : 2009 EN 437 : 2003 + A1 : 2009)
  • Page 104 WOLF GMBH POSTFACH 1380 / D-84048 MAINBURG / TEL. +49.0. 87 51 74- 0 / FAX +49.0.87 51 74- 16 00 www.WOLF.eu 3064816_201804 Document no.: Subject to technical modifications...

This manual is also suitable for:

Cgs-2-20/160lCgs-2-24/200lCgs-2-14/150rCgs-2-20/150rCgs-2-24/150r

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