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Operating instructions for contractors WALL MOUNTED GAS CONDENSING BOILER CGB-2-75/100 wall mounted gas condensing boiler English | subject to modifications 8616724_202108_Englishmaster...
Safety measures ............................8 General safety information ........................... 8 Handover to operator ........................... 9 Declaration of Conformity ..........................9 Description ..........................10 CGB-2-75 / CGB-2-100 wall mounted gas condensing boiler layout ............10 Planning .............................11 Regulations ..............................11 Installation location ............................. 11 4.2.1 Minimum clearances ..........................11...
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5.11.11 Connecting the outside sensor ........................38 5.11.12 Connecting the DHW cylinder sensor ....................... 39 5.11.13 Connecting digital WOLF control accessories ..................39 5.11.14 Connect the speed controller for the feed/heating circuit pump ..............39 5.11.15 Connecting the flue gas damper / supply air damper ................39 5.12...
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Taking the heat generator out of service permanently ................66 9.4.1 Draining the heating system ........................67 Recycling and disposal ......................68 Specifications ........................... 69 11.1 CGB-2-75/100 wall mounted gas condensing boiler .................. 69 11.2 NTC sensor resistances ..........................70 11.3 Dimensions ..............................71 11.4 Connections ...............................
► Follow the instructions in this document. Failure to observe these instructions voids any WOLF GmbH warranty. Scope This document contains instructions for the CGB-2-75/100 wall mounted gas condensing boiler. Target group This document is intended for gas, plumbing, heating and electricity contractors.
Boiler drain & fill valve Cold water High limit safety cut-out High limit safety cut-out (HLSC) eHLSC Electronic high limit safety cut-out Temperature limiter Flue gas high limit safety cut-out Temperature monitor Domestic hot water Feed/heating circuit pump 8616724_202108_Englishmaster WOLF GmbH | 7...
Any faults or damage that impact or might impact safety must be remedied immediately by a qualified contractor. ► All faulty components of the heat generator must be replaced with original WOLF spare parts. General safety information...
► Make the operator aware of the following: – Annual inspections and maintenance must be performed by a contractor. – WOLF recommends concluding an inspection and maintenance contract with a contractor. – Repair work must be performed by a contractor.
(trap). The drain must be able to be inspected. 4.2.1 Minimum clearances Fig. 4.1 Minimum clearances in mm * At least 830 mm when using the low loss header set Minimum lateral clearances 100 mm 8616724_202108_Englishmaster WOLF GmbH | 11...
– Make sure that a drain outlet and safety assembly is provided. The safety assembly from the WOLF accessories range includes an integral 3 bar safety valve. – A minimum flow rate prevents damage to the hot water heat exchanger as a result of overheating or steam hammers.
< 0.11 °dH recommended standard, permissible up to limit of < 1 °dH Water hardness (Germany) : 1 °dH Water hardness (Chinese) : 10.0 mg CaO/L water Table 4.3 Electrical conductivity and water hardness Water hardness (Chinese) : 17.8 mg CaCO3/L water 8616724_202108_Englishmaster WOLF GmbH | 13...
(e.g. more than 10 % of the system volume per year), the cause must be sought immediately and the fault remedied. Balanced flue For safety reasons, use only original WOLF flues and concentric balanced flue systems. DANGER Fire and smoke will travel to other floors! Risk of suffocation, poisoning and burning in the event of exposure to fire from outside.
► Use appropriate measures on site to mitigate this risk, e.g. installation of a suitable snow guard. At low outside temperatures, the water vapour contained in the flue gas may condense and freeze on the balanced flue system. 8616724_202108_Englishmaster WOLF GmbH | 15...
Values apply to HG02 “factory setting” (see Tab. 7.1.); for setting HG02 at minimum, please use the value in parentheses. For calculating the pipe length, see section “Calculating the balanced flue length”, Table 4.7. Enlargement in a duct from DN 110 to DN 160 Table 4.5 Balanced flue lengths 8616724_202108_Englishmaster WOLF GmbH | 17...
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Ø in mm duct size in connection piece up types in series pipe (appliance duct to terminal in m) to header) 2 x CGB-2-75 DN 110 DN 160 DN 160 2 x CGB-2-75 DN 110 DN 160 DN 200...
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These apply to open flue and room sealed operation. C33x room sealed In duct DN 110/160 Fig. 4.6 Minimum shaft sizes Flue routing, rigid in a duct Circular diameter Ø Rectangular width □ DN 110 190 mm 170 mm DN 160 250 mm 230 mm 8616724_202108_Englishmaster WOLF GmbH | 19...
– Type C33x: Gas condensing boiler with combustion air and flue gas routed vertically via the roof. – Lubricate the pipe ends and gaskets for easier installation. – Prior to installation, liaise with your local flue gas inspector regarding the required inspection piece (3) (3a). 20 | WOLF GmbH 8616724_202108_Englishmaster...
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– Install the horizontal flue with a fall of approx. 3° (6 cm/m) towards the heat generator. – Install the horizontal air line with a fall of approx. 3° towards the outside. – Connect the support bend (19) and the flue (DN 110 or DN 110 flexible) in the duct. 8616724_202108_Englishmaster WOLF GmbH | 21...
Enlargement for support bend from DN 110 to DN 160 – If required, the flue pipe can be extended in the duct from DN 110 to DN 160 after the support bend. 4.5.5 Installation of the flue in the duct with support pipe (optional) Fig. 4.11 Installation with support pipe 22 | WOLF GmbH 8616724_202108_Englishmaster...
Residual head of the heating circuit pump (accessory) The pump assembly modulates subject to burner load. The residual head is specified in the diagrams. Water volume (l / min) Table 4.7 Residual head of pump assembly depending on modulation level 8616724_202108_Englishmaster WOLF GmbH | 23...
– Fitting assembly for heating flow, heating return and integral safety assembly – Pump assembly with variable speed pump and integral safety assembly – Low loss header set for one or two appliances in a cascade – Dirt filter in the heating return 8616724_202108_Englishmaster WOLF GmbH | 25...
► Remove the inner packaging. Fig. 5.3 Mounting brace on the rear of the gas condensing boiler NOTE Foreign bodies and drilling dust inside the heat generator. Fault ► Use the expanded polystyrene cover supplied. 26 | WOLF GmbH 8616724_202108_Englishmaster...
Fig. 5.5 Overpressure cascade with low loss header set Heating circuit connection ► We recommend you connect the heating system with the aid of a WOLF heating circuit connection kit. NOTE Boiling noise, power loss and malfunction! Deposits in the heat exchanger ►...
► Flush the heating system to remove residues and dirt from the pipework. ► Connect DHW flow and return with a three-way diverter valve and/or the return of the heat generator. When connecting a cylinder from another manufacturer, the cylinder sensor from the WOLF accessory range must be used.
► Clean the gas line before connecting the heat generator. ► Use a gas ball valve with fire protection. ► Install the gas ball valve upstream from the heat generator in an easily accessible location. 30 | WOLF GmbH 8616724_202108_Englishmaster...
* When, leaving the wall, the flue gas pipe shall be placed completely in open position, which shall leave eaves, glass houses, canopies, fences, etc. * The terminal in all directions shall avoid any possible access to inlet of the ventilator, which may bring the combustion material into the room and risk life. 8616724_202108_Englishmaster WOLF GmbH | 31...
► Slide the next balanced flue pipe (4) 50 mm into the socket of the separator (5). ► Ensure that the balanced flue pipe (4) is fully secured in this position, e. g. with a pipe clamp (6) or with 32 | WOLF GmbH 8616724_202108_Englishmaster...
► It must be possible to remove removable covers without tools and they must be secured to prevent them falling. 5.10.2 Installing the roof outlet Ø 130 Fig. 5.14 Roof outlet [mm] Roof outlet Universal tile Flat roof collar Mounting bracket Adaptor for “Klöber base panels” 8616724_202108_Englishmaster WOLF GmbH | 33...
The maximum current carrying capacity of the outputs is 1.5 A. Do not exceed a total of 4 A. ► In case of a permanent connection, connect the power supply via a mains isolator (e.g. fuse, heating system emergency stop switch) that ensures at least 3 mm contact separation. 34 | WOLF GmbH 8616724_202108_Englishmaster...
Control unit casing Fixing screws for control unit casing Cover for on-site connections Fixing screws Cover for auxiliary modules (WOLF Link Home / Fixing screws I/O module) Opening the entire control unit casing ► Undo the fixing screws for the control unit casing (4).
PCB 1(a) = 10 V, 2(b) = GND. 5k NTC outside sensor 5k NTC cylinder sensor eBus (WOLF control accessories e.g. BM-2, MM-2, KM-2, SM1-2, SM2-2) PWM/0-10V Connection for controlling the speed of the feed/heating circuit pump NOTE Increased electromagnetic interference at the installation site! Possible control faults.
The parameters for output A1 are described in Table 7.2.11. Fig. 5.20 Connecting output A1 5.11.9 Connecting input E1 ► Insert and secure the connecting cable through the cable gland. ► Connect the cable to terminal E1. 8616724_202108_Englishmaster WOLF GmbH | 37...
5.11.11 Connecting the outside sensor ► The outside sensor can be connected to the terminal strip of the heat generator at connection AF or to the terminal strip of the BM-2 programming unit. Fig. 5.23 Connecting the outside sensor 38 | WOLF GmbH 8616724_202108_Englishmaster...
Fig. 5.26 Connection for feed/heating circuit pump speed controller ► If using a WOLF pump assembly, connect the 2-pole pump connector to the right side of the PWM / 0-10 V connection. ► If you are using a third party item, follow the manufacturer’s instructions to connect the accessory cable (item no.
Preparation ► The gas tap must be shut. ► Flush the heating system before connecting the heat generator. 40 | WOLF GmbH 8616724_202108_Englishmaster...
Control modules The control modules are used to set or display specific parameters of the heat generator. BM-2 programming unit This control module communicates with the heat generator and all connected extension modules via eBus. 8616724_202108_Englishmaster WOLF GmbH | 41...
Either an AM display module or a BM-2 programming unit must be installed for operation. Fig. 5.29 Possible control modules 5.14.1 Plugging in the control module Fig. 5.30 Plugging in the control module ► Insert the control module (BM-2 programming unit or AM display module) above the WOLF logo. 42 | WOLF GmbH 8616724_202108_Englishmaster...
WOLF recommends that commissioning be performed by WOLF Customer Service. Preparation for commissioning ► Check that all flue gas accessories have been correctly installed and that none are leaking.
► Vent system, check that automatic air vent valve is functioning properly ► Check the system pressure. System pressure over 1.5 bar: ✔ System pressure OK. System pressure below 1.5 bar: ► Top up with water. 44 | WOLF GmbH 8616724_202108_Englishmaster...
During commissioning and maintenance, only a check of the CO, CO and O is required. ► Test the combustion air parameters with the heat generator closed. ► Wait for at least 60 seconds after the burner has started before testing the combustion air. 8616724_202108_Englishmaster WOLF GmbH | 45...
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► If necessary, adjust the CO value as described in 6.9 Setting the CO level. ► Exit parameter HG47 / HG49. ✔ The heat generator shuts down. ► Close the test port and ensure the cap is seated firmly! 46 | WOLF GmbH 8616724_202108_Englishmaster...
(2) in accordance with ► Correct the CO Table 6.3. Gas type Upper load Lower load Natural gas 8,6 ... 8,9 % CO 8,3 ... 8,6 % CO (5,0 ... 5,5 % O (5,6 ... 6,1 % O 8616724_202108_Englishmaster WOLF GmbH | 47...
► Follow the instructions in 6.9.3 to check the CO values. ► Exit parameters HG47 and HG49. ✔ The heat generator shuts down. ► Close the test port and ensure the cap is seated firmly! 48 | WOLF GmbH 8616724_202108_Englishmaster...
Fig. 6.5 Flue cascade Check adjacent appliances for leaks Check first heat generator for leaks Calculating the dimensions of the flue cascade The dimensions of the flue cascade must be calculated in accordance with DIN EN 13384 (see Table 4.6) 8616724_202108_Englishmaster WOLF GmbH | 49...
Configuring the heat generator Standard settings for heat generator on the control module. ► Set parameters (Table 7.1). 6.11 Finishing the commissioning process ► Complete commissioning report (12.1 Commissioning report). ► Document values in “System and operator's log”. 50 | WOLF GmbH 8616724_202108_Englishmaster...
Parameter settings BM-2 programming unit installation and operating instructions for contractors AM display module installation and operating instructions for contractors Parameter list Changes may only be made by a contractor or WOLF customer service. NOTE Improper use! System faults. ► Arrange for a contractor to set and change parameters.
4.5 (Overview of connection types) must be taken into account. 7.2.3 HG03: Upper burner output DHW HG03 limits the upper burner output in DHW mode (maximum heat generator load). Valid for DHW cylinder heating. This percentage value corresponds approximately to the real burner output. 52 | WOLF GmbH 8616724_202108_Englishmaster...
WOLF control accessories. When heating is disabled, frost protection mode, emissions test mode and CO configuration will remain enabled. DHW disabled/enabled 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, DHW heating, emissions test mode and CO configuration will be disabled, regardless of any digital WOLF control accessories.
Output A1 is switched cyclically by the time program in the control accessory if DHW circulation has been enabled. 2 minutes ON, 8 minutes OFF. Output A1 is switched cyclically if no accessory controller is installed. 54 | WOLF GmbH 8616724_202108_Englishmaster...
After completing cylinder heating (when the cylinder has reached the set temperature), the cylinder primary pump will run on up to the maximum set run-on time. The cylinder primary pump will switch off prematurely if, during the run-on time, the heat generator water 8616724_202108_Englishmaster WOLF GmbH | 55...
The “Max. cylinder heating time” function remains active even if parallel pump operation is enabled. If HG20 is set to OFF, the “Max. cylinder heating time” function is disabled. WOLF recommends setting HG20 to OFF in heating systems with high DHW consumption, e.g. hotels, sports facilities, etc.
Note: The heat exchanger protection function reduces the modulation level when the spread is >28 K. 7.2.24 HG39: Soft start time Burner runtime at low level, in heating mode after burner start. 7.2.25 HG40: System configurations System configurations in accordance with 12.4 (see “HG40 system configuration” on page 75). 8616724_202108_Englishmaster WOLF GmbH | 57...
HG59: Output A4 HG59 can be selected only if the “I/O module” expansion board is connected. The flue gas damper function cannot be selected. All other functions can be set as for HG14 (output A1). 58 | WOLF GmbH 8616724_202108_Englishmaster...
Cylinder primary pump upstream of low loss header. Control on boiler sensor; feed pump off during cylinder heating. Header sensor Cylinder primary pump downstream of low loss header. Control on header sensor; feed pump on during cylinder heating. 8616724_202108_Englishmaster WOLF GmbH | 59...
HLSC triggered. ► Check the heating circuit pump. – The temperature at the combustion ► Vent the system. chamber cover has exceeded ► Press reset button. 170°C. ► Clean the heating water heat exchanger. 60 | WOLF GmbH 8616724_202108_Englishmaster...
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Flame detection error – A flame is recognised before the ► Press reset button. burner starts. ► Check monitoring electrode. Boiler sensor faulty – Faulty boiler sensor or lead. ► Check sensor. – Boiler temp. < 0°C or > 98°C ► Check lead. 8616724_202108_Englishmaster WOLF GmbH | 61...
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– Boiler coding card fault. ► Switch power supply OFF/ON. in the BCC ► Refit the correct boiler coding card. ► Press reset button. ► Enter contractor code “1111”. ► Enter the correct BCC code. 62 | WOLF GmbH 8616724_202108_Englishmaster...
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PCB and burner control unit board. disrupted. Prog. mode – Burner control unit is controlled by No action. Reset – Reset button pressed too many ► Switch power supply OFF/ON. times. ► Press reset button. 8616724_202108_Englishmaster WOLF GmbH | 63...
► Press reset button. Fault code unknown – Fault not known. ► Check software version. ► Call out a contractor. ► Contact WOLF Service. email: service@wolf.eu Table 8.1 Fault messages 8.3.2 Warning messages Warning messages do not lead directly to the heat generator being switched OFF. The issue which caused the warning may lead to malfunctions or faults.
– Burner operational Cycle block – Burner block after a burner cycle for the duration of the cycle block W/o burner – Operation without burner; input E1 closed 8616724_202108_Englishmaster WOLF GmbH | 65...
The F1 and F2 fuses are located on the PCB (HCM-2). F1: Fine wire fuse (5 x 20 mm) M 4 A F2: Micro fuse T 1.25 A ► Remove the faulty fuse. ► Insert the new fuse. 66 | WOLF GmbH 8616724_202108_Englishmaster...
► Isolate the entire system from the power supply. ► Switch OFF the heat generator at the ON/OFF switch. ► Isolate the system from the power supply. ► Safeguard the system against reconnection. ► Disconnect the heat generator from the power. 8616724_202108_Englishmaster WOLF GmbH | 67...
► Use safety gloves. ► Open the drain valve (e.g. heat generator BDF valve). ► Open the air vent valves on the radiators. ► Drain off the heating water. Shutting off the gas supply ► Close the gas valve. 68 | WOLF GmbH 8616724_202108_Englishmaster...
► Dispose of packaging made of cardboard, recyclable plastics and synthetic filler materials in an environmentally compatible manner through appropriate recycling systems or a recycling centre. ► Please observe the applicable national and local regulations. 8616724_202108_Englishmaster WOLF GmbH | 69...
Ω 1733 1669 1608 1549 1493 1438 1387 1337 1289 1244 1200 1158 Temperature °C Ω 1117 10178 1041 1005 Resistance °C Temperature Resistance Ω Temperature °C Ω Resistance °C Temperature Resistance Ω Temperature °C Ω Resistance Table 11.2 NTC sensor resistances 8616724_202108_Englishmaster WOLF GmbH | 71...
PE distributor (grounding connector) 13 Service PCB X1: GBC-P 14 Contact board AM/BM Boiler water temperature sensor 15 WOLF Link Home (optional) Water pressure sensor Return temperature sensor Internal appliance pump speed (temporarily use WILO PWM connector) 74 | WOLF GmbH...
Fan PWM signal Fan 230 V AC eHLSC-2 sensor of CGB-2 (dual sensor) Ignition transformer ZAG 2C HLSC combustion chamber cover 10 CGB-2 flue gas temperature sensor Ignition electrode Gas burners 11 PE distributor monitoring electrode 8616724_202108_Englishmaster WOLF GmbH | 75...
– Burner starts subject to demand from the header temperature control. – Feed/heating circuit pump enabled as a feed pump. – Header temperature control – Input E2: Header sensor – Parameter HG08 (T-Flow ): 90°C – Heating circuit and cylinder heating with MM-2. 76 | WOLF GmbH 8616724_202108_Englishmaster...
Control 0 - 10 V by external controller 0 - 2 V burner OFF, 2-10 V burner output min. to max. within the programmed limits. – Automatic output reduction when approaching T-boiler (HG22). Shutdown when T-boiler reached 8616724_202108_Englishmaster WOLF GmbH | 77...
– Header temperature control via cascade module – Input E2: not assigned, – Automatic output reduction when approaching BT (HG22) is enabled. Shutdown when BT reached – Use a low loss header or plate heat exchanger for hydraulic separation. 78 | WOLF GmbH 8616724_202108_Englishmaster...
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This declaration of conformity is issued under the sole responsibility of the manufacturer 本合格声明由制造商全权负责发布 Mainburg, 01/08/2021 德国美茵堡,2021年08月01日 Gerdewan Jacobs Jörn Friedrichs Holger Schlafke Technical Director / 技术总监 Head of Development / 研发主管 Head of Quality/质量经理 8616724_202108_Englishmaster WOLF GmbH | 79...
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