Wolf CGB-75 Installation And Technical Manual
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Wolf CGB-75 Installation And Technical Manual

Wall mounted gas boiler
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Installation instructions and
technical guide
Gas condensing boiler
CGB-75
CGB-100
Wolf GmbH · Postfach 1380 · D-84048 Mainburg · Tel. +49-8751/74-0 · Fax +49-8751/741600 · Internet: www.wolf-heiztechnik.de
Document no. 30 62 555
Wall mounted gas boiler
Wall mounted gas boiler
Subject to modifications
07/09
GB

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Summary of Contents for Wolf CGB-75

  • Page 1 Gas condensing boiler CGB-75 Wall mounted gas boiler CGB-100 Wall mounted gas boiler Wolf GmbH · Postfach 1380 · D-84048 Mainburg · Tel. +49-8751/74-0 · Fax +49-8751/741600 · Internet: www.wolf-heiztechnik.de Document no. 30 62 555 Subject to modifications 07/09...

  • Page 2: Table Of Contents

    Index ....................... Page Safety instructions ......................3 Standards and regulations..................4-5 Control / Function / Operation ................. 6-7 Delivered condition / standard delivery.................8 Layout CGB-75 / CGB-100 ...................9 Installation instructions ....................10 Installation ........................11 Dimensions / installation dimensions................12 Installation ......................13-16 Installation of the balanced flue system........17 Power connection ...............

  • Page 3: Safety Instructions

    Maintenance work must only be carried out by a qualified heating contractor. Regular maintenance and the exclusive use of original Wolf spare parts are necessary preconditions for trouble-free operation and a long service life. We therefore recommend you arrange a maintenance contract with a local heating contractor.

  • Page 4: Standards And Regulations

    Regulations) and the Water Supply (Water Fitting) Regulations 1999, or The Water Bylaws 2000 (Scotland). It should also Wolf gas fired boilers must only be installed by a recognised be in accordance with the relevant requirements of the Local heating contractor. This heating contractor will also be...
  • Page 5 DHW production in heating systems with flow temperatures up to 95 °C and 6 bar permissible operating pressure in accordance with EN 12 828. The Wolf gas condensing boiler is also approved for installation in garages. Open flue gas condensing boilers must only be installed in a room which complies with the appropriate ventilation requirements.

  • Page 6: Control / Function / Operation

    Control / Function / Operation ON/OFF switch Reset Thermometer button temperature selector Illuminated Heating water signal ring temperature selector ON/OFF switch The condensing boiler is OFF in position 0. Reset A fault is reset by pressing the reset button which will also restart the system. Pressing the reset button reactivates the system, if there was no fault.

  • Page 7: Control / Function / Operation

    Control / Function / Operation Setting Winter mode (settings 2 to 8) In winter mode, the boiler heats to the temperature selected at the heating water temperature controller. According to the pump operating mode, the circulation pump operates constantly (factory setting) or only in parallel with the burner activation / run- on period.

  • Page 8: Delivered Condition / Standard Delivery

    Delivered condition / standard delivery As delivered condition Accessories Gas condensing boiler The standard delivery includes: The following accessories are required for installation of the 1 Gas condensing boiler ready to connect with the casing gas condensing centre: fitted - Balanced flue accessories (see design information) 1 Mounting bracket for mounting on the wall, with installation - Room temperature-dependent or weather-compensated accessories...

  • Page 9: Layout Cgb-75 / Cgb-100

    Layout CGB-75 / CGB-100 Ventilation air test point Flue gas test point Non-return valve Flue Ignition electrode Combustion chamber casing Monitoring electrode Gas fan Quick-acting air vent valve Combustion chamber temperature limiter Gas:air mixing chamber Flash trap Gas restrictor Temperature limiter...

  • Page 10: Installation Instructions

    Installation instructions General notes Electrical connection must be made on site. min. Please maintain the 350 mm clearance to the ceiling to enable 350 mm inspection and maintenance work on the boiler to be carried out, otherwise the necessary inspection and function tests on components cannot be ensured during maintenance.

  • Page 11: Installation

    Installation Opening the casing cover We recommend you remove the casing cover during the installation. Release the casing cover with the l.h. and r.h. screw. Release the bottom of the casing cover and unhook at the top. Seal the front casing tightly with screws after completing the service.

  • Page 12: Dimensions / Installation Dimensions

    Dimensions / installation dimensions Ø 160/110 132,5 125 112,5 105 1 Heating flow 2 Heating return 3 Condensate drain 4 Gas connection Overpressure cascade DN 160 with low loss header set 30 62 555_0709...

  • Page 13: Installation

    Figure: Heating circuit connection set (accessory) Provide a BDF valve at the lowest system point. Safety equipment The CGB-75 and CGB-100 have not been fitted with an expansion vessel at the factory. This must be fitted externally (available from the Wolf accessories range). Ensure the expansion vessel is correctly sized.
  • Page 14 Installation Note: - Sludge separator in the boiler return of the CGB-75/100 - Desalination of the heating water to < 3 °dH Provide a BDF valve at the lowest system point. - Control of the cylinder heating only via the MM module...
  • Page 15 Installation Condensate drain connection Connect the siphon supplied to the connector on the combustion chamber pan. Please note: The siphon must be filled with water prior to commissioning. If condensate is directly routed to the public sewer, ensure ventilation, so that the public sewer cannot affect the condensing boiler.

  • Page 16: Installation

    Install a gas ball valve with fire protection in the gas supply line upstream of the Wolf condensing boiler. Otherwise explosions may occur during a fire. Size the gas supply line in accordance with details laid down in local regulations.

  • Page 17: Installation Of The Balanced Flue System

    Installation of the balanced flue system For flues and concentric balanced flue systems, use only original Wolf components. Please observe the technical information regarding balanced flue systems prior to installing the flue or the balanced flue connection. The flue gas test ports must remain accessible for your local flue gas inspector, even after fitting the ceiling bezels.

  • Page 18: Power Connection

    Electrical connection General notes The installation must be carried out by a The power supply terminals are 'live' even when licensed electrical contractor. Observe electrical the ON/OFF switch has been switched OFF. regulations and those of the local power supply utility.
  • Page 19 Electrical connection Changing a fuse Isolate the condensing boiler from the power supply prior to changing a fuse. The ON/OFF switch on the boiler does not provide separation from the power supply. Danger through 'live' electrical components. Never touch electrical components or contacts as long as the condensing boiler has not been Fuse isolated from the power supply.
  • Page 20 Electrical connection The functions of output A1 can be scanned and adjusted with Wolf control accessories with eBUS capability. The following functions can be allocated to output A1: Code Explanation No function Output A1 is not activated DHW circulation pump 100% Output A1 is activated by control accessories (timed) if DHW has been enabled.
  • Page 21 Figure: Connection, room thermostat The functions of input E1 can be scanned and adjusted with Wolf control accessories with eBUS capability. The following functions can be allocated to input E1: Code...

  • Page 22: Filling The System

    Filling the system Fill the system and vent it properly to safeguard the perfect functioning of the condensing boiler. Before connecting the gas condensing boiler, flush the heating system to remove residues such as welding pearls, hemp, putty, etc. from the pipework.

  • Page 23: Conversion To Other Gas Types

    Conversion to other gas types (if required) The gas condensing boilers CGB-75/CGB-100 are equipped as part of the standard delivery for operation with natural gas H (G20). For operation with LPG (G31), the gas restrictor must be replaced. 4 x screws Unplug the connector ...
  • Page 24 Pull the flue pipe up out of the condensate pan. Conversion type plate Figure: Updating the type plate Conversion sets for CGB-75/100 for conversion to other gas types: (Please state the corresponding part number when ordering) Conversion to LPG P (G31) Part no. 86 12 714 ID 740*...

  • Page 25: Checking The Gas Supply Pressure

    Checking the gas supply pressure Checking the gas supply pressure (Gas supply pressure) Work on gas components must only be performed by a licenced gas fitter. Work which is carried out incorrectly may lead to gas escaping, resulting in a risk of explosion, asphyxiation or poisoning.

  • Page 26: Commissioning / Setting The Bus Address

    Commissioning / BUS address adjustment Only qualified personnel must carry out the commissioning and initial start-up of the boiler as well as instruct the user. ON/OFF Reset button Thermometer - Check the boiler and system for leaks; switch Illuminated signal ring Normal operating pressure when system is cold 1.5 - 2.0 bar;...

  • Page 27: Displaying / Modifying Control Parameters

    The control parameters can be modified or displayed via control accessories with eBUS capability. For procedures, check the operating instructions of the relevant accessories. Column 1 settings apply to control accessories ART, AWT Column 2 settings apply to Wolf control system with BM programming module Parameter Unit Factory setting min.

  • Page 28: Adjusting The Modulating Pump

    The speed limits for heating mode can be changed with the BM programming module. The settings in column 1 apply to control accessories ART, AWT The settings in column 2 apply to Wolf control systems with programming module BM Parameter...

  • Page 29: Limiting The Maximum Output

    CGB-100 Heating output (kW) Display value Table: Output setting Limiting the maximum output relative to a flow/return temperature of 80/60 °C Settings for parameter GB04 / HG04 or with Wolf connection accessories with eBUS capability in [%] 30 62 555_0709...

  • Page 30: Testing The Combustion Parameters

    Testing the combustion parameters Test the combustion parameters with the boiler closed! Testing the combustion air - Remove the screw from the l.h. test port Test port Test port "Inlet air" "Flue gas" - Open the gas shut-off valve - Insert the test probe - Start the gas condensing boiler and turn the heating water temperature selector to the emissions test symbol (illuminated ring of the status display flashes yellow)

  • Page 31: Co Adjustments

    adjustments Adjusting the gas:air connection Carry out the adjustments in the following sequence: At the factory, the gas combination valve has been adjusted for the gas type stated on the type plate. Only adjust the gas combination valve after the system has been changed to a different gas type or when servicing.

  • Page 32: Co Adjustments

    adjustments B) CO adjustment at the lower load (soft start) - Remove the protective screw over the zero point adjusting Zero point screw with a Torx screwdriver adjusting - Restart the condensing boiler by pressing the "Reset screw button" - Check and correct (if required) the CO content approx.

  • Page 33: Commissioning Report

    Commissioning report Commissioning steps Test value or confirmation 1.) Gas type Natural gas H Wobbe index ________________ kWh/m³ Net calorific value ________________ kWh/m³ 2.) Gas supply pressure checked? 3.) Gas leak test carried out? 4.) Balanced flue system checked? 5.) Water connections checked for leaks? 6.) Fill the siphon 7.) Boiler and system vented? 8.) System pressure 1.5 - 2.5 bar?

  • Page 34: Maintenance And Design Data

    Maintenance and design data Residual head of the heating circuit pump (accessory) The pump modulates subject to burner load. See diagrams for residual height. CGB-75/100 residual head with pump assembly (accessory) 1000 1500 2000 2500 3000 3500 4000 4500 Water volume [l/h]...
  • Page 35 80 °C Max. spread A heat exchanger protection function is integrated into the CGB-75/100. This prevents stresses in the material by limiting the maximum temperature differential between the flow and return. As of 28 K, the output is reduced. If 38 K is nevertheless reached, the burner shuts down briefly without a fault message.

  • Page 36: Design Information

    - Desalination via reverse osmosis - Topping up with distilled water Maximum permissible total hardness in °dH Total hardness of the untreated potable water CGB-75 in °dH Water treatment CGB-100 necessary We recommend allowing for the expected top-up water during the first fill.

  • Page 37: System Log

    System log Planning Location Boiler output Lowest boiler output Lowest boiler output for the system Bmin System output B,tot B,tot System volume system Maximum expected Total volume expected during the top-up water volume system service life top-up Fill and top-up water volume system top-up Total hardness of the potable water c...

  • Page 38: Function Description/System Design

    Function description / system design Control units Control units for appliances with a low loss header with KM/MM Programming module Generally, at least one programming module (BM) is required. This enables both individual heating circuits and up to 8 heating circuits (1 direct and 7 mixer circuits) to be operated and adjusted.

  • Page 39: Function Description/System Design

    Information on expansion vessel sizing can be found in the pricelist. A minimum pressure limiter (0.8 bar) is integrated into the CGB-75/100. If the majority of radiators are located below the appliance (e.g. in the case of attic installations), a low water indicator should also be used.
  • Page 40 System example 1: 1 CGB-75/100 + 1 heating circuit + 1 mixer circuit 30 62 555_0709...

  • Page 41: System Example 2

    System example 2: 1 CGB-75/100 + 1 heating circuit + 1 mixer circuit 30 62 555_0709...
  • Page 42 System example 3: 1 CGB-75/100 + 1 heating circuit + 3-6 mixer circuits + 1 cylinder 30 62 555_0709...
  • Page 43 System example 4: 1 CGB-75/100 + 1 heating circuit + 1 mixer circuit + 1 cylinder 30 62 555_0709...
  • Page 44 System example 5: 1 CGB-75/100 + 1 heating circuit + 1-6 mixer circuits + 1 cylinder 30 62 555_0709...
  • Page 45 System example 6: 2 CGB-75/100 + 1 heating circuit + 1-6 mixer circuits + 1 cylinder 30 62 555_0709...

  • Page 46: System Examples 1-6

    Key to system examples Key to the Wiring arrow with letters (e.g. "A"): Wiring is carried out to the relevant control unit system examples (e.g. "A") OS ..Outside temperature sensor ATF ..Flue gas temperature sensor DK..Unmixed heating circuit E Bus ..

  • Page 47: Parts List For The System Examples

    Parts list for the system examples Description CGB-75 CGB-100 Programming module mixer module Solar module Cascade module Low loss header 30 62 555_0709...

  • Page 48: Balanced Flue Routing

    Design information Balanced flue routing C13x C33x C43x C33x C53x C93x C43x C83x C83x C93x 30 62 555_0709...
  • Page 49 Where necessary, adapt the installation examples to the relevant Building Regulations and requirements of your country/region. Discuss any questions relating to the installation of inspection covers and ventilation apertures with your local flue gas inspector. The length dimensions for a concentric balanced flue and flues relate exclusively to original Wolf components. 30 62 555_0709...
  • Page 50 Design information Minimum duct sizes applicable to open flue and balanced flue operation >30 >20 C93x balanced flue in a duct C33x balanced flue B33 open flue DN 110 in a duct DN 110/160 in a duct DN 110 C93 x balanced flue System DN 110/160 horizontal and DN 110 vertical...
  • Page 51 If fire resistance is not required, route the pipes for combustion air supply and flue gas expulsion Particularly for safety reasons, use only original Wolf between the top edge of the ceiling and the roof components for concentric balanced flues and for skin inside a duct made from non-combustible, conventional flues.
  • Page 52 Design information Flue gas temperature limiter Calculating the balanced flue length The electronic flue gas temperature limiter switches the oil The calculated length of the balanced flue system or condensing boiler off when the flue gas temperature exceeds the flue is derived from the straight pipe length and the 110 °C.
  • Page 53 Design information Balanced flue route, vertical and concentric (examples) Gas condensing boiler Gas condensing boiler connection DN 110/160 Inspection piece Inspection piece, 87° tee Pipe clip DN 160 Balanced flue DN 110/160 500 mm 1000 mm 2000 mm Mounting bracket DN 160 for roof outlet Universal tile for pitched roof 25-45°...
  • Page 54 Design information Horizontal concentric balanced flue C13x, C83x and B33 and flue on an external wall C53x (examples) Dormer (on site) Horizontal balanced flue routing through a pitched roof Flue on an external wall (where required) 120 mm Ø opening in the chimney side.
  • Page 55 Design information Eccentric balanced flue C53, B23 Install the balanced flue distributor 110/110 mm eccentrically Downstream of the support bend (19), the flue can be routed (26) for a separate balanced flue. in DN 110 inside the duct. When connecting a balanced flue certified acc. to Building Regulations, observe the permit of the relevant body.
  • Page 56 Design information Supplementary installation notes Flat roof: Affix the ceiling outlet approx. Ø 170 mm (8) Install all horizontal balanced deep into the roof cover. flues with > 3° slope (6 cm/m) Pitched roof: At (7, 7a), observe the installation instructions t o w a r d s t h e b o i l e r.
  • Page 57 Straight balanced flues may be up to 2.0 m long, when are designated with the DVGW quality seal and are matched for use with Wolf gas condensing boilers. When using CE- installing the system in a balanced flue chimney. In addition to the boiler connection bend, up to two 90°...

  • Page 58: Wiring Diagram

    Wiring diagram 30 62 555_0709...

  • Page 59: Specification

    Specification Type CGB-75 CGB-100 Rated output at 80/60 °C 70.1 91.9 Rated output at 50/30 °C 75.8 98.8 Rated heat input 71.5 Lowest output (modulating at 80/60) 18.2 18.2 Lowest output (modulating at 50/30) 19.6 19.6 Lowest heat input (modulating) 18.5...

  • Page 60: Troubleshooting

    Troubleshooting Any faults will be displayed as fault codes by Wolf controllers with eBUS capability. To these faults, cause and remedy may be allocated using the following table. This table is designed to allow your local heating contractor to trace the fault more easily.
  • Page 61 Troubleshooting Fault Fault Cause Remedy code BCC missing Boiler coding card was removed Fit the correct boiler coding card CRC fault, BCC Faulty boiler coding card Replace boiler coding card Incorrect BCC The boiler coding card is incompatible with the control Fit the correct boiler coding card unit PCB BCC no.

  • Page 62: Notes

    Notes 30 62 555_0709...

  • Page 63: Notes

    Notes 30 62 555_0709...

  • Page 64: Ec Declaration Of Conformity

    Dichiarazione di conformita campione di costruzione - EG Con la presente dichiariamo che le nostre caldaie Murali a Gas Wolf e le caldaie a Gas Wolf corrispondono al e campioni di costruzione, come sono descritte nel certificato di collaudo EG „campione di costruzione“ e che esse soddisfano le disposizioni in vigore nella normativa: 90/396/EWG apparecchiature a Gas.

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