Wolf COB Installation Instructions And Technical Manual
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Wolf COB Installation Instructions And Technical Manual

Boiler for heating boiler with stratification cylinder oil condensing boiler
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Installation instructions and
technical guide
Oil condensing boiler
COB
COB-TS
Wolf GmbH · Postfach 1380 · D-84048 Mainburg · Tel. +49-8751/74-0 · Fax +49-8751/741600 · Internet: www.wolf-heiztechnik.de
Document no.: 3062547_201507
Boiler for heating
Boiler with stratification cylinder
Subject to modifications
GB

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  • Page 1 Installation instructions and technical guide Oil condensing boiler Boiler for heating COB-TS Boiler with stratification cylinder Wolf GmbH · Postfach 1380 · D-84048 Mainburg · Tel. +49-8751/74-0 · Fax +49-8751/741600 · Internet: www.wolf-heiztechnik.de Document no.: 3062547_201507 Subject to modifications...

  • Page 2: Table Of Contents

    25. Flue gas damper installation / wiring diagram ...........38 26. Flue gas damper tightness test ..............39 Commissioning ..................... 40-44 27. Commissioning with Wolf control accessories (BM) ......40-41 28. Commissioning without Wolf control accessories (BM) ..... 42-43 29. Commissioning report ................44 30.

  • Page 3: Safety Instructions

    1. Safety instructions The following symbols are used in conjunction with these important instructions concerning personal safety, as well as operational reliability. "Safety instructions" are instructions with which you must comply exactly, to prevent risks and injuries to individuals and material losses. Danger through 'live' electrical components! NB: Switch OFF the ON/OFF switch before removing the casing. Never touch electrical components or contacts when the ON/OFF switch is in the ON position! This results in a risk of electrocution that may lead to injury or death. The terminals are 'live' even when the ON/OFF switch is in the OFF position. This indicates technical instructions which you must observe to prevent damage and malfunctions.

  • Page 4: Cob/Cob-Ts Installation/Standard Delivery

    2. COB/COB-TS installation/ standard delivery COB-15/20/29/40 oil condensing boiler COB-15/20/29 oil condensing boiler for heating with connection option for with TS stratification cylinder, DHW cylinder e.g. SE-2, SEM-1, BSP on the right, floorstanding COB-15/20/29 oil condensing boiler COB-15/20/29 oil condensing boiler...

  • Page 5: Specification

    3. Specification Recesses for Balanced flue individual piping connection of the heating connections Flow Entries for oil hoses (optional) Return Optional fixing point for oil filter Condensate drain level Opening the casing Closing the casing Type plate 3062547_201507...
  • Page 6 3. Specification Oil condensing boiler COB-15 COB-15/TS COB-20 COB-20/TS Rated output at 80/60 °C, stage 1/2 9,0 / 14,4 9,0 / 14,4 13,1 / 19,0 13,1 / 19,0 Rated output at 50/30 °C, stage 1/2 9,5 / 15,1 9,5 / 15,1...

  • Page 7: Specification

    3. Specification Oil condensing boiler COB-29 COB-29/TS COB-40 Rated output at 80/60 °C, stage 1/2 18,5 / 28,2 18,5 / 28,2 25,3 / 38,0 Rated output at 50/30 °C, stage 1/2 19,6 / 29,6 19,6 / 29,6 26,8 / 40,0 Rated load, stage 1/2...
  • Page 8 4. Layout of components COB-TS oil condensing boiler with stratification cylinder 1 Cylinder heating from above with deflector and divider 2 DHW draw-off at the highest point 3 Cold water supply with control and distribution appliance 4 Cold water draw-off for cylinder heating...

  • Page 9: Layout/Description Of Components

    5. Description of components COB component description Automatic air vent Ignition transformer High limit safety cut-out Blast tube Flame monitor connection Oil pump motor Two-stage oil pump Flue gas temperature limiter Boiler sensor Water pressure switch Drain valve TS component description Heating flow 1"...

  • Page 10: Standards And Regulations

    To save energy and protect against scaling Wolf oil condensing boilers must only be installed by a if the total hardness is greater than 15 °dH recognised heating contractor. This heating contractor (2.5 mol/m³), the DHW temperature may be set will also be responsible for the proper installation and the to a maximum of 50 °C.

  • Page 11: Installation Instructions

    - The combustion air must be free from halogenated hydrocarbons. - A surface temperature of 40 °C is not exceeded in the case of COB if operated as intended. The respective national fire regulations are to be observed in the case of installation in oil storage rooms.

  • Page 12: Installation

    Safety equipment Domestic hot water may be used as fill water and top-up water. The COB has not been fitted with an expansion vessel at the factory. This must be fitted externally (available from the The addition of chemicals or de-scaling using single-stage ion Wolf accessories range).
  • Page 13 Test pressure on heating water side max. 4 bar The COB (from date of manufacture May 2010) can be Prior to testing, close the shut-off valves in the heating circuit for operated with fuel oil with up to 10 % alternative constituents the appliance, because otherwise, the safety valve (accessory) –B10- to DIN V 51603-6.

  • Page 14: Installation Accessories

    9. Installation - accessories We recommend making the connection to the heating system with the following parts from the Wolf accessories range. COB connection set adjacent to the wall comprising: 2 cross pieces, each with one connection 2 clips 1 corrugated stainless steel pipe 1", length 1 300 mm 1 corrugated stainless steel pipe 1", length 800 mm...

  • Page 15: Boiler/Ts Cylinder

    10. Installation - boiler/TS cylinder Example: COB-15/20/29 oil condensing boiler with TS stratification cylinder on the right, floorstanding (when looking at front of boiler). The pipework for the heating flow and heating return, as well as the heating water flow and heating water return, are connected to the stratification cylinder with corrugated stainless steel pipes (accessories) (see chapter 9 "Installation - accessories").

  • Page 16: Installation Examples

    11. Installation examples Pipe assembly for three heating circuits with manifold for safety assembly installation Pipe assembly for two heating circuits with manifold for safety assembly installation Pipe assembly for one heating circuit for safety assembly installation Safety assembly for fixing to the corrugated stainless steel pipes of heating flow and return The safety assembly and the required pipe assembly can be installed on the left, on the right or at the back of the boiler on a wall or attached to the side of the boiler casing.

  • Page 17: Oil Connection In A Single-Line System

    0.3 bar in the oil line. We therefore recommend using electromagnetically controlled anti-lift valves. The electrical anti-lift devices can be connected to the COB in two ways: 1. The anti-lift valve is connected at output A1. For this, output A1 must be programmed to 9 (oil shut-off valve), see HG14.

  • Page 18: Siphon/Neutralisation/Condensate Pump

    13. Siphon/neutralisation/condensate pump Condensate drain without neutralisation If low sulphur fuel oil EL (sulphur content < 50 mg/kg) is used, it may be possible to forego neutralisation of the condensate after consultation with the lower water authority. The condensate may be discharged into drainage pipes only in accordance with ATV DVGW worksheet A251.

  • Page 19: Installation Of A Balanced Flue System

    In the worst case scenario, a smaller slope for the balanced flue may lead to corrosion or Bei COB-15/-20/-29 muss der beiliegende Achtung operating faults. A b g a s - M e s s s t u t z e n a u f d e m L u f t - / Abgasstutzen des Kessels montiert werden.

  • Page 20: Filling The Heating System

    Displacement COB-15 COB-20 COB-29 COB-40 device distance to 98-103 98-103 123-128 123-125 ridged profile (mm) Displacement device distance - Assembly is carried out in reverse order. Diagram: View of COB displacement device 3062547_201507...

  • Page 21: Electrical Connection

    16. Electrical connection General notes The installation must be carried out by a Terminal box licensed electrical contractor. Observe VDE regulations as well as all local regulations by your power supply utility. The power supply terminals are 'live' even when the ON/OFF switch has been switched OFF. Isolate the boiler from the power supply Terminal box before changing the fuse. The ON/OFF switch The terminal box is supplied fitted to the back panel of the on the boiler does not provide separation boiler.

  • Page 22: Control Unit

    17. Control unit °C ON/OFF switch Reset button Thermometer Illuminated Heating water signal ring temperature temperature selector 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. If the boiler is in a cycle block, this is reset by pressing the button (2 seconds) Illuminated signal ring as status indicator Display...
  • Page 23 17. Control unit Setting Winter mode (settings 2 to 8) In winter mode, the boiler heats the flow temperature to the value set on the thermostat. According to the pump operating mode, the circulation pump operates constantly (factory setting) or only in parallel with the burner activation / run-on period. Summer mode Winter mode is disabled by rotating the heating water temperature selector into position.

  • Page 24: Displaying/Modifying Control Parameters/Settings Report

    18. Displaying / modifying control parameters The control parameters can only be modified or displayed via Wolf control accessories with eBUS capability. For installation and procedures, check the operating instructions of the relevant accessories. BM programming module Modifications must only the carried out by a recognised heating contractor or by the Wolf R.h. rotary selector - L.h. rotary selector - customer service. temperature selection program selection Display To prevent damage to the heating system, cancel night setback when outside temperatures fall below -12 °C. If this rule is not observed, ice...

  • Page 25: Contractor Level Parameters

    19. Contractor level parameters Contractor level Press the r.h. rotary selector to change to control level 2. Turn the r.h. rotary selector clockwise to select the contractor level and confirm the selection by pressing the r.h. Heating rotary selector again. The display shows the code scan. contractor Code scan The correct code is set by pressing (display indication flashes) and then turning the r.h.
  • Page 26 19. Contractor level parameters This parameter shifts the minimum and maximum fan speed parallel downwards or Matching the pipe length upwards. Parameter HG00 This enables the CO value for burner stages 1 and 2 to be adjusted at the same HG00 time. See also chapter 22 "CO adjustment by matching the pipe lengths"...
  • Page 27 19. Contractor level parameters Pump operating mode 2: Buffer primary pump for BSP cylinder Heating circuit pump become the buffer primary pump. The manifold sensor (buffer) only affects the heating operation. In case of cylinder heating, the reference temperature is provided by the internal boiler sensor. In heating mode, the buffer primary pump runs only when there is a burner demand.
  • Page 28 19. Contractor level parameters The functions of input E1 can only be scanned and adjusted with Wolf control Programmable input E1 accessories with eBUS capability. Parameter HG13 The following functions can be allocated to input E1: HG13 Explanation Room thermostat Closed contact is a prerequisite for enabling the burner in heating mode.
  • Page 29 19. Contractor level parameters The functions of output A1 can only be scanned and adjusted with Wolf control Programmable output A1 accessories with eBUS capability. Parameter HG14 The following functions can be allocated to output A1: HG14 Explanation DHW circulation pump 100% Output A1 is switched by control accessories (BM) if DHW circulation has been enabled.
  • Page 30 19. Contractor level parameters The cylinder hysteresis regulates the start point for cylinder heating. The higher the Cylinder hysteresis setting, the lower the start point for cylinder heating. Parameter HG15 HG15 Example: Set cylinder temperature 60 °C Cylinder hysteresis 5 K Cylinder heating commences at 55 °C and ends at 60 °C. Factory setting: 5 K Setting range: 1 to 30 K Cylinder primary pump...
  • Page 31 19. Contractor level parameters Maximum boiler water The control unit is equipped with an electronic boiler thermostat which has an adjustable maximum shutdown temperature (maximum boiler water temperature). The burner is temperature TK-max. switched off if this temperature is exceeded. The burner will be started again when the Parameter HG22 boiler water temperature has fallen by as much as the burner switching differential.

  • Page 32: Cascade Operation

    COB-40 oil condensing boilers (with the same output) with an output range of 18.5 kW to 112.8 kW (cascade COB-29) or 25.3 kW to 152.0 kW (cascade COB-40) can be linked together to form a single cascade. Subject to load, this digital cascade controller KM can control the header flow, a mixer circuit and a DHW cylinder circuit.

  • Page 33: Flue System Design

    21. Cascade operation Flue system design Balanced flue routing Oil condensing boilers with a separate, concentric, balanced flue outlet (DN 80/125 or DN 110/160) above the roof, type C33x, may only be installed in attics, or in rooms where the ceiling also forms the roof, or where only the roof construction is located above the ceiling.

  • Page 34: Flue Gas Header Version

    150 cm². Where necessary, adapt the installation examples to the relevant Building Regulations and requirements of your country/region. Discuss any questions relating to the installation, particularly of inspection covers and ventilation apertures (ventilation generally required above 50 kW output) with your local heating engineer. Number COB-29 COB-29 COB-29 COB-29 COB-40 COB-40...

  • Page 35: Flue Gas Header Version / Notes

    23. Cascade operation Flue gas header design / notes The maximum horizontal length of the flue gas header is 1.5 m between the appliances and 1.5 m downstream of the last appliance. In addition to the boiler connection bend, a maximum of two 87° diverters may be installed. Pipe length calculation: The calculated length of the flue comprises the straight pipe length and the length of the pipe bends.
  • Page 36 [in Germany; check local regulations]. 1 Oil condensing boiler 36 Siphon 2 Connection adaptor with test nipple 37 PP header for air and flue gas (included in COB standard delivery) 38 End piece with inspection aperture and condensate 16 Rose drain 23 Support rail 24 87°...

  • Page 37: Flue Gas Damper Installation

    A1 (see chapter 25 "Wiring diagram cascade operation"). - Fit the cover. Proceed with chapter 26 "Flue gas damper tightness test" and "Commissioning". Programmable output A1 (230 VAC; 200 VA) COB back view 3062547_201507...

  • Page 38: Flue Gas Damper Installation / Wiring Diagram

    Flue gas damper with servomotor Power supply (230 VAC; 200 VA) Flue gas damper limit switch must be zero volt. Otherwise 230 V ~ the COB control unit will be Limit switch destroyed. COB-15/20/29/40 Junction box on site Programmable output A1 (230VAC;...

  • Page 39: Flue Gas Damper Tightness Test

    - Set the program selector (l.h. rotary selector) to “Standby” on the BM program- ming module. - Then turn the first COB to position 1 “Emissions test” by means of the heating water temperature selector è COB starts. - Operate the first COB for at least 5 minutes.

  • Page 40: Commissioning

    27. Commissioning with Wolf control accessories (BM) If no control accessory is installed, see chapter 28 "Commissioning without Wolf control accessories (BM)". Commissioning Only qualified personnel must carry out the commissioning and operation of the boiler, as well as instruct the user. - Check the boiler and system for leaks. Normal operating pressure when system is cold 1.5 - 2.0 bar. Prevent water leaks. "Flue gas" "Inlet air" - Check location and seating of the installation. (e.g. displacement device test port test port position) - Check the fuel level in the oil tank and water level in the siphon or neutralisation box.
  • Page 41 - If the value is outside the set value, the CO value must be adjusted via the pump pressure (see chapter 28 "Commissioning without Wolf control accessories"). - Reset HG28 burner operating mode from 1 to 2. - Terminate the emissions test mode by turning the program selector switch on the BM programming module to the required operating mode.

  • Page 42: Commissioning Without Wolf Control Accessories (Bm)

    28. Commissioning without Wolf control accessories (BM) Commissioning Only qualified personnel must carry out the commissioning and operation of the boiler, as well as instruct the user. - Check the boiler and system for leaks. Normal operating pressure when system is cold 1.5 - 2.0 bar. Prevent water leaks. "Flue gas" "Inlet air" - Check location and seating of the installation. test port test port - Check the fuel level in the oil tank. - Check all connections and component links for leaks.
  • Page 43 1 Pump Danfoss Turn clockwise - higher CO value Turn anti-clockwise - lower CO value Appliance open COB-15 COB-20 COB-29 COB-40 Stage 2 set value 13.2 ± 0.3% 13.2 ± 0.3% 12.7 ± 0.3% 12.7 ±...

  • Page 44: Commissioning Report

    29. Commissioning report Commissioning steps Test value or confirmation 1.) Fuel oil Standard EL Low sulphur EL Bio-oil B10 2.) Oil leak test carried out? 3.) Balanced flue system checked? 4.) Water connections checked for leaks? 5.) Siphon filled? 6.) Boiler and system vented? 7.) Function test carried out? 8.) Function test carried out? 9.) Flue gas test:...

  • Page 45: Maintenance And Design Data

    13344 2772 12697 2662 12086 2558 11508 2458 10961 2362 10442 2271 9952 2183 9487 2100 9046 2020 8629 1944 Pressure drop on the heating water side COB-15 COB-15 10K-spread COB-15 20K-spread 1000 1200 1400 1600 1800 2000 Water volume (l/h) 3062547_201507...

  • Page 46: Maintenance And Design Data

    30. Maintenance and design data Pressure drop on the heating COB-20 water side COB-20 10K-spread COB-20 20K-spread 1000 1200 1400 1600 1800 2000 Water volume (l/h) Pressure drop on the heating water side COB-29 COB-29 10K-spread COB-29 20K-spread 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000...

  • Page 47: Design Information - Balanced Flue System

    Flue (flexible) DN83, DN110 Concentric balanced flue (on an external wall) DN 110/160 Flue DN 160 (for cascade) The necessary type plates and certificates are included with the relevant Wolf accessories. Observe all additional installation instructions included with accessories. 3062547_201507...
  • Page 48 Balanced flue routing Versions as condensing boilers Max. length, vertical COB-15 COB-20 COB-29 COB-40 B23 Flue in a duct and combustion air directly via the boiler (open flue) B33 Flue in a duct with horizontal, concentric connection line (open flue) B33 Connection to a moisture-resistant flue gas chimney with...
  • Page 49 31. Design information Minimum duct sizes Flue DN80 (COB-15/20/29), DN110 (COB-40) for balanced flue operation C93x COB-15/-20 Assumptions: In the installation room, 2 x tee, 1 x 87° bend + 1.5 m horizontal COB-29 with 87° support bend COB-40 Square duct a x a (mm)
  • Page 50 31. Design information Concentric balanced flue C33x, C83x, C93x and flue on an external wall C53x (examples) DN 80/125 and DN 110/160 1 Oil condensing boiler 2 Connection adaptor with test nipple for air and flue gas (included in COB standard delivery) 4 Balanced flue 500 mm 1000 mm 2000 mm 5 Spacer clip 7 Balanced flue, vertical (roof outlet for...
  • Page 51 31. Design information Vertical concentric balanced flue C33x (examples) system DN 80/125 and DN 110/160 1 Oil condensing boiler 2 Connection adaptor with test nipple for air and flue gas (included in COB standard delivery) 3 Balanced flue incl. inspection aperture (250 mm long) 4 Balanced flue DN 80/125 500 mm 1000 mm 2000 mm 5 Spacer clip...
  • Page 52 Secondary ventilation Balanced flue routing, open flue B33 and B23 (examples) DN 80/125 and DN 110/160 1 Oil condensing boiler 2 Connection adaptor with test nipple for air and flue gas (included in COB standard delivery) 4 Balanced flue 500 mm 1000 mm 2000 mm 5 Spacer clip (only if required) 10 Inspection tee 87°...
  • Page 53 31. Design information Supplementary installation instructions for balanced flue DN 80/125 Flat roof: Affix the ceiling outlet approx. Ø 130 mm (14) in the roof During installation, slide the separator (8) fully into the coupling. cover. Push the next balanced flue (4) 50 mm (dim. "S") into the coupling Pitched roof: At (12), observe the installation instructions on the of the separator, and secure in this location, e.g.
  • Page 54 31. Design information General notes A clearance between the concentric balanced flue and Particularly for safety reasons, use only original Wolf combustible materials or components is not required, as components for flues and concentric balanced flue systems. temperatures are limited to 85 °C at the rated boiler output.
  • Page 55 Original Wolf components are designed for long-term use and boiler connection tee, up to two 90° diverters may be installed. are matched for use with Wolf oil condensing boilers. When The flue gas chimney must be CE-designated. using CE-designated third party equipment, the installer is...

  • Page 56: Wiring Diagram

    32. Wiring diagram 3062547_201507...

  • Page 57: Reset

    33. Reset Reset Observe the following steps to implement a reset: - The ON/OFF switch must be set to O (OFF). - Press and hold down the reset button on the standard control unit whilst setting °C the ON/OFF switch to I (ON). - Hold down the reset button again for at least 2 seconds after switching on the system.

  • Page 58: Troubleshooting

    34. Troubleshooting Any faults will be displayed as fault code by Wolf control accessories with eBUS capability. The cause and remedy for a fault can be established using the following table. This table is designed to allow your local heating contractor to trace the fault more easily.

  • Page 59: Troubleshooting

    34. Troubleshooting Fault Fault Cause Remedy code Insufficient water The pressure switch does not switch on, water Check system pressure >1.5 bar pressure pressure is too low (< 0.8 bar) Check water pressure switch, check lead, press reset Condensate pump is Faulty condensate pump, drain line blocked, no Check pump, check drain line, check not pumping anything...

  • Page 60: Product Fiche According To Regulation (Eu) No. 811/2013

    Any specific precautions that shall be taken See installation See installation See installation See installation when the space heater is assembled, installed instruction instruction instruction instruction or maintained 3062547_201507 Wolf GmbH, Postfach 1380, D-84048 Mainburg, Tel. +49-8751/74-0, Fax +49-8751/741600, Internet: www.wolf-heiztechnik.de Material number: 3020224 03/2015...
  • Page 61 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 3062547_201507 Wolf GmbH, Postfach 1380, D-84048 Mainburg, Tel. +49-8751/74-0, Fax +49-8751/741600, Internet: www.wolf-heiztechnik.de Material number: 3020524 03/2015...
  • Page 62 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 3062547_201507 Wolf GmbH, Postfach 1380, D-84048 Mainburg, Tel. +49-8751/74-0, Fax +49-8751/741600, Internet: www.wolf-heiztechnik.de Material number: 3020547 03/2015...
  • Page 63 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 3062547_201507 Wolf GmbH, Postfach 1380, D-84048 Mainburg, Tel. +49-8751/74-0, Fax +49-8751/741600, Internet: www.wolf-heiztechnik.de Material number: 3020570 03/2015...

  • Page 64: Technical Parameters According To Eu Regulation No. 813/2013

    23,775 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 65: Notes

    37. Notes 3062547_201507...
  • Page 66 37. Notes 3062547_201507...

  • Page 67: Ec Declaration Of Conformity

    38. Declaration of conformity DECLARATION OF CONFORMITY (to DIN EN ISO/IEC 17050-1) Number: 3062547 Issued by: Wolf GmbH Adress: Industriestraße 1, D-84048 Mainburg Product: Oil condensing boiler COB/COB-TS The product described above conforms to the requirements specified in the following documents: §6, 1. BImSchV, 26.01.2010 DIN EN 230, 10/2005 DIN EN 267, 11/1999 DIN EN 303, 12/2003...
  • Page 68 Wolf GmbH · Postfach 1380 · D-84048 Mainburg · Tel. +49-8751/74-0 · Fax +49-8751/741600 · Internet: www.wolf-heiztechnik.de...

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