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Wolf CGB-35, Installation Instructions Manual

The Wolf CGB-35 Maintenance Instructions Manual is essential for keeping your product in top condition. This comprehensive manual offers step-by-step guidance, ensuring that you perform proper maintenance. Download the manual for free from manualshive.com and give your Wolf CGB-35 the care it deserves.

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3061490_0709

Index

Index  ..............................................................................................................................................................Page 

Safety instructions

 .................................................................................................................................................3

Standards and regulations

..................................................................................................................................4-5

Control unit / Function / Operation 

.....................................................................................................................6-7

Delivered condition / Standard delivery

 .................................................................................................................8

Layout ....................................................................................................................................................................9

Positioning information

 ........................................................................................................................................10

Assembly

 ............................................................................................................................................................. 11

Dimensions / Installation dimensions

 ..................................................................................................................12

Installation

 ......................................................................................................................................................13-16

 

Installation of a balanced flue system

 .......................................................................................................17

 

Power supply

 ........................................................................................................................................18-21

 

Filling the siphon

 .......................................................................................................................................22

 

Filling the system

.......................................................................................................................................23

 

Checking the gas supply pressure

 .......................................................................................................24-25

 

Commissioning

 ..........................................................................................................................................26

 

Setting the BUS address

 ...........................................................................................................................27

 

Displaying/modifying control parameters

 ..................................................................................................28

 

Adjusting the modulating pump

 .................................................................................................................29

 

Limiting the maximum output

 ....................................................................................................................30

 

Testing the combustion parameters

 ..........................................................................................................31

 

CO

2

 settings

 .........................................................................................................................................32-33

 

Commissioning report

 ............................................................................................................................... 34

Technical conversion options of this gas fired condensing boiler

 ........................................................................ 35

Maintenance (see maintenance instructions supplied) 
Technical maintenance and design information

..............................................................................................36-37

Design information - balanced flue system

.....................................................................................................38-48

Design information - hydraulics

 ......................................................................................................................49-53

Wiring diagram

 ....................................................................................................................................................54

Specification

 ........................................................................................................................................................55

Troubleshooting

 ...................................................................................................................................................56

Notes 

 .............................................................................................................................................................57-59

EC declaration of conformity

 ...............................................................................................................................60

Summary of Contents for CGB-35

Page 1: ...s Gas fired condensing boilers CGB 35 Boiler CGB 50 Boiler Document no 3061490_0709 Subject to technical modifications GB Wolf GmbH Postfach 1380 84048 Mainburg Tel 08751 74 0 Fax 08751 741600 Internet www wolf heiztechnik de ...

Page 2: ... pressure 24 25 Commissioning 26 Setting the BUS address 27 Displaying modifying control parameters 28 Adjusting the modulating pump 29 Limiting the maximum output 30 Testing the combustion parameters 31 CO2 settings 32 33 Commissioning report 34 Technical conversion options of this gas fired condensing boiler 35 Maintenance see maintenance instructions supplied Technical maintenance and design in...

Page 3: ...n with these important instructions concerning personal safety as well as technical reliability Safety instructions are instructions with which you must comply exactly to prevent injury and material losses Danger through live electrical compon ents Please note Switch OFF the ON OFF switch before removing the casing Never touch electrical components or con tacts when the ON OFF switch is in the ON ...

Page 4: ...ions 1999 or The Water Bylaws 2000 Scotland It should also be in accordance with therelevantrequirementsoftheLocalAuthority Building Regulations including amendments to the Approved Documents Part Land J 2002 The Building Regulations Scotland The Building Regulations Northern Ireland andtherelevantrecommendationsofthefollowingBritish Standards BS 5440 Flues and ventilation of gas fired boilers not...

Page 5: ...greater than 3 58 mol m we recommend using a water treatment facility in the cold water supply line for DHW heating to prolong the maintenance interval descaling DHW heat exchanger Standards and regulations Gas fired condensing boiler CGB Gas fired condensing boilers according to DIN EN 297 DIN 3368 T5 T6 T7 T8 DIN EN 437 DIN EN 483 draft DIN EN 677 draft DIN EN 625 and Gas Appliance Directive 90 ...

Page 6: ...ssing the reset button reactivates the system if there was no fault Illuminated ring as status indicator Display Explanation Flashing green Standby power supply ON no heat demand Constant green Heat demand pump running burner OFF Flashing yellow Emissions test mode Constant yellow Burner ON flame steady Flashing red Fault DHW temperature selector When gas fired condensing boilers are combined with...

Page 7: ...After the emissions test mode has been activated the boiler will heat to the selected maximum hea ting output Any previous cycle block will be cancelled The emissions test mode terminates after 15 minutes or when the maximum flow temperature has been exceeded For a renewed activation turn the heating water temperature selector anti clockwise and then back into position Summer mode Winter mode is d...

Page 8: ...riesarerequiredfortheinstallation of this gas fired condensing boiler Balanced flue accessories see design information Room temperature dependent or weather compensated control unit Condensate drain outlet with hose retainer Maintenance shut off valves for primary flow and return Gas ball valve with fire protection facility Additional accessories in accordance with the pricelist We recommend Blow ...

Page 9: ...g flow Gas supply pipe Gas air mixing chamber Flue gas sensor Ionisation chamber housing Flue pipe Heating circuit pump auto venting Overflow valve Heating return Return sensor Temperature limiter Combustion chamber Intermediate flange with non return valve Safety valve plug in type Connection Expansion vessel Flow sensor Ignition and monitoring electrodes Power cable Insulating ring Displacer bod...

Page 10: ... components cannot be ensured during maintenance Secure the drain hoses safely with their retaining plate above the drain outlet siphon The drain should be able to be inspected easily The gas fired boiler may only be installed in rooms which are protected from frost General notes The combustion air supplied to the boiler must be free from chemicals e g fluoride chlorine or sulphur Such materials a...

Page 11: ...ting connections for gas central heating DHW and electrics Mounting the boiler with a mounting bra cket Opening the casing lid L h rotating locking screw R h rotating locking screw Fig Open the rotating locking screws We recommend you remove the casing lid during ins tallation Pivot the control unit lid down Unlock the casing lid with the l h and r h rotating locking screw Release the lower part o...

Page 12: ...12 3061490_0709 Dimensions Installation dimensions CGB Fig Dimensions Fig Dimensions Fig Connections 1 Heating flow 2 Gas connection 3 Heating return 4 Condensate drain ...

Page 13: ... boiler will suffer permanent damage as soon as the pressure builds during heat up System components may burst which would result in a risk of scalding An exception would be cap valves upstream of the expansion vessel There is no factory fitted safety valve Route the blow off line into a drain funnel Minimum system pressure 0 75 bar CGB 35 and CGB 50 are approved exclusively for sealed systems up ...

Page 14: ...rom an ion exchanger are not permissible Thoroughly flush the heating system prior to filling with water Dirt trap Install the dirt trap for all systems on site in the return pipe to protect the boiler and pump from coarse dirt and sediments Sludge separator Install a sludge separator upstream of the boiler in the return pipe of all older systems which are predominantly equipped with steel pipewor...

Page 15: ...structions if you install a neutra lising system accessory Fig Neutralising system accessory Installation Connection of a 200 litre Wolf DHW cylin der or third party cylinder Connect the DHW flow and return with a three way diverter valve or the return pipe of the gas fired boiler Use a DHW sensor from the Wolf accessory range when connecting a DHW cylinder made by third parties A detailed descrip...

Page 16: ...f poisoning and explosion Install a gas shut off valve with fire pro tection in the gas supply line upstream of the Wolf gas fired boiler Otherwise ex plosions may occur during a fire Size the gas supply line in accordance with current regulations Gas fittings on the gas burner may be pres sure tested to 150 mbar Higher pressure may damage the gas burner fitting resul ting in a risk of explosion a...

Page 17: ...ou maintain a minimum distance of 2 5 m bet ween the air inlet and flue terminal Also take the Technical Guide into consi deration For concentric air flue pipes balanced flue systems use only original Wolf com ponents Please observe the technical information regarding balanced flue systems prior to installing the flue pipe or the ventilation air connection Different countries have different regula...

Page 18: ...terminals are live even when the ON OFF switch has been swit ched OFF Power supply 230 V AC 50 Hz Power supply ext accessories 230 V AC 50 Hz max 300 VA Programmable output 230 V AC 50 Hz Programma ble input zero volt Outside temp sensor Data BUS controller radio clock AF with radio clock receiver outside radio sensor Installation information power supply Isolate the system from the power supply b...

Page 19: ... sensor must be connected to the blue plug of the control unit Observe the cylinder installation instructions Blue plug Fig Connection DHW circulation pump external accesso ries Connection DHW circulation pump external accessories 230 V AC Insert the cable glands into the terminal box Insert and secure the cable through the cable gland Connect the DHW circulation pump 230 V AC which is part of the...

Page 20: ...utes 5 Flame transmitter Output A1 is activated after a flame has been recognised 6 Cylinder primary pump only for central heating boilers factory setting for A1 Output A1 is activated when the cylinder is heated up 7 Ventilation damper Output A1 is activated before each burner start The burner will however only be enabled after input E1 has been closed Important In any case input E1 must also be ...

Page 21: ...ting operation will be blocked summer mode independent of any digital Wolf control acces sories 2 Maximum thermostat or system pressure switch Optional connection for a maximum thermostat or system pressure switch To enable the burner input E1 must be closed As long as the contact is open the burner will remain blocked for DHW and central heating incl emissions test mode and frost protection 3 Not...

Page 22: ...22 3061490_0709 Filling the siphon Filling the siphon Remove the siphon Fill the siphon with water Install the siphon Fig Siphon Siphon ...

Page 23: ... gas tap Open the manual air vent valve Open the cap of the automatic air vent valve on the heating circuit pump by one revolution but do not remove the cap Open all radiator valves Open all flow and return valves on the gas fired con densing boiler Fill the system to 2 bar pressure In operation the pressure gauge must indicate between 1 and 2 5 bar Start the gas fired condensing boiler set the he...

Page 24: ...rol unit out Release the plug at test nipple 1 and vent the gas supply pipe Connect the differential pressure meter to at test port 1 Connect against atmosphere Switch ON the ON OFF switch After starting the boiler check the supply pressure at the differential pressure gauge Work on gas components MUST ONLY be preformed by a registered gas fitter Work which is carried out incorrectly may lead to g...

Page 25: ...ments and do not start the boiler There is a risk of the equip ment malfunctioning Checking the gas supply pressure If all screws are not fully tightened gas might escape resulting in a risk of explo sions suffocation and poisoning Checking the gas supply pressure Switch OFF the ON OFF switch Close the gas shut off valve Remove the differential pressure gauge and reseal the test port with its plug...

Page 26: ...system ON OFF switch on the control unit Check the over ignition and the regular flame structure of the main burner If the system pressure on the heating water side primary drops below 1 5 bar top up with water until the pressure reached between 2 0 and a maximum of 2 5 bar The illuminated ring shows green if the boiler starts correctly Check that the condensate drains correctly Make the customer ...

Page 27: ...flashing yellow Boiler 3 3 3 flashing yellow red Boiler 4 4 4 flashing yellow green When operating several boilers number of boilers 1 in conjunction with a cascade module KM set the eBUS address of each boiler in accordance with the table below BUS address setting Hold down the reset button after 5 seconds the corresponding flashing code will be displayed see table Select the corresponding addres...

Page 28: ...ump ON C 2 10 10 GB06 HG06 Heating circuit pump mode 0 Pump ON in winter mode 1 Pump ON when the burner is ON 0 0 1 GB07 HG07 Heating circuit pump run on time Heating circuit pump run on time in heating mode in min Heating circuit pump run on time in heating mode in min min 1 0 30 GB08 HG08 or HG22 Maximum set flow temperature Applies to heating mode C 80 40 90 GB09 HG09 Cycle block applies to hea...

Page 29: ...g curve slightly after such a measure as the average radiator temperature will be reduced by the wider spread In addition as the return temperature will drop a wider spread will also improve the utilisation of con densing technology modulating pump Grundfos Boiler Spread Rated output Flow rate Max pump speed heating mode Power consumption pump CGB 35 15 K 25 K 34 9 kW 34 9 kW 2000 l h 1200 l h 100...

Page 30: ...atural gas E H LL and LPG Limiting the maximum output Limiting the maximum output relative to a flow return temperature of 80 60 C Settings for parameter GB04 with Wolf connection accessories with eBUS capability in Maximum output in kW Table Output setting CGB 35 Heating output kW 8 10 12 14 16 17 19 21 23 24 26 28 30 31 32 Display value 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 CGB 50 Heatin...

Page 31: ...t port Ensure the screws seal tightly Fig Test ports Test the combustion parameters with the boiler doors closed Fig Control unit overview ON OFF switch Temperature selector Flue gas test port Air supply test port Testing the flue gas parameters Flue gas can escape into the installation room if the test port is not sealed This can results in a risk of asphyxiation Remove the screw from the l h tes...

Page 32: ...he control unit lid down Unlock the casing lid with the l h and r h rotating locking screws Release the lower part of the casing lid and unhook at the top Remove the screw from the l h flue gas test port Insert the test probe of the CO2 test equipment into the flue gas test port Turn the temperature selector to the emissions test position illuminated status display ring flashes yellow Check the CO...

Page 33: ... work refit the casing lid and check the CO2 value with the boiler closed Observe the CO emissions whilst making CO2 adjustments Thegascombinationvalve is incorrectly adjusted if the CO value lies 200 ppm when the CO2 value is correct In that case take the following steps Fully insert the zero point adjusting screw Open the zero point adjusting screw 3 revolutions for natural gas and 2 revolutions...

Page 34: ...e 1 5 2 5 bar 9 System flushed 10 Heating water hardness between 2 and 11 dH 11 No chemical additives inhibitors antifreeze added 12 Entered type of gas and output onto label 13 Function test carried out 14 Flue gas test Gross flue gas temperature Ventilation air temperature Net flue gas temperature Carbon diox content CO2 or oxygen content O2 Carbon monoxide content CO ________________ __________...

Page 35: ...sion High limit safety cut out STB Boiler Gas type Gas restrictor Flue gas STB Combustion chamber STB CGB 35 Natural gas H yellow 660 17 20 521 27 41 063 27 41 068 LPG P red 510 17 20 520 CGB 50 Natural gas H light grey 850 17 30 257 27 41 063 27 41 068 LPG P lilac 620 17 30 258 Conversion to other gas types from to CGB 35 CGB 50 Natural gas H LPG P 86 11 508 86 11 510 LPG P Natural gas H 86 11 50...

Page 36: ...l 100 CGB 35 Residual head with modulated pump Grundfos Residual boiler head mbar Residual boiler head mbar Residual boiler head mbar Residual boiler head mbar CGB 35 Heating water DHW modu lation level 43 Flow rate l h Minimum modulation level 20 Maximum modulation level 100 CGB 35 Residual head with modulated pump class A Wilo CGB 35 Heating water DHW modulation level 82 Flow rate l h Minimum mo...

Page 37: ...sor resistances Resistance Ohm Temperature C 0 C 16325 15 C 7857 30 C 4028 60 C 1244 5 C 12697 20 C 6247 40 C 2662 70 C 876 10 C 9952 25 C 5000 50 C 1800 80 C 628 Boiler Type 1 2 Category Operating mode To be connected to Opern flue Balanced flue moisture resist chimney balanced flue chimney balanced flue routing acc to build Regs cert LAF moisture resi stant flue pipe CGB 35 50 B23 B33 C53 C53x C...

Page 38: ...93x C43x C83x C53x C33x IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII IIIII I I I I I I I I I I I I I I I I I I II II II II II I II II I II I I II I I I I I I I I I I I I I I I I I I I I I I II II I II C33x C43x C83x C93x C33x B33 C13x ...

Page 39: ...rtical concentric connection pipe open flue Calculation acc to DIN EN 13384 LAS manufacturer C13x Horizontal concentric roof outlet through a pitched roof balanced flue on site dormer 20 11 C33x Vertical concentric roof outlet through a pitched roof or flat roof vertical concentric balanced flue routing for installation in a duct balanced flue 22 13 C33x C93x Vertical flue pipe for routing through...

Page 40: ...80 or DN 110 C93 x balanced flue system DN 80 125 horizontal DN 100 or DN 80 vertical Flexible flue pipe Minimum duct sizes Round Ø Rectangular DN 83 150 mm 130 mm DN 110 190 mm 170 mm Balanced flue routing rigid inside a duct Minimum duct sizes Round Ø Rectangular DN 80 150 mm 130 mm DN 110 190 mm 170 mm B23 C83x IIII IIIIIIIIIIIIIIIIII I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I ...

Page 41: ... above the roof 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 General notes Particularly for safety reasons use only original Wolf components for concentric air flue pipes balanced flue systems Where necessary adapt the installation examples to the relevant Building Regulations and requirements in ...

Page 42: ...the boi ler room agree suitable arrangements with your local heating engineer Flue pipe connections are created using couplings and gaskets Always arrange couplings against the conden sate flow direction Connection to the balanced flue Generally bevel or deburr trimmed flue pipes to ensure a gas tight installation of pipe joints Ensure that gaskets are proper ly fitted Remove all contamination pri...

Page 43: ...ineer prior to the installation Type C33x Gas fired condensing boiler with combustion air and flue gas routed vertically above the roof 1 Gas fired condensing boiler 2 Gas fired condensing boiler con nection DN 80 125 3 Balanced flue incl inspection aperture DN 80 125 250 mm long 4 Balanced flue DN80 125 500 mm 1000 mm 2000 mm 5 Spacer clip 6 Fixing bracket DN125 for roof outlet 7 Balanced flue ve...

Page 44: ...pe on an outside wall where required 90 mm Ø opening in the chimney side Install the flue pipe airtight into the chimney side C53 x B33 C13 x Dormer Design information 1 Gas fired condensing boiler 2 Gas fired condensing boiler connection DN 80 125 3 Balanced flue incl inspection aperture DN80 125 250 mm long 4 Balanced flue DN80 125 500 mm 1000 mm 2000 mm 5 Spacer clip 10 Inspection elbow 87 DN80...

Page 45: ...owingbalancedflueorflueswithCE 0036 CPD 9169003 certification may be used Flue DN 80 Concentric balanced flue DN 80 125 Flue DN 110 Concentric balanced flue on an external wall DN 80 125 Flue flexible DN 83 The necessary type plates are supplied with the respective WOLF accessory Observe all additional installation instructions included with accessories Otherwise there is a risk of equipment malfu...

Page 46: ...N 83 can be connected downstream of the support bend 23 Install the horizontal flue pipe with approx 3 slope 6 cm m towards the boiler Route the horizontal air supply with a 3 slope towards the outside install the air inlet with wind protection permissible wind pressure at the air inlet 90 Pa The burner will not operate with higher wind pressure Eccentric balanced flue C53 Design information 1 Gas...

Page 47: ...pport rail 22 Determine clearance A Balanced flue pipe length 4 always approx 100 mm longer than distance A Always trim the flue pipe on the smooth side never on the coupling side Chamfer the flue pipe after trimming Clearance A Clearance A Offset Flat Affix the ceiling outlet approx Ø 130 mm 14 in the roof cover Pitched At 11 observe the installation instructions on the hood regarding roof pitche...

Page 48: ...ection to a moisture resistant balan ced flue chimney LAS flue gas chimney or flue gas system Chimneys and flue gas systems must be certified for condensing combustion equipment in accordance with local Building Regulations approval by the relevant authority Sizing via calculation tables subject to flue gas category In addition to the boiler connection bend or tee piece a maximum of two 90 diverte...

Page 49: ... a temperature limiter to prevent excessive tem peratures in the underfloor heating circuit Contamination Protect the condensing boiler against contamination In new systems use a dirt trap strainer and in older systems and those which are predominantly equip ped with steel pipework install a sludge separator in the return pipe Symbols used in hydraulic diagrams Hydraulic system overview Heat consu...

Page 50: ...rol This type of connection affects the boiler flow moni toring The boiler may malfunction Direct connection of a mixer circuit without hydraulic decoupling Reason The permissible boiler flow velocity will be exceeded if the three way mixer is fully opened This affects the boiler flow monitoring The boiler may malfunction Install a sufficiently large bypass between the flow and return in the mixer...

Page 51: ...thereby preven ting the boiler pump and the mixer circuit pump from affecting each other The hydraulic balance is substantially easier to achie ve since every consumer circuit requires only one reducer The pump rate in the mixer circuit is reduced because the mixer pressure drop must be added to the boiler circuit The mixer circuit pump will be switched OFF if for an underfloor heating system an e...

Page 52: ...I Three way mixer DN 20 kVS 6 3 up to 45 kW with injection control heating curve distance 10 K DN 25 kVS 12 45 kW with injection control heating curve distance 10 K Mixer motor VF Flow sensor part of the standard delivery of the MM R control unit weather compensated thermostat incl flow sensor V Pipework Pipework in the mixer circuit MK Flow return bypass in the mixer circuit Flow volume MK T Rate...

Page 53: ...raising via the low loss header The reducer is included on the boiler packaging The check valve prevents the boiler from being affected by a flow created by the external pump This is vital for cas cade systems The dirt trap protects the boiler from coarse particles from the heating system Use the ball valve when servicing the filter Use only the KM controller Only this device can regulate the heat...

Page 54: ...X3 X6 X4 X7 X5 X9 Parameterstecker X8 br br gn gn ws ws X12 B 4 1 Speicherfühler br ws gn br ws gn br gn ws ge ws br gn br gn ge ws ge gn sw bl br bl br bl br bl br sw br bl sw ws rs br ws gr gn ge ws ge gn br X11 1 Heiztherme A2 A1 br bl sw ge gn 1 2 3 4 AF E1 eBUS 1 2 a b Netz Z A1 N N N L1 L1 L1 o o o o o o MT 3 15 A F1 1 2 1 2 1 2 br bl ge gr sw ws rt L1 N gn ws gr rs br ge L1 N L1 N L1 N rt B...

Page 55: ... 393 855 x 400 x 393 Gas connection value Natural gas H Hi 9 5 kWh m 34 2 MJ m LPG P Hi 12 8 kWh kg 46 1 MJ kg m h kg h 3 47 2 57 4 94 3 66 Gas supply pressure Natural gas mbar 20 20 LPG mbar 37 50 37 50 Factory setting maximum flow temperature C 75 75 Max system pressure heating bar 3 0 3 0 Heating water heat exchanger water content litre 2 5 2 5 DHW temperature range adjustable 1 C 15 65 15 65 F...

Page 56: ...re the burner starts Press the reset button 12 Flow sensor faulty Gas pressure too low Flow temperature sensor or lead faulty Gas pressure value set at the gas pressure switch only displayed after 15 min Check lead Check the flow sensor Check gas pressure Check gas pressure switch accessory 14 Cylinder sensor faulty DHW temperature sensor or lead faulty Check sensor and lead 15 Outside temp Outsid...

Page 57: ...ow 25 K Vent the heating system check the sy stem pressure Check the heating circuit pump 50 Activation of boiler co ding card The parameter plug must still be enabled Press reset 2x 52 Activation of boiler co ding card The parameter plug must still be enabled Press reset 2x 60 Ionisation current fluctuates The siphon or the flue gas system is blocked severe storm Clean siphon check the flue gas s...

Page 58: ...58 3061490_0709 Notes ...

Page 59: ...59 3061490_0709 Notes ...

Page 60: ... rapport aux installations alimentées de gaz 90 396 CEE 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 appa...

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