Wolf COB-2 Page 2 Operation Instructions Manual Download

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02 | WOLF GmbH 3066501_201910

Table of contents

About this document ................................................................................................................ 05

1.1 Scope ......................................................................................................................................................... 05

1.2

Target group ............................................................................................................................................... 05

1.3

Other applicable documents ...................................................................................................................... 05

1.4

Safekeeping of these documents ............................................................................................................... 05

1.5

Symbols ..................................................................................................................................................... 05

1.6 Warnings .................................................................................................................................................... 05

1.7 Abbreviations ............................................................................................................................................. 06

2 Safety ......................................................................................................................................... 07

2.1

Intended use .............................................................................................................................................. 07

2.2

Safety measures ........................................................................................................................................ 07

2.3

General safety information ......................................................................................................................... 07

2.4

Handover to operator ................................................................................................................................. 08

2.5

Declaration of Conformity ........................................................................................................................... 08

3 Description ................................................................................................................................ 09

3.1

Layout of COB-2-TS oil condensing boiler ................................................................................................. 09

3.2

COB-2 oil condensing boiler components .................................................................................................. 10

3.3

TS stratification cylinder components ........................................................................................................ 11

4 Planning .................................................................................................................................... 12

4.1 Regulations ................................................................................................................................................ 12

4.1.1 Local regulations ........................................................................................................................................ 12

4.1.2 General regulations .................................................................................................................................... 12

4.2

Installation location ..................................................................................................................................... 13

4.2.1 Minimum wall clearances to the front and side .......................................................................................... 13

4.2.2 Minimum clearances (above) ..................................................................................................................... 13

4.2.3 Installation site requirements ..................................................................................................................... 14

4.3

Heating system .......................................................................................................................................... 14

4.3.1 Safety equipment ....................................................................................................................................... 14

4.3.2 Heating water ............................................................................................................................................. 15

4.3.3 WOLF accessories - heating system ......................................................................................................... 16

4.4

Fuel supply ................................................................................................................................................. 17

4.4.1 Suction line in the single line system ......................................................................................................... 18

4.4.2 Fuel requirements ...................................................................................................................................... 19

4.5

Condensate drain ....................................................................................................................................... 19

4.6

Air/flue gas routing ..................................................................................................................................... 19

4.6.1 Installation of the air/flue gas lines ............................................................................................................. 20

4.6.2 Overview of connection types .................................................................................................................... 21

4.6.3 Permitted connection types ........................................................................................................................ 22

4.6.4 Air/flue gas routing lengths ......................................................................................................................... 22

4.6.5 Minimum shaft sizes ................................................................................................................................... 24

4.6.6 Notes on connection .................................................................................................................................. 25

4.7

Cascade operation ..................................................................................................................................... 26

4.7.1 Control configuration .................................................................................................................................. 26

4.7.2 Directly heated DHW cylinder .................................................................................................................... 26

4.7.3 Heating system .......................................................................................................................................... 27

4.7.4 Fuel supply ................................................................................................................................................. 27

4.7.5 Air/flue gas routing ..................................................................................................................................... 28

5 Installation ................................................................................................................................. 30

5.1

Transporting the boiler/stratification cylinder .............................................................................................. 30

5.2

Checking the delivery ................................................................................................................................. 30

5.3

Removing / fitting the casing ...................................................................................................................... 31

5.4

Position the heat generator and cylinder .................................................................................................... 31

5.5

Installing the safety assembly and pipe assembly ..................................................................................... 32

5.5.1 Installation examples .................................................................................................................................. 33

5.6

Connect the cold water .............................................................................................................................. 34

5.7

Connecting the oil line ................................................................................................................................ 35

5.7.1 Connecting the filter/air vent combination .................................................................................................. 35

Summary of Contents for COB-2

Page 1: ...3066501_201910 GB Operation instructions for contractors COB 2 TS OIL CONDENSING BOILER COB 2 for central heating TS for central heating with stratification cylinder English subject to modifications ...

Page 2: ... 3 1 Safety equipment 14 4 3 2 Heating water 15 4 3 3 WOLF accessories heating system 16 4 4 Fuel supply 17 4 4 1 Suction line in the single line system 18 4 4 2 Fuel requirements 19 4 5 Condensate drain 19 4 6 Air flue gas routing 19 4 6 1 Installation of the air flue gas lines 20 4 6 2 Overview of connection types 21 4 6 3 Permitted connection types 22 4 6 4 Air flue gas routing lengths 22 4 6 5...

Page 3: ...ing on the heat generator 49 6 5 Configuring the system 50 6 6 Venting pumps and TS stratification cylinder 50 6 6 1 Venting feed heating circuit pump 50 6 6 2 Vent heating circuit of the TS stratification cylinder 50 6 6 3 Venting the oil pump 51 6 7 Configuring CO2 51 6 7 1 Checking the flue system 51 6 7 2 Test the CO2 levels with the casing open 52 6 7 3 Setting CO2 levels 52 6 7 4 Changing th...

Page 4: ...Fault messages 65 8 4 2 Warning messages 68 9 Decommissioning 69 9 1 Taking the heat generator out of service temporarily 69 9 2 Putting the heat generator back into service 69 9 3 Taking the heat generator out of service in an emergency 69 9 4 Taking the heat generator out of service permanently 69 10 Recycling and disposal 71 11 Specifications 72 11 1 COB 2 oil condensing boiler 72 11 2 TS strat...

Page 5: ... in a suitable location and must be available at all times The user is responsible for the safekeeping of all documents The documents are provided by the contractor 1 5 Symbols The following symbols are used in this document Symbol Meaning An action which must be taken A necessary requirement The outcome of an action i Important information regarding the proper use of the heat generator A referenc...

Page 6: ...on to prevent the risk 1 7 Abbreviations BMS Building management system HC Heating circuit HCP Heating circuit pump BDF Boiler drain fill valve CW Cold water AFR Air flue gas routing concentric eccentric or separate BFC Balanced flue chimney PP Primary pump CPP Cylinder primary pump HLSC High limit safety cut out DHW Domestic hot water FHP Feed heating circuit pump ...

Page 7: ...pare parts 2 3 General safety information DANGER Electrical voltage Danger of death from electrocution All electrical work must be performed by a contractor DANGER Insufficient combustion air supply or flue gas removal Risk of asphyxiation or severe to life threatening poisoning Switch OFF the heat generator if you can smell flue gas Open windows and doors Notify a contractor CAUTION Oil leak Drin...

Page 8: ...ly genuine WOLF spare parts Do not make any technical changes to the heat generator or control components The pH level must be checked after 8 to 12 weeks by a contractor This guide and the other applicable documents must be kept safely in a suitable location and must be available at all times The system user is responsible for the safety environmental compatibility and energy quality of the heati...

Page 9: ... 20 29 stratification cylinder q Condensate pan w Trap e Neutralising system accessory r Condensate pump accessory t Circulation y Cold water u Domestic hot water i DHW draw off at the highest point o Cylinder heating from above with deflector and divider a Sensor well for cylinder temperature sensor s Protective magnesium anode d Circulation line f CW stratification pipe g Drain in standard deliv...

Page 10: ...2 COB 2 oil condensing boiler components q Automatic air vent valve w High limit safety cut out e Blast tube r Oil pump motor t Two stage oil pump y Boiler sensor u Ignition transformer i Fan o Differential pressure sensor a Flue gas temperature sensor s Water pressure sensor d Drain valve ...

Page 11: ...urn 1 w DHW connection e Regulated TS stratification pump r Immersion pipe cylinder sensor t Plate heat exchanger y Stratification sensor u Cylinder primary pump PP i Heating flow 1 o Cold water connection optional accessory a Expansion vessel 8 l accessory s Air vent valve d Circulation pump accessory f Protective anode under cover g Drain ...

Page 12: ...stallations Scale formation Sheet 1 Water side corrosion Sheet 2 Corrosion by fuel gases Sheet 3 Germany The following also apply to installation and operation in Germany Technical regulations for oil installations IWO TRÖL as amended DIN 1988 Codes of practice for drinking water installations DIN 18160 Chimneys DWA A 251 Condensate from condensing boilers DWA A 791 Technical regulations for subst...

Page 13: ...s must be observed 4 2 Installation location The COB 2 and TS are installed adjacent to the wall which means that a clearance only needs to be observed at the front A surface temperature of 40 C is not exceeded during proper use 4 2 1 Minimum wall clearances to the front and side The recommended wall clearances simplify installation maintenance and servicing 700 700 700 700 700 COB 2 COB 2 COB 2 T...

Page 14: ...ance with DIN 4807 Fit the expansion vessel onsite WOLF accessories range WARNING Risk of explosion due to pressure buildup Scalding and physical injury Do not install a shut off valve between the expansion vessel and the heat generator This does not include butterfly valves upstream of the expansion vessel Route the discharge pipe of the butterfly valve into a drain outlet Make sure that a drain ...

Page 15: ...rdance with VDI 2035 Electrical conductivity and water hardness The limits for conductivity and water hardness are dependent on the specific system volume VA VA system volume max rated heating output According to VDI 2035 in systems with multiple boilers use the maximum rated heating output of the smallest heat generator Heating water quality requirement relating to the entire heating system Total...

Page 16: ... L At least 304 L of desalinated water must be added when filling the system The system can then be topped up with potable water Top up water The total amount of filling and top up water over the life cycle of the heat generator must not exceed three times the nominal volume of the heating system oxygen ingress If a system requires large volumes of top up water e g more than 10 of the system volum...

Page 17: ...ation pump EE 0 2 2 Thermometers in flow and return 2 Ball valves in flow and return With without mixer With manifold for 2 or 3 pipe assemblies Neutralising box 1 Granulate fill 1 Installation accessories Condensate lifting system with a potential free alarm output 1 Condensate pump with potential free alarm output 1 Condensate tank with cover and wall mounting bracket 1 PVC hose 10 mm 6 m long 1...

Page 18: ...tion line length When sizing the line lengths the individual resistances filter non return valve and six 90 bends are already taken into account Type Throughput Internal diameter of line Inlet height H m kg h mm 4 3 2 1 0 1 2 3 COB 2 15 COB 2 20 COB 2 29 Up to 2 5 4 40 40 40 40 40 35 25 13 COB 2 40 Up to 3 7 4 40 40 40 38 29 22 15 9 Table 4 5 Calculation of inlet height If the suction height or th...

Page 19: ...at low temperatures ambient temperature between 5 C and 20 C and protected from exposure to direct sunlight in the case of plastic tanks in particular Up to date information indicates that bio oil should not be stored for longer than one year Table 4 6 Fuel requirements 4 5 Condensate drain If the condensate is fed directly into the on site drain Use a flexible hose to connect the trap to the on s...

Page 20: ...haft outside of the installation room If this is not done there is no guarantee of any mechanical protection Fire resistance must be guaranteed for at least 90 minutes Air flue gas routing via existing shaft Cleaning and inspection not possible from the outlet Make sure that the following clearance is maintained between the cleaning and inspection opening in the shaft channel and the front edge of...

Page 21: ...ture exceeds 120 C The heat generator restarts when the reset button is pressed Appliance connection with flue gas test port The following applies to the connection with flue gas test port Required for the proper operation of the heat generator Easily accessible by the chimney sweep Fitted to the heat generator at the factory Alternatively install immediately after the 87 bend connected directly t...

Page 22: ...nd certificates are included with the relevant WOLF accessories 4 6 4 Air flue gas routing lengths The calculation was made taking the pressure conditions into account geodetic height 325m The specified lengths refer to concentric balanced flues and standard flues and apply to original WOLF components only Maximum length Type Design variants Maximum length m 1 COB 2 15 20 29 40 B23 Flue in a shaft...

Page 23: ... 83 Rigid DN 80 29 24 21 Flexible DN 83 27 21 17 C93x Vertical flue for installation in a shaft with minimum dimensions rigid or flexible with horizontal concentric connection pipe DN 110 160 vertical DN 110 Rigid DN 110 22 Flexible DN 110 22 1 Available fan draught COB 2 15 32 65Pa COB 2 20 45 65Pa COB 2 29 55 105 Pa COB 2 40 70 150 Pa maximum length corresponds to the total length from the heat ...

Page 24: ... mm m m a x a mm DN60 COB 2 15 COB 2 29 COB 2 40 COB 2 15 20 COB 2 29 COB 2 40 Fig 4 5 Shaft size q Max vertical length m w Rigid flue e Flexible flue Open flue operation B23 B33 and room sealed operation C53 x Due to the need for permanent secondary ventilation between the flue and shaft in accordance with DIN 18160 when installing rigid and flexible air flue gas lines in a shaft the following mi...

Page 25: ... flue room sealed 3m Recommended maximum length of horizontal supply air pipe 3 m Special requirements for flues that are not surrounded by combustion air in accordance with locally applicable combustion regulations Type C63x Combustion air supply and flue gas systems room sealed and open flue which have not been tested with the oil firing site 3m If using third party equipment that is only CE DIB...

Page 26: ...instructions for contractors BM 2 programming unit installation and operating instructions for contractors The heat generators have control PCBs with functions which are tailored to the WOLF control modules Configuration only in conjunction with a KM 2 cascade module The KM 2 cascade module controls the header flow based on the load one mixer circuit one DHW cylinder circuit The MM 2 mixer module ...

Page 27: ...fore be installed upstream of the heating water circuit or DHW cylinder circuit Ensure that the heating water flow rate through the heat generator is set lower than that through the subsequent heating circuit The flow rate should be set upstream of the low loss header via a line regulating valve or butterfly valve Hydraulic separation Instead of the low loss header a heat exchanger can be installe...

Page 28: ...DN 110 160 max 14m Fig 4 9 Cascade control with separate vertical concentric balanced flue type C33x Flue gas routing with header flue gas cascade DANGER Escape of flue gases Risk of asphyxiation or severe to life threatening poisoning A flue cascade is only permitted with a tested flue gas damper Design according to EN 13984 1 Comply with all building regulations and requirements in your country ...

Page 29: ...fter the final heat generator 2 m Geodetic height 325m If the conditions at the installation site are different an individual calculation is required Number 2 x 2 x 3 x 4 x 2 x 3 x 4 x COB 2 29 29 29 29 40 40 40 Installation Type B23 Flue internal diameter DN 110 160 160 160 160 160 160 Total flue gas mass flow rate g s 26 6 26 6 40 0 53 3 35 0 52 5 70 0 Maximum flue gas temperature C 76 83 Maximu...

Page 30: ...eat generator Transport to the installation site Remove strap and packaging Remove the fixing screws on the pallet Lift the heat generator and cylinder off the pallet 5 2 Checking the delivery The following parts are included with the COB 2 and COB 2 TS Standard delivery COB 2 COB 2 TS COB 2 15 20 29 40 oil condensing boiler TS 15 20 29 stratification cylinder Trap with hose Stainless steel cleani...

Page 31: ... casing 1 1 Fig 5 3 Attaching the casing Insert the casing cover 1 Put the panel in place 2 Tighten the screws 3 5 4 Position the heat generator and cylinder i Maintain minimum wall clearances This will simplify installation maintenance and servicing 4 2 1 Minimum wall clearances to the front and side Remove the casing Fig 5 2 Removing the casing Use the adjustable feet to level the heat generator...

Page 32: ...lation position 1 2 Side casing Wall left right rear 3 Wall left right rear Safety assembly Install the safety assembly for the heating flow and return Route the discharge pipes of the safety valves into a drain outlet Fig 5 5 Safety assembly with levelling part Pipe assembly Install the pipe assembly on the safety assembly Fig 5 6 Pipe assemblies q Pipe assembly for 1 heating circuit w Pipe assem...

Page 33: ...Installation 3066501_201910 WOLF GmbH 33 5 5 1 Installation examples Fig 5 7 Connection set next to heat generator on the wall Fig 5 8 Connection set behind heat generator on the wall ...

Page 34: ...the regulations of DIN 1988 Germany as well as those of your local water supply utility when connecting cold water and DHW Failure to observe Fig 5 10 Cold water connection to DIN 1988 in the installation voids any WOLF GmbH warranty i Parallel DHW operation is not possible for heat generators with a TS stratification cylinder If the system parameter A10 enable parallel mode is set to parallel DHW...

Page 35: ...is performed in the following cases Before commissioning For underground oil lines before they are covered After work on the oil lines except for oil filter changes 5 7 1 Connecting the filter air vent combination CAUTION Oil leak Drinking water may be contaminated by hazardous substances Install the oil line with the system disconnected from the power supply NOTE Contaminants in the oil line Syst...

Page 36: ...x must be filled with water prior to commissioning 5 8 1 Connecting the trap Remove the sealing plug on the trap plug so that the condensate can drain freely Otherwise this leads to an operating fault Connect the trap to the connectors on the combustion chamber pan Connect a drain hose to the trap and the on site drain Make sure that the line has a consistent downward incline and is properly venti...

Page 37: ...ing water Water damage Check neutralising box for leaks The neutralising box must be filled with water prior to commissioning to check for leaks All connections are fitted without leaks Observe the neutralising box installation instructions Fig 5 13 Trap with neutralising box q Trap w Neutralising box optionally with condensate pump ...

Page 38: ...m Never install damaged parts Create flue connections using sockets and gaskets Ensure that gaskets are fitted correctly Always arrange sockets against the direction of the condensate flow Always trim the flue on the smooth side never on the coupling side Bevel or deburr trimmed flues to ensure gas tight installation of pipe joints Remove contamination before installation Wet or lubricate all air ...

Page 39: ...ke the offset B into account Bend B 87 At least 204mm 45 At least 93mm Table 5 1 Offset bend Installing a balanced flue in an existing chimney duct Make sure that there is appropriate clearance between the outside of the flue and the wall of the duct Fig 4 6 Minimum shaft size mm Flue lines retaining straps and spacers must be installed in channels and ducts in such a way that the ventilated cross...

Page 40: ... collar 1 into roof cover When using universal tile 3 observe the installation instructions on the cowl regarding roof pitch Guide the roof outlet 5 through the roof from above Secure vertically with mounting bracket 4 to a rafter or brickwork 5 10 Electrical connection DANGER Risk of electrical voltage even when the ON OFF switch is set to OFF Danger of death from electrocution Isolate the entire...

Page 41: ... connections to stratification cylinder and condensate pump w Terminal box at rear factory default e Opening for heat generator cable feed through r Lines for heat generator connections 5 10 3 Removing the terminal box If required the terminal box can be mounted on the wall to the left of the heat generator or above it Fig 5 19 Installation positions for terminal box installed on the wall q Termin...

Page 42: ...l box 5 10 4 Installing the terminal box on the wall Position the cable outlets in the terminal box to the left 1 the right 2 or at the top 3 Screw the strain relief into the inserts Strip approximately 70 mm of the insulation on the connecting cable Push the cable through the strain relief Screw the strain relief into place Terminate the appropriate cores at the Rast5 plug Push the inserts into t...

Page 43: ...tification pump e Control signal stratification pump r Stratification sensor t Alarm switch condensate pump y Power plug condensate pump Make the electrical connection at the TS stratification cylinder as shown in the image Fig 5 22 Electrical connection at the TS stratification cylinder q Regulated TS stratification pump w Control signal stratification pump e Stratification sensor r A1 programmab...

Page 44: ...Cylinder sensor a eBus Terminal assignment in terminal box E2 a b Netz N L1 Z1 N L1 A1 N L1 ZHP N L1 L1 LP N SF 1 2 AF E1 eBUS 1 2 a b 1 2 1 2 1 2 1 2 1 2 E2 a b 230VAC 24 V Fig 5 24 Terminal box terminal assignment Terminal Explanation Mains Power supply Z1 230 V output when ON OFF switch is in the ON position Maximum of 1 5 A per output no more than 600 VA in total ZHP FHP Feed heating circuit p...

Page 45: ...ential in the control unit 5 10 6 Connect the flue gas damper to the power supply cascade operation only Open the lower casing cover of the HCM 2 Strip insulation from the power cable of the damper motor and signal contact Pull the Rast5 plug from output A1 Push the power cable of the flue gas damper motor through the strain relief insert and secure Terminate the cores at the Rast5 plug A1 and ins...

Page 46: ...turn until approx 2 bar 1 5 to 2 5 pressure is indicated Slowly open the expansion vessel 5 12 2 Checking the hydraulic pipework for leaks Test criteria Unit Value Measures Maximum flow rate 100l min L h 6 000 Max test pressure on the heating water side bar 4 Heat generator tested at the factory bar 4 5 Minimum system pressure bar 1 0 Safety valve bar 3 Close the shut off valves in the heating cir...

Page 47: ...5 25 Possible control modules 5 14 1 Selecting a slot i Either an AM display module or a BM 2 programming unit must be installed on the heat generator for operation Select the slot for the control module Fig 5 26 Possible slots for control modules ...

Page 48: ...TE Unqualified personnel System damage The heat generator may only be commissioned and used for the first time by a contractor The operator must be instructed by a contractor 6 1 Preparation for commissioning Check that all flue gas accessories have been correctly installed and that none are leaking Unscrew the trap remove and fill with water Water will run out of the drain hole on the side Check ...

Page 49: ...ontrol module Fig 6 1 Plugging in the control module Place the control module in the slot above the WOLF logo Fit casing Fig 5 3 Attaching the casing 6 4 Turning on the heat generator Fig 6 2 ON OFF switch Press the ON OFF switch Commissioning assistant is launched ...

Page 50: ...e commissioning assistant is closed automatically after the final configuration To open the commissioning assistant again perform a reset of the control module i A parameter reset is only possible for control modules connected to the heat generator 6 6 Venting pumps and TS stratification cylinder 6 6 1 Venting feed heating circuit pump Installation instructions for feed heating circuit pump Check ...

Page 51: ...bles If there are no air bubbles Select venting off Put the heat generator into service If there are still air bubbles repeat the process Check the oil supply if necessary 6 7 Configuring CO2 Fig 6 4 Appliance connection with flue gas test port q Inlet air test port w Flue gas test port 6 7 1 Checking the flue system i The burner enters a fault state if during commissioning the oil pump does not s...

Page 52: ... HG49 Set CO2 level 6 7 3 Setting CO2 levels 6 7 3 Setting CO2 levels Select parameter HG47 in the contractor level BM 2 or the contractor menu AM Wait for approx 2 minutes Select value i The CO2 level can be increased by lowering the number or decreased by increasing the number Adjust the number by 1 in increments until the measured CO2 level is within the set range Exit parameter HG47 Select par...

Page 53: ...ction Insert the oil pressure gauge into the oil pump s pressure gauge test port 4 Enable emissions test mode Stage 1 Compare value with Table 6 2 Pump pressure Press the emissions test key Stage 2 Compare value with Table 6 2 Pump pressure HG Casing open COB 2 15 COB 2 20 COB 2 29 COB 2 40 47 Stage1 5 0 bar 8 5 bar 9 8 bar 14 bar 49 Stage2 13 5 bar 17 0 bar 24 0 bar 25 bar Table 6 2 Pump pressure...

Page 54: ...When doing so ensure the caps are seated firmly 6 8 Commissioning cascade BM 2 programming unit installation and operating instructions for contractors AM display module installation and operating instructions for contractors KM 2 cascade module installation and operating instructions for contractors 6 8 1 Setting the eBus address in the programming unit or display module NOTE Duplicated eBus addr...

Page 55: ...t button to turn the first COB 2 on COB 2 turns on Wait for at least 5 minutes Measure the CO2 level for the second third and fourth heat generator Remove cap from inlet air test port Insert test probe 2 cm Measure CO2 value CO2 value exceeds 0 2 in the first 15 minutes there is a leak in the flue system Find and fix the leak Measure the CO2 level again CO2 level remains below 0 2 no leak in the f...

Page 56: ...e The heat generator shuts down Close the test ports When doing so ensure the caps are seated firmly 6 9 Configuring the heat generator Standard settings for heat generator on the control module Set parameters 7 1 Parameter list 6 10 Finishing the commissioning process Document values in System and operator s log Complete commissioning report 12 1 Commissioning report ...

Page 57: ...230 VAC A1 for various functions Various Various None HG15 Cylinder hysteresis C 1 30 5 HG16 Minimum heating circuit pump rate 15 100 45 HG17 Maximum heating circuit pump rate 15 100 100 HG19 CPP run on time min 1 10 4 HG20 Max cylinder heating time min 30 OFF 300 120 HG21 Minimum boiler temperature BTmin C 20 90 20 HG22 Maximum boiler temperature BTmax C 50 90 80 HG23 Maximum DHW temperature C 60...

Page 58: ...G01 Set burner hysteresis 15 C r HG60 Minimum hysteresis 7 C t HG33 Burner hysteresis runtime 10 minutes Time curve of the dynamic burner hysteresis for a user defined burner hysteresis HG01 of 15 C and a selected hysteresis time HG33 of 10 minutes After the hysteresis time the burner switches off at the minimum burner hysteresis HG60 of 7 C 7 2 2 HG07 Run on time heating circuit pump If there is ...

Page 59: ... enabled Zirkomat Zirkomat DHW circulation remote control When input E1 is configured as the DHW circulation remote control output A1 is automatically set to DHW circulation pump Output A1 is locked for other settings With input E1 closed output A1 is activated for 5 minutes After input E1 has been switched off and 30 minutes have elapsed the Zirkomat function is re enabled for the next operation ...

Page 60: ...lue gas ventilation air damper Output A1 is switched first before each burner start The burner will only be enabled after input E1 has been closed Closed contact E1 is a prerequisite for enabling the burner in heating DHW and emissions test mode A fault is generated FC8 if output A1 is switched and input E1 does not close or open within 1 minute If output A1 is configured as a flue gas damper inpu...

Page 61: ...linder primary pump will continue to run for 90 seconds after cylinder heating is complete 7 2 12 HG20 Max cylinder heating time Cylinder heating commences as soon as the cylinder temperature sensor calls for heat The heating circuit pumps would be constantly off if the heat generator were undersized the cylinder were scaled up limescale or if DHW were constantly drawn off during DHW priority mode...

Page 62: ...er water temperature HG22 This ensures that even in spring and autumn the heat generator temperature is higher than the cylinder temperature thereby ensuring short heating times 7 2 17 HG28 Burner operating mode You can select any burner operating mode Setting Description HTG 1 stage DHW 1 stage Single stage burner operation stage 1 HTG 2 stage DHW 2 stage factory setting Two stage burner operatio...

Page 63: ...ator continues to be limited by the maximum boiler temperature HG22 7 2 24 HG47 49 CO2 setting CO2 adjustments can be made for the heat exchangers to match the flue system by changing the fan speed for burner operation stage 1 HG47 or burner operation stage 2 HG49 7 2 25 HG56 Input E3 HG56 can be selected only if the I O module expansion board is connected The flue gas damper function cannot be se...

Page 64: ...e cylinder primary pump can be installed upstream or downstream of the low loss header Boiler sensor 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 ...

Page 65: ...es the heat generator with a lockout 8 2 Displaying the message history i It is possible to open a message history and display the most recent fault messages in the contractor level BM 2 or the contractor menu AM Select message history in the contractor level BM 2 or the contractor menu AM 8 3 Dealing with fault and warning messages Identify the code Determine the cause Table 8 1 Fault messages Ta...

Page 66: ... the heat generator Check that the heating flow and return are connected correctly Press reset button 8 Flue gas supply air damper does not respond Flue gas supply air damper contact E1 fails to close or open when there is a demand Check wiring of flue gas supply air damper 11 False flame A flame is recognised before the burner starts Check solenoid valve for oil pump Check ignition electrodes and...

Page 67: ...tton 38 BCC update required Boiler coding card fault PCB requires a new boiler coding card if replacement part Reinsert boiler coding card Check boiler coding card 39 BCC system error Boiler coding card fault Replace boiler coding card 42 Condensate pump not pumping Condensate pump is defective Drain line is blocked No power supply to the condensate pump Check the condensate pump Check drain line ...

Page 68: ...on Check CO2 values Service the equipment 5 Flame failure Flame failure during operation Flue gas return system flue gas in the supply air Air in the oil feed line Heat generator contaminated Check flue system for leaks Check oil line and oil level Press reset button Check CO2 values Service the equipment 22 Differential pressure sensor not responding Differential pressure too low in pre purge pha...

Page 69: ...erator back into service Activate a heating mode using the control module 9 3 Taking the heat generator out of service in an emergency Fig 9 1 ON OFF switch Switch OFF the heat generator at the ON OFF switch Notify a contractor 9 4 Taking the heat generator out of service permanently Prepare for decommissioning DANGER Risk of electrical voltage even when the ON OFF switch is set to OFF Danger of d...

Page 70: ...the appliance to cool to below 40 C Use safety gloves WARNING High temperatures Risk of burns on the hands from hot components Before working on the open heat generator allow it to cool below 40 C 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 oil supply Close the oil shut off valve ...

Page 71: ...e with the Waste Disposal Act the following components must be disposed of or recycled in an environmentally compatible manner by means of appropriate collection points Old appliance Wearing parts Defective components Electrical or electronic waste Environmentally hazardous liquids and oils Environmentally compatible means separated by material groups to ensure the greatest possible recyclability ...

Page 72: ... 12 7 0 3 O2 setting casing open 3 8 0 4 3 8 0 4 3 8 0 4 3 8 0 4 CO2 maximum casing closed 13 5 13 5 13 5 13 5 O2 minimum casing closed 2 7 2 7 2 7 2 7 Pump pressure stage 1 bar 5 0 8 5 9 8 14 Pump pressure stage 2 bar 13 5 17 0 24 0 25 0 Maximum negative pressure in oil line bar 0 3 0 3 0 3 0 3 Flow temperature factory setting Heat generator C 80 80 80 80 DHW C 65 65 65 65 Max flow temperature C ...

Page 73: ... oil condensing boiler specifications 11 2 TS stratification cylinder TS stratification cylinder 15 20 29 Rated capacity equivalent L 160 200 160 240 160 260 Continuous cylinder output kW L h 15 370 20 490 29 710 Output factor NL60 3 5 4 5 5 0 DHW output L 10min 250 280 300 Standby input kWh 24 h 1 47 1 47 1 47 Max permitted cold water supply pressure bar 10 10 10 Minimum anode current protective ...

Page 74: ... 1490 Fig 11 1 COB 2 15 20 29 40 oil condensing boiler for heating with connection option for DHW cylinder e g SE 2 SEM BSP mm 6 0 5 1132 COB 2 15 20 29 1290 6 0 5 1132 COB 2 15 20 29 1290 Fig 11 2 COB 2 15 20 29 oil condensing boiler with TS stratification cylinder q Cylinder left floorstanding mm w Cylinder right floorstanding mm ...

Page 75: ...ication cylinder rear floorstanding 11 4 2 Connections 462 203 122 603 1084 426 194 516 919 260 Fig 11 4 COB connections mm q Air flue gas connection w Knock outs for individual pipework for heating connections e Heating flow r Optional fixing point for oil filter t Heating return y Condensate drain level ...

Page 76: ... 37 38 Resistance Ω 4582 4388 4204 4028 3860 3701 3549 3403 3265 3133 3007 2887 Temperature C 39 40 41 42 43 44 45 46 47 48 49 50 Resistance Ω 2772 2662 2558 2458 2362 2271 2183 2100 2020 1944 1870 1800 Temperature C 51 52 53 54 55 56 57 58 59 60 61 62 Resistance Ω 1733 1669 1608 1549 1493 1438 1387 1337 1289 1244 1200 1158 Temperature C 63 64 65 66 67 68 69 70 71 72 73 74 Resistance Ω 1117 10178 ...

Page 77: ... 5 10 15 20 25 30 L h mbar Fig 11 5 Hot water side pressure drop COB 2 15 q Pressure drop mbar w Water volume L h e 10K spread r 20K spread 200 400 600 800 1000 1200 1400 1600 1800 2000 0 0 5 10 15 20 25 30 L h mbar Fig 11 6 Hot water side pressure drop COB 2 20 q Pressure drop mbar w Water volume L h e 10K spread r 20K spread ...

Page 78: ...7 Hot water side pressure drop COB 2 29 q Pressure drop mbar w Water volume L h e 10K spread r 20K spread 0 400 800 1200 1600 2000 2400 2800 3200 3600 4000 4400 4800 5200 5600 6000 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 160 170 180 190 200 210 L h mbar Fig 11 8 Hot water side pressure drop COB 2 40 q Pressure drop mbar w Water volume L h e 10K spread r 20K spread ...

Page 79: ...lue gas test Gross flue gas temperature _____________ tA C Intake air temperature _____________ tL C Net flue gas temperature _____________ tA tL C Stage 1 Carbon dioxide content CO2 or oxygen content O2 _____________ Stage 1 Carbon monoxide content CO _____________ ppm Stage 2 Carbon dioxide content CO2 or oxygen content O2 _____________ Stage 2 Carbon monoxide content CO _____________ ppm 10 Cas...

Page 80: ...V X11 1 9 GND 3V3 eBus N C wBus VISTX CCTX CCRX X1 1 16 X2 1 10 VISRX bl br gn ws bl br gegn 1 2 4 3 4 3 1 2 sw br rt or 6 5 gnge 8 1 8 1 1 2 9 10 eBus 1 1 2 9 10 2 eBus X32 X3 0 8 1 X34 X33 rt sw vio br bl gr gn ge rt sw vio br bl gr gn ye rt sw vio br bl gr gn ge X52 X51 S1 X53 X50 S1 sw WLAN LAN S1 X31 6 1 X1 1 4 br bl sw br br ye PWM ye br sw sw sw sw sw sw sw sw br 1 sw br 2 HCM 2 A Fig 12 1 ...

Page 81: ...e 7 6 sw br rt or 6 5 N Fan N Fan L Ignition N Ignition L 7 5 4 9 1 6 7 L Flame 1 0 X3 1 8 3 4 5 2 1 ye gn ye br wh gn gr br 6 7 8 gnge 9 4 br gr 1 1 2 2 3 5 5 6 6 4 4 8 8 9 9 7 7 X6 HCM 2 gnge 2 3 GND 3 3 X4 1 X5 gnge bl sw PE 1 2 Out Vc23 OBC CM368 Fig 12 2 Oil burner control unit OBC CM368 wiring diagram q Appliance chassis earthing w Oil pump e Oil valve 1 r Oil valve 2 t Oil burner y Ignition...

Page 82: ... r Limit switch When the limit switch is open the burner is blocked both for DHW and heating as well as for emissions tests and frost protection 12 3 HG40 System configuration Hydraulic and electrical details Hydraulic System Solutions technical guide i Shut off valves air vent valves and safety equipment are not depicted in these hydraulic diagrams These should be provided for each system individ...

Page 83: ...enabled as a heating circuit pump Boiler temperature controller set value is specified by heating circuit or mixing circuits Input E2 not assigned 12 3 2 System configuration 02 One or more mixing circuits via mixer modules no direct heating circuit on the condensing boiler M Fig 12 5 System configuration 02 One or more mixing circuits q MM 2 mixer module w Mixing circuit1 Burner is enabled subjec...

Page 84: ...ow loss header plate heat exchanger for hydraulic separation Fig 12 7 System configuration 11 Cylinder for hydraulic separation q Input Cylinder temperature sensor w Input E2 Header temperature sensor e Cylinder primary pump r Feed heating circuit pump t Cylinder temperature sensor y Cylinder u Header temperature sensor Burner starts subject to demand from the header temperature control heating mo...

Page 85: ...ader sensor heating mode only In case of cylinder heating the reference temperature is provided by the boiler sensor Heating circuit with MM 2 see hydraulic schemes no 16 52 018 003 16 52 018 005 and 16 52 018 006 12 3 4 System configuration 12 Low loss header with header sensor direct heating circuit A1 Fig 12 9 System configuration 12 Low loss header with header sensor q Input E2 Header temperat...

Page 86: ...ol 0 10 V by external controller 0 2 V burner OFF 2 10 V burner output min to max within the programmed limits 12 3 6 System configuration 52 BMS set boiler temperature Fig 12 11 System configuration 52 BMS set boiler temperature q Input E2 w BMS e Feed heating circuit pump Burner starts subject to demand from the boiler thermostat cycle block and soft start active Feed heating circuit pump enable...

Page 87: ... circuit pump e Header temperature sensor Burner starts following a demand from the cascade module via eBus 0 100 burner output min to max within the programmed limit Feed heating circuit pump enabled as a feed pump Header temperature control via cascade module Input E2 not assigned Automatic output reduction when approaching BTmax HG22 is enabled Shutdown when BTmax is reached Use a low loss head...

Page 88: ... A Rated heat output Prated kW 15 20 29 39 Seasonal space heating energy efficiency ηs 92 92 93 93 Annual energy consumption for space heating QHE kWh 8522 11391 16387 21978 Sound power level indoors LWA dB 53 54 59 59 Any specific precautions that shall be taken when the space heater is assembled installed or maintained See installation instruction See installation instruction See installation in...

Page 89: ... Any specific precautions that shall be taken when the space heater is assembled installed or maintained See installation instruction See installation instruction See installation instruction See installation instruction Supplier s name or trade mark Wolf GmbH Name COB 2 15 SEM 1 500 Load profile XXL Water heating energy efficiency class A F B Water heating energy efficiency class A F B Rated heat...

Page 90: ...alled or maintained See installation instruction See installation instruction See installation instruction See installation instruction Supplier s name or trade mark Wolf GmbH Wolf GmbH Wolf GmbH Name COB 2 20 SEM 1 500 COB 2 20 SEM 1 750 COB 2 20 SEM 1 1000 Load profile XXL XXL XXL Water heating energy efficiency class A F Water heating energy efficiency class A F B B B Rated heat output Prated k...

Page 91: ...lled or maintained See installation instruction See installation instruction See installation instruction See installation instruction Supplier s name or trade mark Wolf GmbH Wolf GmbH Wolf GmbH Name COB 2 29 SEM 1 500 COB 2 29 SEM 1 750 COB 2 29 SEM 1 1000 Load profile XXL XXL XXL Water heating energy efficiency class A F B A B Water heating energy efficiency class A F B B B Rated heat output Pra...

Page 92: ...9 59 Any specific precautions that shall be taken when the space heater is assembled installed or maintained See installation instruction See installation instruction See installation instruction See installation instruction Supplier s name or trade mark Wolf GmbH Name COB 2 40 SEM 1 1000 Load profile XXL Water heating energy efficiency class A F B Water heating energy efficiency class A F B Rated...

Page 93: ...y power consumption in standby PSB kW 0 003 0 003 0 003 0 003 0 003 0 003 0 003 Seasonal central heating efficiency ns 92 92 92 92 93 93 93 Efficiency at rated heating output and high temperature operation1 n4 94 1 94 1 93 9 93 9 94 0 94 0 93 9 Efficiency at 30 rated heating output and low temperature operation2 n1 98 8 98 8 98 2 98 2 98 8 98 8 98 4 Heat loss on standby Pstby kW 0 068 0 068 0 091 ...

Page 94: ...335 1 2012 AC 2014 EN 60335 2 102 2016 EN 62233 2008 AC 2008 EN 61000 3 2 2014 EN 61000 3 3 2013 EN 61000 6 3 2007 A1 2011 AC 2012 EN 55014 1 2006 A1 2009 A2 2011 EN 55014 2 2015 The product complies with the following directives and ordinances 92 42 EEC Efficiency Directive 2014 30 EU EMC Directive 2014 35 EU Low Voltage Directive 2009 125 EC ErP Directive 2011 65 EU RoHS Directive EU Regulation ...

Page 95: ...ements specified in the following documents DIN EN 12897 2006 09 The product complies with the following directives and ordinances 2009 125 EC ErP Directive EU Regulation 812 2013 EU Regulation 814 2013 and is identified as follows This declaration of conformity is issued under the sole responsibility of the manufacturer Mainburg 1 April 2019 Gerdewan Jacobs Technical Director Jörn Friedrichs Head...

Page 96: ...WOLF GmbH Postfach 1380 D 84048 Mainburg Tel 49 0 87 51 74 0 Fax 49 0 87 51 74 16 00 www WOLF eu ...

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