Wolf FGB Series Installation And Maintenance Instructions For Contractors Download Page 103

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3064458_201811

103

Gerdewan Jacobs

Engineering Director

Mainburg, 01/08/2017

EU DECLARATION OF CONFORMITY

(to ISO/DIN 17050-1)

Number: 3064219
Issued by:

Wolf GmbH

Address:

Industriestrasse 1, D-84048 Mainburg

Product:

Gas condensing boiler

FGB-28 FGB-K-28

FGB-35 FGB-K-35

The product described above conforms to the requirements specified in the following documents:

§6, 1. BImSchV, 26.01.2010

DIN EN 437 : 2009 EN 437 : 2003 + A1 : 2009)

DIN EN 15502-2-1 : 2013 (EN 15502-2-1 : 2012)

DIN EN 13203-1 : 2015 (EN 13203-1 : 2015)

DIN EN 15502-1 : 2015 (EN 15502-1 + A1 : 2015)

DIN EN 60335-1 : 2012 / AC 2014 (EN 60335-1 : 2012 / AC 2014)

DIN EN 60335-2-102 : 2010 (EN 60335-1 : 2006 + A1 : 2010)

DIN EN 62233 : 2009 (EN 62233 : 2008)

DIN EN 61000-3-2 : 2015 (EN 61000-3-2 : 2014)

DIN EN 61000-3-3 : 2014 (EN 61000-3-3 : 2013)

DIN EN 55014-1 : 2012 (EN 55014-1 : 2006 + A1 : 2009 + A2 : 2011)

In accordance with the following Directives

92/42/EEC (Efficiency Directive)

2016/426/EU (Gas Appliances Directive)

2014/30/EU (EMC Directive)

2014/35/EU (Low Voltage Directive)

2009/125/EC (ErP Directive)

2011/65/EU (RoHS Directive)

EU Regulation 811/2013

EU Regulation 813/2013

this product is identified as follows:

0085

Jörn Friedrichs

Head of Development

This declaration of conformity is issued under the sole responsibility of the manufacturer

Summary of Contents for FGB Series

Page 1: ...w wolf eu Document no 3064458_201811 Subject to technical modifications Installation and maintenance instructions for contractors Wall mounted gas condensing boiler FGB wall mounted gas condensing boiler FGB K wall mounted gas condensing combi boiler FGB 28 FGB 35 FGB K 28 FGB K 35 from FW 1 20 ...

Page 2: ...ing output 56 25 Checking the combustion parameters 57 26 High efficiency pump function description 58 27 Commissioning report 60 Maintenance 28 1 Maintenance Fault messages 62 28 2 Maintenance Spare parts maintenance set 63 28 3 Preparing for maintenance 64 28 4 Determining the soiling level on the heating water heat exchanger flue gas side 65 28 5 Burner maintenance 66 28 6 Checking the ignition...

Page 3: ... and energy quality of the heating system German Immission Control Act Energy Saving Ordinance Germany Inform the system user that these instructions and the other applicable documents must be kept in a safe place These installation instructions apply to the FGB K gas condensing boilers Old equipment may only be disconnected from the gas and electricity supply by a qualified contractor Always disp...

Page 4: ... x cable ties 1 x trap 1 x 1000 mm condensate hose 1 x bleed key The following accessories are required for installing the gas condensing boiler Air flue gas accessories see design information Condensate drain outlet with hose retainer Maintenance shut off valves for heating flow and return Gas ball valve with fire protection Safety assembly for DHW Cylinder connections short circuiting pipework f...

Page 5: ...ediately by a qualified contractor Only replace faulty components and equipment with original WOLF spare parts Danger if you smell gas Close the gas tap Open the windows Do not operate any electrical switches Extinguish naked flames Phone the gas supply utility company and an ap proved contractor from an external location Danger if you smell flue gas Switch OFF the appliance Open windows and doors...

Page 6: ...m the power supply e g by remov ing the separate mains fuse or by means of a main switch or a heating emergency stop switch and check to ensure there is no voltage Safeguard the system against reconnection Inspection and service Ensure the correct operation of the gas boiler by having a contractor carry out inspections at least once a year and maintenance repair when required DVGW TRGI 2008 G600 W...

Page 7: ...p and fan Danger through live electrical components danger from ignition voltage danger of burns from hot components Fig Gas combination valve Risk of poisoning or explosion in the event of gas escaping Fig Gas connection Risk of poisoning or explosion in the event of gas escaping Fig Terminal box Danger through live electrical components ...

Page 8: ...8 3064458_201811 Cold water connection G 1 2 DHW connection G 1 2 Heating flow G 3 4 Heating return G 3 4 38 at 28 kW 83 at 35 kW 3 Dimensions ...

Page 9: ...ial load and TR 30 C Hi net cv Hs gross cv 109 98 109 98 109 98 109 98 Flow temperature factory setting C 75 75 Flow temperature up to approx C 85 85 Max overall positive pressure heating circuit bar 2 5 2 5 Max residual head for heating circuit High efficiency pump EEI 0 20 1075 l h pump rate 25 kW at dt 20 K mbar 450 450 450 450 1376 l h pump rate 32 kW at dt 20 K mbar 350 350 Max permiss overal...

Page 10: ...alve 12 Combustion chamber high limit safety cut out 13 Expansion vessel 14 Pressure sensor 15 Return temperature sensor 16 Flue gas temperature sensor 17 3 way valve motor 18 Heating circuit pump with air vent valve 19 Heating flow 20 Cylinder flow 21 Gas supply pipe 22 Cylinder return 23 Heating return FGB wall mounted gas condensing boiler 1 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 2 3 4 6...

Page 11: ...alve 14 Combustion chamber high limit safety cut out 15 Expansion vessel 16 Pressure sensor 17 Return temperature sensor 18 Flue gas temperature sensor 19 3 way valve motor 20 Heating circuit pump with air vent valve 21 Flow limiter 22 Flow sensor 23 Heating flow 24 DHW connection 25 Gas supply pipe 26 Cold water connection 27 Heating return 1 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26...

Page 12: ...llation 6 Standards and regulations The following general regulations rules and guidelines must be observed for installation in particular DIN EN 806 Specifications for installations inside buildings conveying water for human consumption DIN EN 1717 Protection against pollution of potable water installations DIN EN 12831 Heating systems in buildings Method for calculating the design heat load DIN ...

Page 13: ...inance currently applicable version DVGW Code of Practice G637 The following apply to installation and operation in Austria in particular ÖVE regulations Provisions of the ÖVGW and the corresponding Austrian standards ÖVGV TR Gas G1 ÖVGW TRF G2 Provisions of ÖVGW guideline G41 for condensate drainage Local regulations of building and industry regulatory agencies usually represented by the flue gas...

Page 14: ... The adjustable cylinder water temperature can exceed 60 C Short term operation at temperatures above 60 C must be monitored in order to prevent scalding For permanent operation appropriate precautions should be taken to prevent draw off temperatures above 60 C e g thermostatic valve To protect against scaling the DHW temperature should be set to max 50 C when the total water hardness is 15 dH 2 5...

Page 15: ... through the strain relief cable glands and secured Tighten the cable glands securely to ensure that no water can enter the casing Sound insulation Under certain critical installation conditions e g installation on a drywall additional measures may be necessary to soundproof the boiler In such a case use anti vibration rawl plugs and if necessary rubber mounts or insulation strips The installation...

Page 16: ...ty Also take into account the condition of the wall to prevent gas or water from escaping resulting in a risk of explosion and flooding 1 Mark the Ø12 holes to be drilled for the suspension bracket taking into account the minimum clearances 2 Insert the rawl plugs and fit the suspension bracket using the screws supplied 3 Hook the boiler onto the suspension bracket using the mounting stay 8 Instal...

Page 17: ... Undo the central screw at the bottom of the front casing Push in the two locking hooks at the bottom left and right and pull the casing forwards Lift the front casing upwards to release it and remove it 9 Opening the casing ...

Page 18: ...er If mixer taps are used provide a centralised pressure reducer Observe the regulations of EN 806 as well as those of your local water supply utility when connecting cold water and DHW Your warranty is void if the installation does not comply with the illustration shown Note When selecting the installation material for the system observe engineering standards and take into account possible electr...

Page 19: ...mponents or assemblies may lead to gas escaping which results in a risk of poisoning and explosion Install a gas ball valve with fire protection in the gas supply line upstream of the condensing boiler This prevents a risk of explosion during a fire Size the gas supply line in accordance with DVGW TRGI regulations Mount the gas ball valve in an easily accessible place Carry out a tightness test on...

Page 20: ...fely secured above the tundish trap If the condensate is directly routed to the sewer pipe provide a ventilation facility This is to prevent retroactive effects from the sewer pipe to the gas condensing boiler If installing a neutralising system accessories observe the instructions supplied According to Code of Practice ATV DVWK A251 no neutralising system is required for condensing boilers up to ...

Page 21: ...our local flue gas inspector even after ceiling bezels have been fitted Please note Fig Example ventilation air flue system For concentric balanced flue systems use only original Wolf parts Prior to installation read the technical information regarding balanced flue systems As regulations in the individual Federal States Germany differ we recommend consulting the relevant authorities and local flu...

Page 22: ... components Please note Turn OFF the omnipolar isolator before removing the casing Never touch electrical components or contacts when the isolator is in the ON position This carries a risk of electrocution that could result in injury or death During servicing and installation work isolate the entire system from the power supply at all poles to prevent risk of electrocution No mains isolator on the...

Page 23: ...ush the retaining bracket on the casing upwards and pivot the control unit forwards Open the control unit cover using a screwdriver Only open the cable entries required Insert cable with cable gland and secure Otherwise room sealed operation is not ensured M12 M12 M12 M16 M16 Please note Cable glands ...

Page 24: ...al strip Power supply 230 V 50 Hz Room thermostat input jumper Please note No external voltage must be connected to input E1 as this would destroy the PCB Outside temperature sensor T_Outside 5K NTC Cylinder temperature sensor T_DHW 5K NTC eBus Supply ...

Page 25: ...er cables min 3 x 0 75 mm No other consumers may be connected to the power cable In rooms with a bathtub or shower the appliance may only be connected via an RCD Installation information electrical connection Isolate the system from the power supply before opening Check that the appliance is isolated from the power supply Remove the front casing Pivot the front of the control unit forwards Open th...

Page 26: ...ecting the cylinder sensor Insert and secure the connecting cable through the cable en try Connect the connection cable for cylinder sensor SF to the SF terminals as shown in the wiring diagram When installing the appliance in places where there is a risk of high electromagnetic interfer ence it is advisable to fit shielded sensor and eBUS cables The cable shield should be connected at one end to ...

Page 27: ...th FGB FGB K without programming unit in eBus system Wolf portal server Local home network DSL router LAN WLAN LAN WLAN Wolf boiler with ISM7e interface module FGB FGB K operating options without programming unit Description Authorisation Operating mode Possible system status winter summer standby off Change Set flow temperature Permanent set flow temperature with non weather compensated control u...

Page 28: ...Hi rES Confirm Press for 1 s Key 5 Operating mode key inactive if programming unit in eBus system OFF Press briefly Frost protection active Summer mode Press briefly Only DHW heating enabled Winter mode Press briefly Heating and DHW heating enabled Key 6 Heating key Display adjustment of set flow temperature Press Colder H54 0 fixed temperature Display adjustment of set value correction Press H54 ...

Page 29: ...rsion Info button 3 1 2 7 6 Display DHW mode A flashing symbol indicates an active heat demand for DHW heating Only shown if DHW heating is available Heating mode A flashing symbol indicates an active heat demand for heating operation Changes are only possible when the heating curve is disabled Shown when there are active fault codes Reset button press 1x briefly Fault codes are reset Display of t...

Page 30: ...nter mode If the appliance is connected to a BM 2 the operating mode button is disabled The BM 2 takes over this function Standby OFF The boiler is switched off only frost protection is enabled Winter mode Winter mode heating operation and DHW heating are enabled Summer mode Summer mode only DHW heating is enabled Operating mode button 5 15 Control unit ...

Page 31: ... by a flashing tS Briefly press reset 4 to select the required menu Press and hold operating menu button 5 for 1 s to exit the contractor level Heating appliance parameter see heating appliance control parameters Display menu see info button Fault history The last 8 faults are displayed Press button 1 to select H01 to H08 Press button 7 to display the fault code To reset the fault history When rES...

Page 32: ... after this time has elapsed It can be terminated sooner by pressing key 4 The heating appliance starts and initially switches to upper load Enabling emissions test mode Emissions test upper load Emissions test lower load for adjusting the CO2 Disabling emissions test mode 7 6 Emissions test mode Reset key 4 1 2 5 seconds 1 2 4 7 6 Display subject to appliance version 15 Control unit ...

Page 33: ...ton 4 to exit the parameter level Reset button 4 1 2 7 6 No Description Factory settings 28 kW 35 kW Natural gas LPG Natural gas LPG Min Max H01 Switching hysteresis burner K 7 7 7 7 5 30 H02 1 Lower burner output heat generator 28 26 31 29 26 100 H03 1 Upper burner output DHW DHW mode 92 87 100 94 26 100 H04 1 Upper burner output HTG heating mode 83 78 92 86 26 100 H07 Run on time heating pump mi...

Page 34: ...1 1 2 3 95 95 95 95 15 100 H51 DHW configuration 1 Combi mode 1 4 1 4 1 4 1 4 1 4 2 Combi mode solar 3 Cylinder mode 4 No DHW heating mode only H522 Pasteurisation function only shown if H51 3 C 5 5 5 5 0 80 H532 Activation interval pasteurisation function only shown if H51 3 Days 7 7 7 7 1 7 H542 Heating curve 0 0 0 0 0 30 H552 DHW quick start only shown if H51 1 2 0 0 0 0 0 Eco 1 Comfort A092 Sy...

Page 35: ...ysteresis regulates the boiler water temperature within the set range by switching the burner on and off The higher the start stop temperature differential is set the greater the boiler water temperature fluctuation around the set value with concurrent longer burner runtimes and vice versa Longer burner runtimes protect the environment and extend the service life of wearing parts Parameter H01 Swi...

Page 36: ...e 60 C Cylinder hysteresis 5 K Cylinder heating commences at 55 C and ends at 60 C Parameter is only shown if H51 3 The cylinder frost protection function starts the charging pump and the burner at a cyl inder temperature of 5 C regardless of the set cylinder hysteresis When the cylinder temperature reaches 10 C the charging pump and burner are stopped again Parameter H15 Cylinder hysteresis Facto...

Page 37: ...he upper limit to which the DHW set temperature can be set using DHW button 1 Please note Take adequate measures to prevent scalding Parameter H23 Maximum DHW temperature Factory setting see table Setting range 60 to 80 C Individual setting _____ Parameter H25 serves to select the excess temperature differential between the cylin der temperature and the boiler water temperature during cylinder hea...

Page 38: ...ecting from 3 precon figured system configurations under parameter H40 This parameter influences the function of the internal appliance pump Parameter H40 System configuration System configuration 01 Direct heating circuit on the condensing boiler Burner is activated following demand from the direct heating circuit Internal appliance pump is enabled as a heating circuit pump Thermostatic boiler co...

Page 39: ...is connected eBus address H10 must be set for each condensing boiler Burner starts following a demand from the cascade module via eBus 0 100 burner output min to max within the programmed limits H02 and H04 Internal appliance pump is enabled as a feed pump Header temperature control via cascade module Automatic output reduction when approaching TVmax H08 is enabled Shutdown when TVmax is reached A...

Page 40: ... 2 pasteurisation mode is disabled The BM 2 takes over this function If pasteurisation is enabled setting 0 the DHW cylinder is heated to the temperature set here unless the cylinder temperature has already reached the pasteurisation temperature within the activation intervals H53 Pasteurisation is disabled with the value 0 Parameter H52 Pasteurisation Factory setting see table Setting range 0 to ...

Page 41: ...ent regulations For all other conditions match the slope to the prevailing circumstances The slope must always be set so that at the min outside temperature the maximum flow temperature for the radiators or the underfloor heating system will be achieved As rule of thumb a slope of 9 can be used for a radiator heating system and a slope of 3 for underfloor heating systems in a well insulated house ...

Page 42: ... Temperature correction 4 H08 flow max heating operation 75 C H21 boiler min temperature 20 C H54 heating curve 12 Flow temperature C Temperature correction 4 20 15 10 5 0 5 10 15 20 20 30 40 50 60 70 80 90 100 12 Outside temperature C Heating curve Sample setting Temperature correction 0 H08 flow max heating operation 75 C H21 boiler min temperature 20 C H54 heating curve 12 Flow temperature C Te...

Page 43: ...r starts and heats the boiler up to the minimum boiler water temperature If the appliance is connected to a BM 2 system frost protection is disabled The BM 2 takes over this function Note Only change the factory setting if you can ensure that the heating system and its components will not freeze up at low outside temperatures Caution Material damage from frost Frost can cause the heating system to...

Page 44: ...hanger the pH value of the heating water must be between 6 5 and 9 0 In mixed installations a pH value of 8 2 to 9 0 must be maintained in accordance with VDI 2035 The pH value should be checked again 8 12 weeks after commissioning as under certain circumstances chemical reactions may cause it to change If it does not fall within this range after 8 12 weeks remedial measures must be taken Heating ...

Page 45: ... be in the range of 2 to 11 2 dH If the total hardness of the untreated potable water is too high some of the filling and top up water must be desalinated A desalinated water must be added A 100 Cmax 0 1 dH Cpotable water 0 1 dH x 100 Cmax Maximum permissible total hardness in dH Cpotable water Total hardness of untreated potable water in dH A 100 11 2 dH 0 1 dH 18 dH 0 1 dH x 100 38 38 of the fil...

Page 46: ...high efficiency pump by one revolution Open all radiator valves Open the flow and return valves on the boiler Slowly fill the entire heating system and gas condensing boiler while cold up to approx 2 bar via the return line external pressure gauge required Inhibitors and antifreeze are not permitted Bleed all radiators and if the system pressure drops significantly top up with water to reach 2 bar...

Page 47: ...t display Info button 3 Fig Filling facility integrated in the appliance on delivery Fill vakve Filling the heating system via the filling facility Open the fill valve on the filling facility Fill the heating circuit via the DHW circuit Close the fill valve and test the entire appliance and the component unions for tightness Observe all information on venting the system see above Note that a pipe ...

Page 48: ...lve and acknowledging the fault Fill the trap from above through the inspection port in the flue pipe bend Fill only through the flue do not fill water into the ventilation air aperture as this could cause the burner to malfunction Reopen the gas ball valve Filling the trap Fig Trap filling via flue ...

Page 49: ...se note The condensate hose attached to the trap must not form a loop or roll up as this could lead to impaired operation The angle of fall to the drain should be approx 5 Fig Condensate hose installation included in standard delivery Fig Install with correct fall Fig Air gap to be maintained At least 5 18 Filling the heating system trap ...

Page 50: ...d category 3 e g heating water without inhibitors For Germany and Austria only drinking water may be used for the initial filling of the heating system using the fill ing facility with system separator An initial filling with treated water deionised water etc corresponds to a higher hazard category for which the CA system separator may not be used To ensure long term and fault free operation of th...

Page 51: ... BM 2 takes over this function Isolate the boiler from the power supply at the on site appliance fuse Close the gas ball valve Allow the temperature in the heating circuit to cool to at least 40 C Risk of scalding Safeguard the heating system against accidental reconnection to the power supply Open the drain valve boiler drain fill valve on site Open the air vent valves on the radiators Drain the ...

Page 52: ...r For operation with LPG P replace the gas restrictor as indicated in the table Gas restrictors 1 Request information regarding the gas type and Wobbe index from your local gas supply utility or LPG supplier 2 For operation with natural gas LL and LPG P match the gas restrictor 3 Enter the gas type in the commissioning report 4 Open the gas ball valve Please note Country of destination Appliance c...

Page 53: ...lve 5 Switch the gas condensing boiler ON by pressing button 5 If the appliance is connected to a BM 2 the operating mode key is disabled The BM 2 takes over this function 6 After the boiler has started read the supply pressure on the pressure gauge and enter it in the commissioning report 7 Turn OFF the boiler close the gas ball valve remove the pressure gauge and tighten the screw in the gas tes...

Page 54: ... key is disabled The BM 2 takes over this function 12 Set the gas type in the contractor level only for LPG Call up the HG parameter list Press and hold key 4 for 10 s Briefly press key 4 again Select H12 via key 1 or 2 Set the gas type according to the table via key 6 or 7 Exit contractor level via key 4 Update the type plate Affix the label Conversion to LPG included with the LPG P conversion ki...

Page 55: ...ion lower CO2 content Anti clockwise rotation higher CO2 content FGB FGB K appliance open at upper load Gas type CO2 in O2 in Natural gas E H LL 9 1 0 2 4 5 0 3 LPG P 10 2 0 2 5 4 0 3 CO2 setting at lower load 1 Activate emissions test mode and press DHW key 2 Clockwise rotation higher CO2 content Anti clockwise rotation lower CO2 content FGB FGB K appliance open at lower load Gas type CO2 in O2 i...

Page 56: ...imum heating output at 80 60 C is matched Limiting the maximum heating output relative to a flow return temperature of 80 60 C Display value Heating output kW 35 kW appliance 28 kW appliance 28 kW appliance Display value 28 30 40 50 60 70 80 90 92 Heating output kW 4 8 5 5 9 0 12 4 15 9 19 4 22 8 26 3 27 0 35 kW appliance Display value 30 31 40 50 60 70 80 90 100 Heating output kW 6 3 6 7 10 2 14 ...

Page 57: ... enable the emissions test mode via buttons 6 and 7 press and hold for 5 s 5 Carry out the checks after a minimum of 20 s of operation measuring first at upper load and then at lower load 6 Flue gas values for permissible values see table 7 After the test has been completed switch the boiler OFF remove the test probe and close the test port Ensure the screws gasket are tight seated firmly Please n...

Page 58: ...fixed set speed both for minimum and maximum burner output The pump rate is not controlled subject to the required heat ing load and power consumption is not reduced DHW mode The heating circuit pump does not modulate it continu ously operates at the selected DHW pump speed See table Factory settings for pump speed Standby mode The pump does not run when the boiler is in standby mode Operating set...

Page 59: ...In the spring and autumn the required room temperature is not achieved Increase the set room temperature at the controller e g with set value setting 4 The required room temperature is not achieved when outside temperatures are very low Select a steeper heating curve at the controller e g increase the flow temperature at standard outside temperatures 26 High efficiency pump function de scription ...

Page 60: ...ment carried out pH value set total hardness set ________________ pH value ____________________ dH 4 Appliance and system vented 5 System pressure 2 0 2 5 bar 6 Water connections checked for leaks 7 Trap filled 8 Gas restrictor inserted according to gas type Natural gas LPG Wobbe index _____________ kWh m Net calorific value heating ______ kWh m 9 Gas supply pressure checked 10 Gas tightness test ...

Page 61: ...necessary Expert parameter H51 16 Gas type and output entered on label 17 Balanced flue system checked 18 Flue gas emissions test emissions test mode Gross flue gas temperature Intake air temperature Net flue gas temperature Carbon dioxide content CO2 or oxygen content O2 Carbon monoxide content CO _____________ tFL C _____________ tIA C _____________ tFL tA C _____________ _____________ ppm 19 Ca...

Page 62: ...ect with reset 4 The most recent faults are shown providing maintenance information for the heating contractor Fault history Press button 1 to select H01 to H08 Press button 7 to display the fault code To return to the contractor level press reset button 4 twice Here use but tons 1 and 2 to select the fault history menu rES in order to reset the fault To reset the fault history When rES is display...

Page 63: ... requires the following FGB spare parts maintenance set Condensate pan gasket Adaptor plate with pressure test connector Universal wrench Cleaning tool Ignition and monitoring electrode Gasket ignition and monitoring electrode Burner gasket DHW heat exchanger gasket Condensate pan flue pipe gasket Spare parts cleaning set Flat gasket mounting plate M6 screws combustion chamber cover M4 screws igni...

Page 64: ...right and pull the casing forwards Lift the front casing upwards to release and remove it Isolating the system from the power supply The mains terminals remain live even when the ON OFF switch has been switched OFF Isolate the system from the power supply Closing the gas ball valve Some components can be very hot Let them cool down or wear gloves Risk of burns Seite 16 Gaskugelhahn Durchgangsform ...

Page 65: ...e gas test port on the device connection flange The appliance starts with the venting program AP function for 30 sec see chapter 15 Control unit and the fan runs at constant speed for 30 sec 28 kW 35 kW Reading What to do Reading What to do 3 mbar 1 Cleaning 3 mbar 1 Cleaning Table Limits for heat exchanger cleaning 1 Up to software version 1 10 limit at 7 mbar Compare the reading with the table a...

Page 66: ... Burner maintenance Disconnect the following plugs Fan Gas combination valve Ignition IO electrode Pull off with small twisting movements Undoing the fitting on the gas combination valve Disconnecting the plug in connections ...

Page 67: ...ry time maintenance work is carried out Remove the burner Visual inspection for damage Replace if damaged Clean with compressed air through suction or by tapping out against the direction of flow Clean sealing faces on heat exchanger and burner Replace the burner gasket Caution Never use boiler cleaning agents acids alkaline solutions or water for cleaning Removing the combustion chamber cover Bur...

Page 68: ...ition ionisation electrode Remove the electrode by releasing the two M4 screws The electrode including gasket must be replaced every time maintenance work is carried out torque for fixing screws 3 0 0 3 Nm Replacing the electrodes Electrode ...

Page 69: ...end Flush only through the flue do not fill water into the ventilation air aperture as this could cause the burner to malfunction Check the expansion vessel If you notice a loss of water check the expansion vessel pre charge pressure The connection valve is located at the front and is secured with a protective cap When the heating circuit is depressurised the pre charge pressure should be about 0 ...

Page 70: ...he condensing boiler on the heating water side Open the manual air vent valve Disconnect the plugs for the flow temperature sensor high limit safety cut out and flue gas temperature Disconnect the return sensor and pressure sensor plugs Release the retaining clips Undo the pump fitting Remove the pipes Removing the flow and return pipes ...

Page 71: ... on the burner flange With the cleaning tool from the maintenance set clean the pin rows diagonally Once residues have been loosened tap the heat exchanger to remove them towards the burner flange The heat exchanger can also be flushed with water Removing the condensate pan Unhooking the heat exchanger Cleaning the heat exchanger Turn through 180 Removing residue from the condensate pan Caution Do...

Page 72: ...ght up and secure them on the heat exchanger The flue pipe must be positioned in the condensate pan Refit the trap Replace and grease the gaskets Fit the pipes to the pump using retaining clips and the threaded connection Connect the flow temperature sensor high limit safety cut out and flue gas temperature sensor plugs Reconnect the return sensor and pressure sensor plugs Assembling the heat exch...

Page 73: ...rner horizontally Place the combustion chamber cover on the combustion chamber and evenly pull it forwards Tighten the screws on the combustion chamber cover Fit the inlet pipe Re connect the following plug in connections Fan Gas combination valve Ignition IO electrode Insert with small twisting movements Filling the condensing boiler on the heating water side Fitting the combustion chamber cover ...

Page 74: ...e do not fill water into the ventilation air aperture as this could cause the burner to malfunction Carry out test as described in chapter 28 4 Determining the soiling level on the heating water heat exchanger The measured pressure drop values must lie below the limits If no improvement is apparent install the heat exchanger spare part Tightening the fitting on the gas combination valve Filling th...

Page 75: ...lace and grease the gaskets of the plate heat exchanger After fitting tighten the screws to a torque of 3 5 0 5 Nm Open the gas ball valve and switch on the appliance Check the gas train and hydraulics for tightness Hook the casing back into place and secure it Press the emissions test mode key Checking the DHW heating Plate heat exchanger PHE Screw PHE Screw PHE Dirt filter Test run Test the comb...

Page 76: ...y setting 7 min The boiler water temperature sensor is a high limit safety cut out and shuts down the appliance at 105 C lockout Þ Fault code 02 The boiler water temperature sensor is a temperature limiter and shuts down the appliance at 95 C without lockout Þ Fault code 06 Flue gas temperature sensor The flue gas temperature sensor shuts down the boiler when the flue gas temperature exceeds 115 C...

Page 77: ...tes that all components of the flue gas route are surrounded by combustion air 2 In Switzerland observe the G1 gas guidelines Information about multiple connections Point Safe differential pressure in accordance with DIN EN 15502 2 1 FGB 28 FGB 35 a The maximum safe differential pressure at the lowest thermal load Δpmax saf max 25 b The maximum safe differential pressure at the highest thermal loa...

Page 78: ...l room sealed Calculation to EN 13384 room sealed balanced flue manufacturer C93x Flue for installation in a shaft connecting pipe DN60 100 vertical DN60 rigid 8 5 C93x Flue for installation in a shaft vertical DN80 connecting pipe DN60 100 connecting pipe DN80 125 connecting pipe DN80 125 rigid rigid flexible 14 15 14 27 39 37 1 The maximum length corresponds to the total length from the applianc...

Page 79: ...may spread if these instructions are not observed The following applies to gas boilers with a balanced flue routed above the roof where only the roof structure lies above the ceiling If fire resistance is required for the ceiling the pipes for combustion air supply and flue gas must be equipped with a casing in the area between the top edge of the ceiling and the roof skin The casing must provide ...

Page 80: ...m Minimum shaft size for room sealed operation C93x 31 Technical information balanced flue Assumption the installation room contains 2x inspection bends 1x 87 bend and 1 5 m horizontal with 87 support bend 5 7 9 11 13 15 17 90 95 100 105 110 115 120 125 130 135 140 max Schachtlänge in m Schachtquerschnitt in mm FGB 28 am Schachtquerschnitt eckig bei C93x in DN 80 Anschluss DN 80 125 Anschluss DN 6...

Page 81: ... recommended Observe special requirements for flues that are not surrounded by combustion air acc to DVGW TRGI 2008 and all locally applicable combustion regulations Connection to a combustion air and flue gas system type C63x that is not tested together with the gas combustion equipment Original Wolf components are designed for long term use are designated with the DVGW quality seal and are match...

Page 82: ... DN125 46 28 28 28 28 DN110 DN125 DN125 50 28 28 28 35 DN110 DN110 DN110 15 28 28 28 35 DN110 DN110 DN125 39 28 28 28 35 DN110 DN125 DN125 45 28 28 28 35 DN110 DN125 DN160 50 28 28 35 35 DN110 DN110 DN110 12 28 28 35 35 DN110 DN110 DN125 32 28 28 35 35 DN110 DN125 DN125 39 28 28 35 35 DN110 DN125 DN160 50 28 35 35 35 DN110 DN110 DN110 10 28 35 35 35 DN110 DN110 DN125 26 28 35 35 35 DN110 DN125 DN1...

Page 83: ... 5 minutes On all other appliances check the CO2 content in the air connector If the CO2 value exceeds 0 2 within 15 minutes the leak must be found and remedied Subsequently close all test ports again When doing so ensure the caps are seated firmly Testing the first FGB for tightness Press reset button 4 to return the first FGB into the previous operating mode è emissions test mode is disabled Pre...

Page 84: ...m 2000 mm 5 Balanced flue vertical DN60 100 roof outlet for flat or pitched roofs L 1200 mm L 1200 mm 1700 mm 6 Universal tile for pitched roof 25 45 7 Flat roof collar 8 Bend 45 DN60 100 9 Inspection bend DN60 100 10 Bend 87 DN60 100 11 Pipe collar 12 Support rail 13 Support bend 87 DN60 to DN80 14 Spacer 15 Flue pipe DN80 500 mm 1000 mm 2000 mm 16 Shaft cover with UV resistant terminal 17 Spacer...

Page 85: ...ction bend 10 Bend 87 DN60 100 11 Pipe collar 12 Support rail 13 Support bend 87 DN60 to DN80 14 Spacer 15 PP flue pipe DN80 500 mm 1000 mm 2000 mm 16 Shaft cover with UV resistant terminal 17 Spacer bracket 18 Balanced flue horizontal with wind protector 19 Connection to flue gas chimney B33 length 250 mm with air apertures Horizontal balanced flue connection to balanced flue chimney examples sys...

Page 86: ...tall horizontal pipe with 3 slope towards boiler Please note 1 Gas condensing boiler 3 Separator slide coupling if required 4 Balanced flue DN60 100 500 mm 1000 mm 2000 mm 9 Inspection bend 11 Pipe collar 12 Support rail 13 Support bend 87 DN60 100 14 Spacer 16 Shaft cover with UV resistant terminal 17 Spacer bracket 31 Technical information balanced flue ...

Page 87: ...utlet 7 approx Ø 130 mm to the roof cover Pitched roof For 6 observe the installation instructions on the cowl regarding roof pitches If an inspection aperture is required for the balanced flue insert a balanced flue with inspection aperture 2 200 mm length Insert roof outlet 5 into the roof from above and secure vertically with the mounting bracket to a rafter or brickwork Install the roof outlet...

Page 88: ... 9 Bend 45 DN 80 125 10 Inspection bend 87 DN 80 125 11 Bend 87 DN 80 125 12 Universal tile for pitched roof 25 45 13 Klöber adaptor 20 50 14 Flat roof collar Notes When installing slide the separator 8 fully into the female connection Push the subsequent balanced flue 4 50 mm dim S into the female connection of the separator and always secure in this position e g with pipe clips DN125 5 or with a...

Page 89: ... air pipe end 18 Balanced flue external walls DN80 125 19 Air inlet external wall DN80 125 20 Conc outlet terminal with clamp fitting 21 Connection to a flue gas chimney B33 Length 250 mm with air aperture 22 Support rail 23 Support bend 87 DN80 24 Spacer 25 PP flue pipe DN80 26 Shaft cover with UV resistant terminal 28 Inspection tee 29 Air pipe Ø 125 mm 30 Air inlet pipe Ø 125 mm Install the hor...

Page 90: ...tical Connection to a concentric balanced flue inside a shaft examples DN80 125 C33x Connection to a flue inside a shaft C93x 1 Gas condensing boiler 2 Adaptor DN60 100 to DN80 125 4 Balanced flue DN80 125 500 mm 1000 mm 2000 mm 5 Spacer bracket 8 Separator slide coupling if required 10 Inspection bend 87 DN 80 125 11 Support bend 87 DN80 125 16 Pipe collar 22 Support rail 26 Shaft cover with UV r...

Page 91: ...l the eccentric balanced flue distributor 80 80 mm 31 for separate air supply flue gas routing downstream of the connection adaptor DN80 125 2 with a test connector When connecting a balanced flue certified acc to Building Regulations observe the permit of the relevant body Install the horizontal flue pipe with a slope of approx 3 6 cm m towards the boiler Route the horizontal air supply with a 3 ...

Page 92: ... observe the installation instructions on the cowl regarding roof pitches If an inspection aperture is required for the balanced flue insert a balanced flue with inspection aperture 3 200 mm length Insert roof outlet 7 into the roof from above and secure vertically with 6 to a rafter or brickwork Install the roof outlet only in its original condition Modifications are not permissible When installi...

Page 93: ...s of a heat exchanger Inhibitors may not be used If an additional heating circuit is operated in parallel to the underfloor heating system it must be hydraulically matched to the underfloor heating system Please note Fig Underfloor heating system example 32 Design information underfloor heating DHW circulation NTC Sensor resistances Flow temperature sensor cylinder temperature sensor DHW outlet te...

Page 94: ... years O O O 12 Assemble appliance 13 Clean fill and install trap and check for secure fit O O O 14 Level of soiling of heating water heat exchanger after cleaning mbar 15 Descale DHW heat exchanger if necessary O O O 16 Clean DHW strainer O O O 17 Check expansion vessel and safety valve O O O 18 Fill and vent the system 18 Open gas supply switch on appliance 19 Gas tightness test O O O 20 Flue ga...

Page 95: ...the fault number Determine the cause of the fault using the table below and remedy it Reset the fault via reset button 4 If the fault message cannot be acknowledged high temperatures at the heat exchanger might be preventing a reset Check that the system is functioning correctly Message history A message history displaying the last 8 fault messages can be called up in the menu level of the heating...

Page 96: ...rn sen sor 5 C Check sensors replace if necessary 04 No flame formation When the burner starts no flame forms by the end of safety time Monitoring electrode faulty Ignition electrode faulty ignition trans former faulty Gas supply Gas condensing boiler contaminated Gas supply Check the gas train gas valve open Ionisation electrode Check the position and condition of the electrode adjust or replace ...

Page 97: ...ess reset button 12 Boiler sensor faulty Boiler sensor or sensor lead has short circuit or pump break Pump Increase the minimum pump speed Excess flow temperature Increase the minimum pump speed Boiler sensor Check leads and plug in connections If OK and no function replace the boiler sensor Press reset button 13 Flue gas sensor faulty Flue gas sensor or sensor lead has short circuit or break Flue...

Page 98: ...p is running If not check cables and plugs If electrical connection OK and no function Replace pump 85 Valve feedback fault The valve feedback does not corre spond to the control unit commands 96 Reset Reset button pressed too many times Switch power supply OFF ON If the fault persists call out a contractor 99 System fault burner control unit Internal burner control unit fault PCB faulty Internal ...

Page 99: ...s GKV GND GND WWF GND RLF GND 5V DHK GND 5V DFL WW GND L1 ZHP N ZHP N Venti N N L WW L HZ L1 Venti L1 BK BL GNYE FGB Control X31 1 X33 1 17 BK GND GND 5V 5V out out BK RD RD VT VT 6 X23 1 3 X21 1 X22 1 2 4 X11 1 8 BN interne Gerätepumpe GN GN BN BN BN BL YE BL YE WH BK Durchflusssensor PWM PE BN BL BN BL GNYE AF GND SF GND E1 GND VLF GND Vent GND Vent Hall Vent PWM STB in STB 24 Abgas Gaskombivent...

Page 100: ...ed heat output Prated kW 24 31 Seasonal space heating energy efficiency ηs 93 93 Annual energy consumption for space heating QHE kWh 13634 17376 Sound power level indoors LWA dB 53 54 Any specific precautions that shall be taken when the space heater is assembled installed or maintained See installation instruction See installation instruction Wolf GmbH Postfach 1380 D 84048 Mainburg Tel 49 8751 7...

Page 101: ...ed kW 24 31 Annual energy consumption for space heating QHE kWh 13634 17376 Annual fuel consumption for water heating AFC GJ 17 17 Seasonal space heating energy efficiency ηs 93 93 Seasonal water heating energy efficiency ηwh 84 84 Sound power level indoors LWA dB 53 54 Any specific precautions that shall be taken when the space heater is assembled installed or maintained See installation instruct...

Page 102: ...ry electricity consumption in standby mode PSB kW 0 002 0 002 0 002 0 002 Seasonal space heating energy efficiency ns 93 93 93 93 Useful efficiency at rated heat output and high temperature regime n4 87 9 87 9 87 4 87 4 Useful efficiency at 30 of rated heat output and low temperature regime n1 98 1 98 1 98 1 98 1 Standby heat loss Pstby kW 0 052 0 052 0 060 0 060 Ignition burner power consump tion...

Page 103: ... 15502 1 A1 2015 DIN EN 60335 1 2012 AC 2014 EN 60335 1 2012 AC 2014 DIN EN 60335 2 102 2010 EN 60335 1 2006 A1 2010 DIN EN 62233 2009 EN 62233 2008 DIN EN 61000 3 2 2015 EN 61000 3 2 2014 DIN EN 61000 3 3 2014 EN 61000 3 3 2013 DIN EN 55014 1 2012 EN 55014 1 2006 A1 2009 A2 2011 In accordance with the following Directives 92 42 EEC Efficiency Directive 2016 426 EU Gas Appliances Directive 2014 30...

Page 104: ...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 Document no 3064458_201811 Subject to technical modifications ...

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