Wolf CGB-35 Maintenance Instructions Manual

Brand: Wolf

Model: CGB-35

Type: Maintenance Instructions Manual

This manual is also suitable for

CGB-50

Maintenance instructions

Gas red condensing boiler

CGB-35 Boiler

CGB-50 Boiler

Document no.: 3061491_0805 Subjecttotechnicalmodications.

Wolf GmbH · PO Box 1380 · 84048 Mainburg · Tel. +49 8751/74-0 · Fax +49 8751/741600 · Internet: www.wolf-heiztechnik.de

3061491_0805

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

Safetyinstructions ...................................................................................................3

Maintenancesteps ............................................................................................ 4-13

Listofrequiredcomponents ..................................................................................14

Overviewofthestepstobetakenandthemaintenancereport ...................... 15-16

Index

With innovative maintenance technology

Maintenance position 2

Maintenance position 1

3061491_0805

The following symbols are used in this

document to highlight special information

and warnings. These important instructions

relate to personal safety and general ope-

rational safety of the equipment.

"Safety Instructions" must be strictly

followed to prevent the risk of endan-

gering or injuring persons or causing

material damage to the equipment.

Danger from 'live' electrical compon-

ents.

NB: Switch off the main ON/OFF switch

before removing any panels.

Never reach into electrical compon-

ents or touch any electrical contacts

when the main ON/OFF switch is tur-

ned on! Otherwise you risk a harmful

or potentially fatal electric shock.

A voltage will still be present at the

mains terminals when the main ON/

OFF switch is turned off.

"NB" indicates technical instructions

which you must observe to prevent

material losses and boiler malfunc-

tions.

Safety instructions

General notes

Maintenanceworkmustonlybecarried

outbyaqualiedheatingcontractor.

 Regular maintenance and the exclusi-

veuseoforiginalWolfsparepartsare

necessarypreconditionsfortrouble-free

operationandalongservicelife.

 Wethereforerecommendyouarrangea

maintenancecontractwithalocalheating

contractor.

Fig.:Gascombinationvalve

Dangerfromelectriccurrent

Escapinggasmaycausepoisoningortheriskofexplosion

Fig.:Ignitiontransformer,highvoltageignitionelectrode,heat

exchanger.Riskfrom'live'electricalcomponents,riskofburning

fromhotcomponents

Fig.:Gasconnection:Escapinggasmaycausepoisoningor

theriskofexplosion

Fig.:Terminalbox:Dangerfromelectriccurrent

3061491_0805

Maintenance steps

Closethegastap.

The mains terminals are 'live' even

when the ON/OFF switch has been

switchedOFF.

•Disconnectthesystemfromthepowersupply.

•Pivotthecontrolunitliddown.

 SwitchOFFthecondensingboileratthe

ON/OFFswitch.

•Unlockthecasinglidwiththel.h.andr.h.

rotatingbolts.Releasethebottomofthe

casinglidandunhookatthetop.

L.h.rotatingbolt

R.h.rotatingbolt

3061491_0805

Maintenance steps

•Releasetheelectricalcable(6x).

•Pivot the heat exchanger into the mainte-

nanceposition1.

Danger of burning

Severalcomponentsmaybehot.Letthesecool

downforapprox.halfanhourorweargloves.

•Crackopenthegassupplyconnection

 andremovethegasket.

•Releasetheheatexchangerlockingspring.

3061491_0805

Maintenance steps

•Pullthemulti-purposebagovertheheatex-

changer.

•Visualburnerunitinspection.

 Replacethemonitoringelectrode.

 Checkandreplacetheignitionelectrode,if

necessary.

Monitoring

electrode

Ignitionelectrode

•Removetheburnerunitupwards.

•Opentheretainingtab.

3061491_0805

Maintenance steps

•Removethedisplacersegmentsoneafter

theother.

Clamp

Lowerdisplacer

section

Sealring

Upperdisplacer

section

•Removetheclamp.

•Hook the multi-purpose bag into the heat

exchanger.

•Releasetheretainerandpivottheheat

exchangerintothemaintenanceposition2.

3061491_0805

Maintenance steps

•Cleanthecondensatepan.

•Cleantheheatexchangerwithabrush.

•Visualuepipeinspection.

•Removethemulti-purposebag.

3061491_0805

Maintenance steps

•Lubricatetheheatexchangergasketsatthe

topandbottomwithsiliconegrease.

•Lubricatetheheatexchangerseat.

Never stretch gaskets.

•Replacetheheatexchangergasketatthe

topandbottom.

3061491_0805

Maintenance steps

•Insertthedisplacerclamp.

•Replacethesealringandthelowerdis-

placersection.

•Tiptheheatexchanger(forward)toreturnit

tomaintenanceposition2.

 Inserttheupperdisplacersectionasfarasit

willgointotheburner.

•Pivot the heat exchanger into the mainte-

nanceposition1,inserttheburnerunitand

threadintherearretainingspring.

 Positionthefrontretainingspringwithakey

intoitsposition.

Assembly

3061491_0805

Maintenance steps

•Pivottheheatexchangerbackintothemain-

tenance position 1 and plug in the cables

(6x).

•Clicktheheatexchangerlockingspringback

intoplace.

•Releasetheretainerandpivottheheatex-

changerfullybackintotheboiler.

Check the lower heat exchanger

gasket.

•Installthegasrestrictorandgasket.

CGB-35

Gas type Colour Diameter

H yellow 660

P red 510

CGB-50

Gas type Colour Diameter

H lightgrey 850

P lilac 620

3061491_0805

Maintenance steps

Checking the siphon

Ifrequired,cleanandre-ll.

Checkfortightt,

 preventuegasfromescaping.

•Checkthebalanceduesystem.

•Ifyounoticealossofwater,checktheex-

pansionvesselinletpressureandincrease

it,ifrequired,to0.75bar.Theheatingcircuit

mustbeatzeropressure.

 Thenllthesystem.

3061491_0805

Maintenance steps

Carrying out a ventilation test

CheckLAFforsoundness,iftheCO

0.2%.

"Fluegas“

testport

"Airsupply"

testport

Check gas train for soundness and

waterconnectionsforleaks.

• Fitthecasing.

Completion

Test run

•ResettheMCBs.

•Openthegastap.

•SwitchtheboilerON.

•Set the program selector to emissions test

mode.

Emissionstestmodeposition

Carrying out a ue gas test

Inemissionstestmode,enterthecaptured

valuesinthemaintenancereport.

Re-adjusttheCO

value,ifrequired.

(seeinstallationinstructions).

3061491_0805

List of required components

Checking control accessories

Fig.:DWT

Fig.:AWT

•ThedisplaymustshowBUSconnection .

BUSconnection

Maintenance requires the following:

1 MaintenancesetCGB-35/50 Partno.8611173

1 Cleaningset-supplementaryset Partno.2482875

1 Cleaningbrush Partno.2440053

1 TestequipmentforBImSchtest[Germany]

We recommend you have the following as part of your service kit:

1 Gasketset,uepipeDN80 Partno.8611184

1 Siliconegrease 10gtube partno.8602264

or400gtube partno.3500103

1 Burnergasket Partno.8611177

1 Returntemperaturesensor partno.8603036

1 Flowtemperaturesensor partno.8603038

1 Fluegastemperaturelimiter partno.8603058

1 Ignitionelectrode partno.8603061

1 Safetyvalvewithclip Partno.2070315

1 Gasketsettiltedbushow/return Partno.8611186

1 Protectiveanodeforenamelledcylinder

3061491_0805

Overview of the steps to be taken and the

maintenance report

No. Step Report item

1 SwitchOFFtheboiler,switchOFFtheemergencystopswitch

2 Closethegassupplyvalve,

3 Removethecasingandthecombustionchamberhousing

4 Undothegastting

5 Pulltheelectricalcablesoffthefan,sensorsandelectrodes

6 Removetheheatexchangerlid

7 Visualinspectionoftheburnerunit O

8 Checktheignitionelectrodesandreplaceifrequired O

9 Cleantheheatingwaterheatexchanger O

10 Cleanthecondensatepan O

11 Checkandreplacegaskets,ifrequiredandlubricatethereplace-

mentswithsiliconegrease

12 Rellgranulate,ifaneutralisingsystemisinstalled O

13 Checktheprotectiveanodeevery2yearsonenamelledcylinders

andreplace,ifnecessary

14 Assembletheboiler

15 Cleanandllthesiphon,installandcheckfortightt O

16 Checktheexpansionvesselincaseofwaterloss O

17 Openthegassupplyvalveandstarttheboiler

18 Gassoundnesstest O

19 Fluegassystemsoundnesstest O

20 Checktheignition O

21 Checktheinteractionwithcontrolaccessories O

22 Fluegastestinemissionstestmode O

23 Grossuegastemperature °C

24 Airsupplytemperature °C

25 Netuegastemperature °C

26 Carbondioxidecontent(CO2) %

27 oroxygencontent(O2) %

28 Carbonmonoxidecontent(CO) %

29 Fluegasloss %

Conrmmaintenance(companystamp,signature)

Date:

3061491_0805

Overview of the steps to be taken and the

maintenance report

No. Step Report item

1 SwitchOFFtheboiler,switchOFFtheemergencystopswitch

2 Closethegassupplyvalve,

3 Removethecasingandthecombustionchamberhousing

4 Undothegastting

5 Pulltheelectricalcablesoffthefan,sensorsandelectrodes

6 Removetheheatexchangerlid

7 Visualinspectionoftheburnerunit O

8 Checktheignitionelectrodesandreplaceifrequired O

9 Cleantheheatingwaterheatexchanger O

10 Cleanthecondensatepan O

11 Checkandreplacegaskets,ifrequiredandlubricatethereplace-

mentswithsiliconegrease

12 Rellgranulate,ifaneutralisingsystemisinstalled O

13 Checktheprotectiveanodeevery2yearsonenamelledcylinders

andreplace,ifnecessary

14 Assembletheboiler

15 Cleanandllthesiphon,installandcheckfortightt O

16 Checktheexpansionvesselincaseofwaterloss O

17 Openthegassupplyvalveandstarttheboiler

18 Gassoundnesstest O

19 Fluegassystemsoundnesstest O

20 Checktheignition O

21 Checktheinteractionwithcontrolaccessories O

22 Fluegastestinemissionstestmode O

23 Grossuegastemperature °C

24 Airsupplytemperature °C

25 Netuegastemperature °C

26 Carbondioxidecontent(CO2) %

27 oroxygencontent(O2) %

28 Carbonmonoxidecontent(CO) %

29 Fluegasloss %

Conrmmaintenance(companystamp,signature)

Date:

Wolf CGB-35 Maintenance Instructions Manual

Brand: Wolf

Model: CGB-35

Type: Maintenance Instructions Manual

This manual is also suitable for

CGB-50

Download PDF

report

Wolf CGB-35 Maintenance Instructions Manual

This manual is also suitable for

Wolf CGB-35 Maintenance Instructions Manual

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