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Wolf CGB-35, CGB-50 Maintenance Instructions Manual

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Maintenance instructions
Gas red condensing boiler
CGB-35 Boiler
CGB-50 Boiler
Document no.: 3061491_0805 Subjecttotechnicalmodications.
GB
Wolf GmbH · PO Box 1380 · 84048 Mainburg · Tel. +49 8751/74-0 · Fax +49 8751/741600 · Internet: www.wolf-heiztechnik.de
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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
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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.
NB
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
4
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systemfrom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
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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.
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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.
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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.
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3061491_0805
Maintenance steps
•Cleanthecondensatepan.
•Cleantheheatexchangerwithabrush.
•Visualuepipeinspection.
•Removethemulti-purposebag.
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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.
NB
•Replacetheheatexchangergasketatthe
topandbottom.
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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
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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.
NB
•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
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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.
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3061491_0805
Maintenance steps
Carrying out a ventilation test
CheckLAFforsoundness,iftheCO
2
>
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
2
value,ifrequired.
(seeinstallationinstructions).
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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
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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
O
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
O
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:
16
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
O
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
O
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:
/