Wolf COB Installation Instructions And Technical Manual

Installation instructions and

technical guide

Oil condensing boiler

COB Boiler for heating

COB-TS Boilerwithstraticationcylinder

Document no.: 3062547_201507 Subject to modications

GB

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

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Index

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

1. Safety instructions ....................................................................................................3

2. COB/COB-TS installation/standard delivery .............................................................4

3. Specication ......................................................................................................... 5-7

4. Layout/description of components ............................................................................8

5. System examples .....................................................................................................9

6. Standards and regulations......................................................................................10

7. Installation instructions ...........................................................................................11

Installation ............................................................................................................ 12-21

8. General notes ........................................................................................ 12-13

9. Installation accessories ...............................................................................14

10. Boiler/TS cylinder ......................................................................................15

11. Installation examples .................................................................................16

12. Oil connection in a single-line system .......................................................17

13. Siphon/neutralisation/condensate pump ...................................................18

14. Installation of a balanced ue system .......................................................19

15. Filling the heating system ..........................................................................20

16. Electrical connection .................................................................................21

Control unit .......................................................................................................... 22-31

17. Control unit .......................................................................................... 22-23

18. Displaying/modifying control parameters/Settings report ..........................24

19. Contractor level parameters ................................................................ 25-31

Cascade operation ............................................................................................... 32-39

20. Control/specication/notes ........................................................................32

21. Flue system design ...................................................................................33

22. Flue gas header version ............................................................................34

23. Flue gas header version / notes .......................................................... 35-36

24. Flue gas damper installation .....................................................................37

25. Flue gas damper installation / wiring diagram ...........................................38

26. Flue gas damper tightness test .................................................................39

Commissioning ..................................................................................................... 40-44

27. Commissioning with Wolf control accessories (BM) ........................... 40-41

28. Commissioning without Wolf control accessories (BM) ..................... 42-43

29. Commissioning report ...............................................................................44

30. Maintenance and design data ............................................................. 45-46

31. Design information - balanced ue system ......................................... 47-55

32. Wiring diagram ..........................................................................................56

33. Reset .........................................................................................................57

34. Troubleshooting ................................................................................... 58-59

35. Product che according to Regulation (EU) no. 811/2013 .................. 60-63

36. Technical parameters according to EU regulation no. 813/2013 ...............64

37. Notes ................................................................................................... 65-66

37. EC Declaration of Conformity ....................................................................67

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1.Safetyinstructions

Thefollowingsymbolsareusedinconjunctionwith

these important instructions concerning personal

safety,aswellasoperationalreliability.

"Safety instructions" are instructions with

whichyoumustcomplyexactly,topreventrisks

andinjuriestoindividualsandmateriallosses.

Dangerthrough'live'electricalcomponents!

NB: Switch OFF the ON/OFF switch before

removingthecasing.

Nevertouchelectricalcomponentsorcontacts

whentheON/OFFswitchisintheONposition!

Thisresultsinariskofelectrocutionthatmay

leadtoinjuryordeath.

Theterminalsare'live'evenwhentheON/OFF

switch is in the OFF position.

This indicates technical instructions which

you must observe to prevent damage and

malfunctions.

NB

Diagram: Terminal box: Danger from electrical voltage

Diagram: Danger from electrical voltage and hot components

Maintenance

NB - only a heating contractor has the

necessaryknowledgeandexpertise!

- According to paragraph 10(3) EnEV the user is required to

have the system serviced regularly to ensure the reliable

and safe function of the oil condensing boiler.

- The boiler should be serviced annually.

- Maintenance is explicitly detailed in the installation and

maintenance instructions.

- Isolate the boiler from the power supply before any

maintenance work is carried out.

- After a service and before the oil condensing boiler is

restarted, check that all components that were removed for

maintenance have been retted correctly.

- We recommend you arrange a maintenance contract with

an approved heating contractor.

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2. COB/COB-TS installation/

standarddelivery

Oil condensing boiler

Connection adaptor for ue gas with test nipple

Siphon with hose

Stainless steel cleaning brush

Maintenance tool with setting gauge

Protective cap for maintenance

COB/TS installation instructions

COB/TS operating instructions

COB/TS maintenance instructions

Oil lter insert 40 μm

Oil condensing boiler

Stratication cylinder

Connection adaptor for ue gas with test nipple

Siphon with hose

Stainless steel cleaning brush

Maintenance tool with setting gauge

Protective cap for maintenance

COB/TS installation instructions

COB/TS operating instructions

COB/TS maintenance instructions

Oil lter insert 40 μm

COBstandarddelivery COB-TSstandarddelivery(notwithCOB-40)

The appliance is fully assembled with the casing tted, and the control unit is fully wired.

COB-15/20/29/40 oil condensing boiler

for heating with connection option for

DHW cylinder e.g. SE-2, SEM-1, BSP

COB-15/20/29 oil condensing boiler

with TS stratication cylinder,

on the right, oorstanding

COB-15/20/29 oil condensing boiler

with TS stratication cylinder,

on the left, oorstanding

COB-15/20/29 oil condensing boiler

with TS stratication cylinder,

at the back, oorstanding

COB-15/20/29: 1290

566

1210

COB-15/20/29: 1290

1132

605

COB-15/20/29: 1290

605

1132

COB-15/20/29: 1290

COB-40: 1490

566

605

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3.Specication

Balanced ue

connection

Opening the casing Closing the casing

Type plate

Return

Optional xing point

for oil lter

Flow

Recesses for

individual piping

of the heating

connections

Entries for oil

hoses (optional)

Condensate

drain level

1084

566

605

603

122

COB-15/20/29: 1290

COB-40: 1490

462

203

COB-40: 1209

COB-15/20: 919

194

516

260

426

COB-29: 930

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3.Specication

Oil condensing boiler COB-15 COB-15/TS COB-20 COB-20/TS

Rated output at 80/60 °C, stage 1/2 kW 9,0 / 14,4 9,0 / 14,4 13,1 / 19,0 13,1 / 19,0

Rated output at 50/30 °C, stage 1/2 kW 9,5 / 15,1 9,5 / 15,1 13,9 / 20,0 13,9 / 20,0

Rated load, stage 1/2 kW 9,2 / 14,7 9,2 / 14,7 13,5 / 19,6 13,5 / 19,6

Oil throughput, stage 1/2 kg/h 0,86 / 1,38 0,86 / 1,38 1,15 / 1,66 1,15 / 1,66

Rated capacity TS (equivalent) Ltr - 160 (200) - 160 (240)

Constant cylinder output TS kW/Ltr/h - 15 / 370 - 20 / 490

Performance factor TS NL60 - 3,5 - 4,5

DHW output TS l/10min - 250 - 280

Standby input TS kWh/24h - 1,47 - 1,47

Max, permissible cold water supply pressure TS bar - 10 - 10

Minimum anode current, protective magnesium anode mA - > 0,3 - > 0,3

External diameter, heating ow G 1½" 1½" 1½" 1½"

External diameter, heating return G 1½" 1½" 1½" 1½"

Condensate connection 1" 1" 1" 1"

Oil connection, ow/return hoses G 3/8" 3/8" 3/8" 3/8"

Cold water inlet G - 3/4" - 3/4"

DHW connection G - 3/4" - 3/4"

DHW circulation connection G - 3/4" - 3/4"

Height mm 1290 1290 1290 1290

Width mm 566 1132 566 1132

Depth mm 605 605 605 605

Boiler weight kg 92 92 92 92

Cylinder weight kg - 76 - 76

Balanced ue connection mm 80/125 80/125 80/125 80/125

Balanced ue routing type B23, B33, C33(x), C43(x), C53(x), C63(x), C83(x), C93(x)

Fuel oil Fuel oil EL, low sulphur, bio-oil B10 or fuel oil EL standard

Nozzle* Danfoss

0,30 / 80°S

Danfoss

0,40 / 80°S LE

Fuel oil lter Siku max, 40 μm

CO

2

setting stage 1 and stage 2 % 13,5 ± 0,3 13,5 ± 0,3 13,5 ± 0,3 13,5 ± 0,3

Pump pressure stage 1 bar 5,0 ± 1,0 5,0 ± 1,0 8,5 ± 1 8,5 ± 1

Pump pressure stage 2 bar 12,0 ± 2,5 12,0 ± 2,5 16,8 ± 2,5 16,8 ± 2,5

Maximum negative pressure in oil lines bar -0,3 -0,3 -0,3 -0,3

Flow temperature, factory setting °C 80 80 80 80

Max, ow temperature °C 85 85 85 85

Heating water pressure drop at Δ T=20 K mbar 3,6 3,6 6 6

Heating water pressure drop at Δ T=10 K mbar 12 12 21 21

Max, permissible boiler pressure bar 3 3 3 3

Heating surface, heating water heat exchanger m² 2,55 2,55 2,55 2,55

Heat exchanger water content Ltr, 7,5 7,5 7,5 7,5

Seasonal efciency [to DIN] at 40/30 °C (H

i

/ H

s

) % 105 / 99 105 / 99 105 / 99 105 / 99

Seasonal efciency [to DIN] at 75/60 °C (H

i

/ H

s

) % 100 / 95 100 / 95 101 / 96 101 / 96

Efciency at rated load at 80/60 °C (H

i

/ H

s

) % 97 / 92 97 / 92 97 / 92 97 / 92

Efciency at 30% partial load and TR=30 °C (H

i

/ H

s

) % 103 / 97 103 / 97 103 / 97 103 / 97

Boiler standby loss qB at 70 °C (EnEv) % 0,75 0,75 0,75 0,75

SEDBUK band A A A A

SAP 2009 annual efciency % 91.4 91.4 91.4 91.4

Rated heat input (stage 2):

Flue gas mass ow rate g/s 6,45 6,45 9,06 9,06

Flue gas temperature 50/30 - 80/60 °C °C 40 - 63 40 - 63 49 - 69 49 - 69

Available fan draught Pa 65 65 65 65

Lowest heat input (stage 1):

Flue gas mass ow rate g/s 4,04 4,04 6,28 6,28

Flue gas temperature 50/30 - 80/60 °C °C 35 - 55 35 - 55 40 - 61 40 - 61

Available fan draught Pa 32 32 45 45

Electrical connection V~/Hz 230/50 230/50 230/50 230/50

Integral fuse (medium slow) A 5 A 5 A 5 A 5 A

Power consumption, stage 1 / stage 2 W 86/128 86/128 99/139 99/139

Protection IP20 IP20 IP20 IP20

Condensate volume at 40/30 °C Ltr,/h 1,2 1,2 1,6 1,6

Condensate pH value approx, 3 approx, 3 approx, 3 approx, 3

CE ID CE-0085BS0326

* These nozzles comply with the emission requirements according to RAL-UZ 46 and ensure reliable operation. No other nozzles are permissible!

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* These nozzles comply with the emission requirements according to RAL-UZ 46 and ensure reliable operation. No other nozzles are permissible!

Oil condensing boiler COB-29 COB-29/TS COB-40

Rated output at 80/60 °C, stage 1/2 kW 18,5 / 28,2 18,5 / 28,2 25,3 / 38,0

Rated output at 50/30 °C, stage 1/2 kW 19,6 / 29,6 19,6 / 29,6 26,8 / 40,0

Rated load, stage 1/2 kW 19,0 / 29,0 19,0 / 29,0 26,0 / 38,8

Oil throughput, stage 1/2 kg/h 1,60 / 2,45 1,60 / 2,45 2,44 / 3,64

Rated capacity TS (equivalent) Ltr - 160 (260) -

Constant cylinder output TS kW/Ltr/h - 29 / 710 -

Performance factor TS NL60 - 5,0 -

DHW output TS l/10min - 300 -

Standby input TS kWh/24h - 1,47 -

Max. permissible cold water supply pressure TS bar - 10 -

Minimum anode current, protective magnesium anode mA - > 0,3 -

External diameter, heating ow G 1½" 1½" 1½"

External diameter, heating return G 1½" 1½" 1½"

Condensate connection 1" 1" 1"

Oil connection, ow/return hoses G 3/8" 3/8" 3/8"

Cold water inlet G - 3/4" -

DHW connection G - 3/4" -

DHW circulation connection G - 3/4" -

Height mm 1290 1290 1490

Width mm 566 1132 566

Depth mm 605 605 605

Boiler weight kg 99 99 122

Cylinder weight kg - 76 -

Balanced ue connection mm 80/125 80/125 110/160

Balanced ue routing Type B23, B33, C33(x), C43(x), C53(x), C63(x), C83(x), C93(x)

Fuel oil Fuel oil EL, low sulphur, bio-oil B10 or fuel oil EL standard

Nozzle* Danfoss 0,55 / 80° S LE

Fuel oil lter Siku max, 40 μm

CO

2

setting stage 1 and stage 2 % 13,5 ± 0,3 13,5 ± 0,3 13,5 ± 0,3

Pump pressure stage 1 bar 8,5 ± 1 8,5 ± 1 11,0 ± 1,0

Pump pressure stage 2 bar 16,8 ± 2,5 16,8 ± 2,5 23,5 ± 2,5

Maximum negative pressure in oil lines bar -0,3 -0,3 -0,3

Flow temperature, factory setting °C 80 80 80

Max. ow temperature °C 85 85 85

Heating water pressure drop at Δ T=20 K mbar 17 17 54

Heating water pressure drop at Δ T=10 K mbar 55 55 205

Max. permissible boiler pressure bar 3 3 3

Heating surface, heating water heat exchanger m² 3,05 3,05 3,85

Heat exchanger water content Ltr. 9,0 9,0 11,5

Seasonal efciency [to DIN] at 40/30 °C (H

i

/ H

s

) % 105 / 99 105 / 99 104 / 98

Seasonal efciency [to DIN] at 75/60 °C (H

i

/ H

s

) % 101 / 96 101 / 96 98 / 93

Efciency at rated load at 80/60 °C (H

i

/ H

s

) % 97 / 92 97 / 92 98 / 93

Efciency at 30% partial load and TR=30 °C (H

i

/ H

s

) % 103 / 97 103 / 97 103 / 97

Boiler standby loss qB at 70 °C (EnEV) % 0,55 0,55 0,45

SEDBUK

band A A A

SAP 2009 annual efciency

% 91.4 91.4 91.4

Rated heat input (stage 2):

Flue gas mass ow rate g/s 13,33 13,33 17,51

Flue gas temperature 50/30 - 80/60 °C °C 55 - 76 55 - 76 56 - 83

Available fan draught Pa 105 105 150

Lowest heat input (stage 1):

Flue gas mass ow rate g/s 9,05 9,05 10,91

Flue gas temperature 50/30 - 80/60 °C °C 40 - 64 40 - 64 43 - 68

Available fan draught Pa 55 55 72

Electrical connection V~/Hz 230/50 230/50 230/50

Integral fuse (medium slow) A 5 A 5 A 5 A

Power consumption, stage 1 / stage 2 W 129 / 178 129 / 178 126 / 205

Protection IP20 IP20 IP20

Condensate volume at 40/30 °C Ltr./h 2,2 2,2 2,8

Condensate pH value approx, 3 approx, 3 approx, 3

CE ID CE-0085BS0326

3.Specication

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7

8

9

10

11

2

3

6

5

4

1

COB-TS oil condensing boiler with stratication cylinder

Cold water

DHW

DHW circulation

Oil condensing boiler Straticationcylinder

1 Cylinder heating from above with deector and divider

2 DHW draw-off at the highest point

3 Cold water supply with control and

distribution appliance

4 Cold water draw-off for cylinder heating

5 DHW circulation line

6 Protective magnesium anode

7 Sensor well for cylinder temperature sensor

8 Drain (in standard delivery)

9 Siphon

10 Neutralising system (accessory)

11 Condensate pump (accessory)

TSstraticationcylindercannotbeinstalledwithCOB-40

NB

4.Layoutofcomponents

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5. Description of components

Automatic air vent

Regulated

stratication pump

Blast tube

connection

Plate-type heat exchanger

Oil pump motor

Immersion pipe,

cylinder sensor

Two-stage oil pump

Stratication sensor

Boiler

sensor

Cylinder primary pump

High limit safety cut-out

Heating return 1"

Ignition

transformer

Flue gas temperature

limiter

Expansion vessel 8 l

(accessory)

Water pressure switch

Heating ow 1"

Drain valve

DHW circulation

(accessory)

Drain

Protective anode

(under cover)

Flame monitor

Fan

Cold water connection

¾" (optional accessory)

COB component description

TS component description

Hot water connection ¾"

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To save energy and protect against scaling

if the total hardness is greater than 15 °dH

(2.5mol/m³),theDHWtemperaturemaybeset

to a maximum of 50 °C.

If the total hardness is greater than 20 °dH

(3.58mol/m³), we recommend using a water

treatmentfacilityinthecoldwatersupplyline

forDHWheating,toprolongthemaintenance

interval(descalingDHWheatexchanger).

COB / COB-TS oil condensing boiler

Two-stage oil condensing boiler with electronic ignition and

electronic ue gas monitoring, for low temperature heating

and DHW heating in heating systems with ow temperatures

of up to 85 °C and a permissible operating pressure of 3 bar.

The COB complies with the following regulations:

EC Directives:

- 92/42/EEC Efciency Directive

- 2004/108/EC EMC Directive

- 2006/95/EC Low Voltage Directive

DIN / EN Standards:

EN 230, EN 303, EN 304, EN 15034, EN 15035, EN 12828,

EN 61000-3-2, EN 61000-3-3, EN 61000-4-3, EN 55014-1,

EN 60335-1, EN 60335-2-102, EN 60529

Stratication cylinder type TS made of steel S235JR with

connections to the on-site pipework.

Corrosion protection through enamel coating on the inside

of the cylinder as per DIN 4753 and additional corrosion

protection through a protective magnesium anode.

Openueoilcondensingboilersmustonlybe

installed in a room which complies with the

appropriateventilationrequirements.Otherwise

there is a risk of asphyxiation or poisoning.

Read these installation and maintenance

instructions before installing the boiler. Also

take the technical guide into consideration.

Note: The DHW temperature should be limited to a

maximum of 55 °C if the hardness of the hot

water is more than 2.86 mmol/l. A reduced DHW

temperature prevents excessive scaling. This

cutsthelevelofmaintenanceandenergyinput.

6. Standards and regulations

Obtainthepermissionofyourlocaluegasinspectorand

thelowerwaterauthoritypriortotheinstallationofWolf

oil condensing boilers.

Wolf oil condensing boilers must only be installed by a

recognised heating contractor. This heating contractor

will also be responsible for the proper installation and the

commissioning of the heating system. The DVGW Code of

Practice G676, boiler room guidelines or Building Regulations

relating to the construction and installation of central boiler

rooms and fuel storage facilities apply.

Thefollowingregulations,rulesandguidelinesmustbe

observedduringinstallation:

- Energy Savings Act (EnEG) and related directives

- EnEV Energy Savings Order

- Technical regulations for oil installations IWO-TRÖL 2006

in the currently applicable version

Note: Pleasereadtheseinstructionscarefullybefore

the installation and keep them in a safe place.

Please also note the technical information in

the appendix.

Any damage or loss resulting from technical

modicationstothecontrolunitortothecontrol

componentsareexcludedfromourliability.

- DIN 1988 Technical rules for DHW installations

- DIN EN 12831 Procedure for calculating the standard

heating load

- EN 12828 Heating systems in buildings

Designing DHW heating systems

- DIN 4701 Rules for calculating the heat demand of

buildings

-

DIN 4751 Part 3

Safety equipment for heating systems with ow

temperatures of up to 95 °C

- DIN 18160 Flue gas systems

- DIN EN 1717 Protection of DHW against contamination in

DHW installations

- ATV-A-251 Materials for drain pipes for condensate from

condensing boilers

- VDI 2035 Avoiding damage in DHW heating systems

Scaling in general water and DHW heating

systems

Local regulations from building and

industry regulatory agencies (mainly covered

by the local ue gas inspector)

- DIN VDE 0100

Regulations regarding the installation of

high-voltage systems with rated voltages up

to 1000 V

- VDE 0105 Operation of high-voltage systems, general

considerations

- DIN EN 60529 Protection through casings

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7. Installation instructions

Transport

Boiler/straticationcylinder

- The boiler and the stratication cylinder are transported, fully packaged, on a pallet

- A sack truck is a suitable means of transportation

- Position the sack truck behind the boiler or stratication cylinder, secure with a strap

and transport to the installation location

The COB and TS are installed adjacent to the wall, which means that a clearance of

70 cm only needs to be observed at the front. When installing the boiler, you should

observe the recommended wall clearances in order to simplify assembly, maintenance

and servicing.

Recommended minimum

wall clearance

Installation information

- Install the boiler or boiler plus DHW cylinder on a level

surface which is substantial enough to carry its weight.

- Level the boiler and stratication cylinder horizontally using

adjustable feet.

Adjustable feet

- Remove strap and packaging

- Remove the four xing screws on the pallet

- Lift the boiler and/or stratication cylinder off the pallet

COB with

TS behind

- The boiler must only be installed in a room that is protected from frost.

Drain the boiler, stratication cylinder and heating system if there is a risk

of frost when the system has been shut down.

- Boilers should not be installed in a room that is subject to aggressive vapours

or in very dusty or highly humid conditions (workshops, washrooms, hobby

rooms, etc.).

- The combustion air must be free from halogenated hydrocarbons.

- A surface temperature of 40 °C is not exceeded in the case of COB if

operated as intended. The respective national re regulations are to be

observed in the case of installation in oil storage rooms.

NB

COB with

TS right

or left

COB-40

minimum

room height

COB

70 cm 70 cm

70 cm

190 cm

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8. Installation - general notes

Note:

Provide a ll and drain valve at the lowest point in the

system.

Safetyequipment

The COB has not been tted with an expansion vessel at

the factory. This must be tted externally (available from the

Wolf accessories range). The expansion vessel must be in

accordance with DIN 4807.

Thereshouldnotbeashut-offvalvebetweenthe

expansionvesselandtheoilcondensingboiler,

because otherwise the pressure build-up would

permanentlydamagetheboilerduringheating.

Thereisariskofsystemcomponentsrupturing,

givingrisetoariskofscalding.

Exceptions are cap valves upstream of the expansion vessel.

The safety assembly from the Wolf accessories range includes

an integral 3 bar safety valve. Route the blow-off line into a

drain outlet.

The minimum system pressure is 1.0 bar.

The oil condensing boiler is permitted exclusively for sealed

systems of up to 3 bar. The maximum ow temperature is

factory-set to 80 °C and may be adjusted to 90 °C if required.

Generally, the maximum ow temperature is 80 °C for DHW

operation.

There is no need for a minimum throughput at flow

temperatures below 80 °C.

We recommend a heating water pH value of between

pH 6.5 and pH 8.5.

Wolf does not assume liability for any damage to the heat

exchanger caused by oxygen diffusion in the heating water. In

the event of oxygen penetrating the system, we recommend

a system separation through the interconnection of a heat

exchanger.

If the limit curve is exceeded, an appropriate portion of the

system water must be treated.

Example:

Total hardness of the domestic hot water: 19°dH

System volume: 1 m³

This means at least 0.3 m³ = 300 l must be desalinated.

Permissible methods:

- Desalination using mixed-bed cartridges. These are

multi-stage ion exchangers. We recommend, for

example, using the "Megall Alu" cartridges from

Taconova for the rst ll, and later as and when required.

- Topping up with distilled water.

Total hardness in °dH

System volume in m

3

Water treatment

necessary

Water treatment not

necessary

0.3 m

3

Inhibitors (substances to prevent corrosion

and limescale deposits) and antifreeze are

not permitted. There is a risk of damage to

the boiler resulting from poor heat transfer or

corrosion.

Heating water

The return line to the appliance should have a dirt trap.

Deposits in the heat exchanger may lead to boiling noise, a

drop in performance or faults in the appliance.

Domestic hot water may be used as ll water and top-up water.

The addition of chemicals or de-scaling using single-

stage ion

exchangers is not permissible.

In the case of high-volume systems or those where large top-

up water volumes (e.g. due to water losses) are required, the

following values must be observed.

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Wehighlyrecommendthatyouuselowsulphurfueloil

toprotecttheenvironment.

Information on the use of bio-oil blends:

1. Permissible bio-oil percentages

The COB (from date of manufacture May 2010) can be

operated with fuel oil with up to 10 % alternative constituents

–B10- to DIN V 51603-6.

2.Bio-oilquality

The bio-oil must comply with EN 14213 when the customer

tank is lled.

3. Oil storage tanks

The customer must obtain written conrmation from the

manufacturer or supplier regarding the suitability of the tank

for the use of bio-oils, giving the maximum permitted FAME

percentage. It must be ensured that the tank ttings, gaskets,

lters and oil pipes are also suitable for bio oil.

4. Cleaning the tank

FAME acts as a solvent, removing all deposits and residues in

the tank and the oil lines. Wolf therefore always recommends

cleaning the tank before lling it with bio-oil.

5. Storing bio-oils

Bio-oil is a natural product with a lower shelf life than fuel

oil EL. Bio-oil must therefore be stored 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, but the mineral oil industry is currently

searching for suitable additives to increase the shelf life.

Information from VDI 2035

The method of commissioning in particular can affect scaling.

Heat the system with burner stage 1 with an even and adequate

throughput.

Before commissioning, all hydraulic pipes must undergo a

tightness test:

Test pressure on heating water side max. 4 bar

Prior to testing, close the shut-off valves in the heating circuit for

the appliance, because otherwise, the safety valve (accessory)

opens at 3 bar. The appliance has already been tested at the

factory for tightness at 4.5 bar.

If the appliance is not watertight, there is a risk of leaks and

resulting material losses.

Themaximumowratemustnotexceed6000l/h(100l/min).

8. Installation - general notes

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9. Installation - accessories

We recommend making the connection to the heating system with the following parts from the Wolf accessories range.

COBconnectionsetadjacenttothewallcomprising:

2 cross pieces, each with one connection

2 clips

1 corrugated stainless steel pipe 1", length 1 300 mm

1 corrugated stainless steel pipe 1", length 800 mm

1 silicon grease tube

COBconnectionsetwithTSadjacenttothewallcomprising:

2 cross pieces, each with two connections

4 clips

3 corrugated stainless steel pipe 1", length 1 300 mm

1 corrugated stainless steel pipe 1", length 800 mm

2 corrugated stainless steel pipes ¾", length 800 mm

1 silicon grease tube

1 trimming set ¾"

COBconnectionset adjacent to thewallfor a freestanding

cylinderuptoSEM-1-750andSE-2-750comprising:

2 cross pieces, each with two connections

3 corrugated stainless steel pipe 1", length 1 300 mm

1 corrugated stainless steel pipe 1", length 800 mm

4 clips

1 silicon grease tube 6 at packings 1"

1 pipe bend 2 at packings 1½" EPDM

1 pump 1 adaptor tting G1½" (fem.)

2

double nipples G 1" (male) - G 1"

on G1" (male)

1 elbow with air vent

TSaccessorysetforcoldwatercomprising:

1 expansion vessel 8 l

1 cold water connection pipe to the expansion vessel

2 double nipples ¾"

1 trimming set ¾"

Pipeassemblycomprising:

1 circulation pump

2 thermometers in ow and return

2 ball valves in ow and return

- Incl. / excl. mixer

- With manifold for 2 or 3 pipe assemblies

For further accessories, such as a safety assembly 1" or wall mounting bracket for pipe assembly, etc., see

"Heatingsystems"pricelist

TSDHWcirculationpumpaccessorysetcomprising:

1 analogue DHW circulation pump

1 corrugated stainless steel pipe ¾"

1 trimming set ¾"

Neutralisationbox,incl.plinthcomprising:

1 granulate ll

1 installation accessories set

(for standard fuel oil EL (sulphur content > 50 ppm),

neutralisation of the condensate is required).

Condensate lifting system with a zero-volt alarm output

comprising:

1 condensate lifting pump with a zero volt alarm output

1 condensate tank with cover and wall mounting bracket

1 PVC hose, 10 mm (6 m long)

1 non-return valve

1 condensate inlet adaptor

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10.Installation-boiler/TScylinder

Example: COB-15/20/29 oil condensing boiler with TS stratication cylinder on the right,

oorstanding (when looking at front of boiler). The pipework for the heating

ow and heating return, as well as the heating water ow and heating water

return, are connected to the stratication cylinder with corrugated stainless

steel pipes (accessories) (see chapter 9 "Installation - accessories").

Diagram: Cold water connection to DIN 1988

Non-return valve

(individually tested)

Drain

Shut-off

valve

Pressure reducing

valve

Shut-off valve

Cold water inlet

Pressure gauge port

DHW lter

Safety valve

(individually tested)

Drain

Above top edge of the cylinder

Boiler ow

Boiler return

Note: When selecting the installation material for the system, it is important to

observe the technical rules and any possible electrochemical processes

(mixed installation).

Cold water connection We recommend the installation of a maintenance valve into the cold water supply line. A

tested and certied pressure reducer must be installed if the cold water supply pressure

is above the maximum permissible operating pressure of 10 bar.

Provide a centralised pressure reducer if mixer taps are used.

Observe the regulations of DIN 1988 as well as those of your local water supply utility

when connecting cold water and DHW. Your warranty rights may be lost if the installation

does not comply with the illustration shown.

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11. Installation examples

Pipeassemblyfortwoheatingcircuits

withmanifoldforsafetyassembly

installation

Pipeassemblyforoneheatingcircuit

forsafetyassemblyinstallation

Safety assembly for fixing to the

corrugated stainless steel pipes of

heatingowandreturn

The safety assembly and the required pipe

assembly can be installed on the left, on

the right or at the back of the boiler on a

wall or attached to the side of the boiler

casing.

Note: The pipe assembly for three heating

circuits should always be wall mounted.

Pipeassemblyforthreeheating

circuitswithmanifoldforsafety

assemblyinstallation

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12.Oilconnectioninasinglelinesystem

Assumptions:

Kinematic viscosity 6 mm²/s at 20 °C, oil temperature = 10 °C

Additional pressure drops: 4 elbows 90°, 1 non-return valve, 1 shut-off valve

In view of possible outgassing of the oil, an inlet height of more than 4 m should be

avoided.

Singlelinesystem

Secure the oil lter with the holder in the positions provided on the outside of the

boiler casing. It can also be secured on the inside of the boiler. In this case, the oil

hose can be up to 90 cm outside the casing when fed in from the top (to the back).

Oillter

Oil lines that are too large may lead to operating faults caused by trapped air.

The oil line must therefore have the smallest possible diameter.

Only materials that are suitable for oil lines should be used. In the case of copper pipes,

only metallic compression tting olives with support sleeves are permissible. They are

a reliable means of preventing air intake.

The oil lines must be installed while the system is isolated from the electrical

supply in order to avoid leaks.

With negative pressure controlled anti-lift valves, the negative pressure on the inlet side is

increased considerably. It is often difcult to adhere to the maximum permissible negative

pressure of 0.3 bar in the oil line. We therefore recommend using electromagnetically

controlled anti-lift valves.

The electrical anti-lift devices can be connected to the COB in two ways:

1. The anti-lift valve is connected at output A1. For this, output A1 must be programmed

to 9 (oil shut-off valve), see HG14.

2. If output A1 is already being used (e.g. for a DHW circulation pump), an adaptor

plug can be used. The plug (mat. no. 1718768761) is inserted between the motor of

the oil pump.

When connecting a feed pump in the supply line, the negative pressure must not exceed

0.5 bar.

Maximum line lengths

insinglelinesystems

Single line system with pump higher than tank

Oil pump,

burner

Floating air

extraction

Single line system with pump lower than tank

Floating air

extraction

Oil pump,

burner

Anti-lift valve

Notes:

Only use lter inserts made of sintered plastic with 25 - 40 μm.

The temperature must not fall below +5 °C. External tanks must have

supplementary heating facilities.

Contaminants can lead to system damage. The oil line must be ushed

prior to commissioning.

The system must be connected as a single line system. A lter/air vent valve

combination from the Wolf product range must be installed. Older two-line

systemsmustbeconvertedtosinglelinesystems.

Two-line systems lead to accelerated oil ageing and the penetration of air into

the oil. They are no longer in line with the latest technology.

In order to prevent damage to the oil pump, the fuel oil must be supplied to the

lter using a suitable manual pump.

Output

Throughput

Internal

line Ø

Inlet height H (m)

kg/h mm 4 3 2 1 0 -1 -2 -3

COB-15

COB-20

COB-29

to 2.5

4 77 68 58 49 40 31 22 13

6 100 100 100 100 100 100 87 64

COB-40 2.5 to 5.0

4 39 34 29 25 20 16 11 6

6 100 100 100 100 100 79 56 32

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3062547_201507

13.

Siphon/neutralisation/condensate pump

Condensate drain without neutralisation

If low sulphur fuel oil EL (sulphur content < 50 mg/kg) is used,

it may be possible to forego neutralisation of the condensate

after consultation with the lower water authority.

The condensate may be discharged into drainage pipes only in

accordance with ATV DVGW worksheet A251. Nevertheless,

neutralisation is required if a sufcient quantity of domestic

wastewater (at least 20 times the volume of the expected

amount of condensate) is not added to the condensate.

Connect the siphon supplied to the connectors on the

combustion chamber pan.

Remove the sealing plug on the siphon plug

before installing the siphon.

With a exible siphon drain hose, form a connection to the on-site

drain (condensate drain level from siphon 260 mm).

When using a condensate pump, route the exible siphon drain

hose into the condensate pump and form a connection from

there to the on-site drain.

Note: The siphon must be filled with water prior to

commissioning.

If the appliance is operated with an empty siphon,

there is a danger of poisoning caused by escaping

ue gases. For this reason, the siphon must be lled

with water prior to commissioning. Undo, remove

and ll the siphon until water runs out of the side

drain. Ret the siphon and make sure the gasket is

perfectly seated.

If condensate is directly routed to the on-site drain, ventilation

must be provided so that the drain pipe cannot affect the boiler.

NB

Condensate drain with neutralisation

For standard fuel oil EL(sulphur content > 50ppm),

neutralisationofthecondensateisrequired.

Note:Thesiphonandtheneutralisationboxmustbelled

with water prior to commissioning.

Observe the neutralisation box installation

instructions.

NB

SiphonDrain hose, siphon

SiphonCondensate pump

19

3062547_201507

14.Installationofabalanceduesystem

Diagram: Example of a C93x balanced ue system

Installationofthebalanceduesystem

Foruesandconcentricbalanceduesystems,

useonlyoriginalWolfcomponents.

Please observe the technical information

regarding balanced flue systems prior

to installing the flue or the balanced flue

connection.

As regulations in the individual Federal States

[Germany] differ, we recommend consulting the

relevant authorities and local ue gas inspector

prior to installation.

NB

Between the ue terminal and the roof surface, there must be

a distance of at least 0.4 m.

Flue connections are created using couplings and gaskets.

Always arrange couplings against the condensate flow

direction.

The balanced flue should be installed with

a slope of at least 3° (6cm/m) to the oil

condensing boiler. Spacer brackets should be

ttedtosecuretheequipmentinposition.

In the worst case scenario, a smaller slope

forthebalanceduemayleadtocorrosionor

operating faults.

Generally bevel or deburr trimmed ues to ensure

a gas tight installation of pipe joints. Ensure that

gaskets are properly tted. Remove all contamination

prior to installation - never t faulty parts.

NB

The local ue gas inspector must have clear

accesstotheuegastestnipples.

NB

InthecaseofCOB-15/20/29theenclosedue

gas measuring nipple must be mounted on the

air/uegasconnectingpieceoftheboiler.

 Alternatively, the ue gas measuring nipple

canbemounted immediatelybehindthatina

horizontal position directly on the 87° elbow

ttedtotheboiler.Whendoingthis,however,

caremustbetakenthattheair/uegasductis

installedabovetheapplianceinsuchawaythat

itispossibletoremovethedisplacer(minimum

distanceaboveCOB-15/20/29is30cm;inthe

caseoftheCOB-40thisis40cm).

NB

C93x

Bei COB-15/-20/-29 muss der beiliegende

Abgas-Messstutzen auf dem Luft-/

Abgasstutzen des Kessels montiert werden.

Alternativ darf derAbgas-Messstutzen

auch unmittelbar nach dem dann direkt

auf dem Kessel aufgesteckten 87°-Bogen

waagrecht montiert werden. Hierbei ist aber

zu beachten, dass die Luft-/Abgasführung

soüberdemGerätzuverlegenist,dassein

Ausbau der Verdrängergewährleistet ist

(Mindestabstand über COB-15/-20/-29 ist

30cm;beiCOB-40istdieser40cm).

Achtung

20

3062547_201507

The displacement device may have slipped during

transport.

To ensure perfect combustion, check the

displacement device is correctly positioned before

commissioning the appliance.

- Unplug the central connector.

- Loosen the three 6 mm Allen screws on the burner ange

(do not unscrew them completely).

- Rotate the burner unit approx. 1 cm to the right

(clockwise).

- Lift the burner unit upwards out of the combustion

chamber lid and hang in place in the maintenance

position, as shown in the gure.

- Undo the wing screws on the combustion chamber lid.

- Lift off the combustion chamber lid and place to one side.

- Measure the distance between the upper edge of the top

displacement device and the upper end of the ridged prole,

then compare with the table below.

Displacement

device distance to

ridged prole (mm)

COB-15 COB-20 COB-29 COB-40

98-103 98-103 123-128 123-125

- Assembly is carried out in reverse order.

Fill the system and vent it properly to ensure

perfect boiler function.

Beforeconnectingtheboiler,ushtheheating

systemtoremoveresiduessuchaswelding

pearls,hemp,putty,etc.fromthepipework.

- Open the cap on the vent in the boiler by one revolution.

- Open all radiator valves.

- Fill the system via the return line at 2 bar (1.5 to 2.5 bar).

- With the entire heating system and boiler in a cold

condition, ll slowly via the inspection/ll & drain valve at

the return until 2 bar pressure is indicated.

- Check the entire system for water leaks.

- Start the boiler, set the heating water temperature to

position "2" (pump running, illuminated signal ring as

status indicator constantly green).

- Vent the pump; for this, briey open and then retighten the

air vent screw.

- Vent the heating circuit completely, switching the boiler

ON for 5 seconds and OFF for 5 seconds at the ON/OFF

switch, ve times in succession.

- When the system pressure drops below 1.5 bar, top up the

water.

NB

Air vent valve

Fillingtheheatingsystem

15.Fillingtheheatingsystem

Diagram: Venting the COB

Checkingthepositionofthedisplacementdevice

Diagram: View of COB displacement device

Displacement device

distance

Unplug the

central connector

Burner in the

maintenance position

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