Wolf CGB-100 Installation And Operating Instructions Manual

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

Doc. no.: 3062555_201804 Subjecttomodications

GB

Installationandoperatinginstructions

Wall mounted gas condensing boiler

CGB wall mounted gas condensing boiler

CGB-75

CGB-100

2 3062555_201804

Tableofcontents

1. Documentation information ................................................................3

2. Safety information ..............................................................................4

3. Standards and regulations .................................................................7

4. Control / Function / Operation ........................................................10

5. Delivered condition / standard delivery ............................................12

6. Layout ..............................................................................................13

7. Siting instructions ............................................................................14

8. Installation .......................................................................................15

9. Dimensions/installation dimensions .................................................16

Installation

10. Installation .......................................................................................17

11. Installation of the air/flue gas routing ...............................................21

Control

12. Electrical connection ........................................................................22

Commissioning

13. Filling the system .............................................................................28

14. Conversion to natural gas E/LL (G20/G25) (if necessary) ...............29

15. Conversion to LPG P (G31) (if necessary) ......................................30

16. Conversion to other gas types (if required) .....................................31

17. Checking the gas supply pressure ..................................................32

18. Commissioning / setting the BUS address ......................................33

19. Displaying / modifying control parameters .......................................34

20. Adjusting the modulating pump (accessory) ....................................35

21. Limiting the maximum output ...........................................................36

22. Testing the combustion parameters .................................................37

23. CO

2

adjustments .............................................................................38

24. Commissioning report ......................................................................40

Specication

25. Maintenance and design data .........................................................41

26. Technical information for water treatment ........................................43

27. System log .......................................................................................45

28. Technical information .......................................................................46

29. Wiring diagram ................................................................................56

30. Specification ....................................................................................57

31. Troubleshooting ............................................................................... 58

32. Product datasheet to EU regulation No. 811/2013 ..........................60

33. Technical parameters to EU Regulation No. 813/2013 ....................61

34. Notes ...............................................................................................62

EU declaration of conformity ...................................................................63

33062555_201804

1. Documentationinformation

1.1 Otherapplicabledocuments

- Technical information

- Maintenance instructions

- System and operator’s log

The instructions for all accessory modules and other accessories also apply where

relevant.

1.2 Safekeepingofthesedocuments

The system user or operator should ensure the safekeeping of all instruction manuals

and documents.

► Handovertheseinstallationinstructionsaswellasallotherapplicablemanuals

to the system user or operator.

1.3 Instructingthesystemuser

- Instruct the system user to take out an inspection and maintenance contract with

an approved contractor.

- Inform the system use that the annual inspection and maintenance may only be

performed by an approved contractor.

- Inform the system use that repair work may only be performed by an approved

contractor.

- Inform the system user that only original spare parts may be used.

- Inform the system user that no technical changes may be made to the boiler or

control unit.

- Inform the system user that they are responsible for the safety, environmental com-

patibility 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.

- Instruct the system user how to operate the heating system.

1.4 Applicabilityoftheseinstructions

These installation instructions apply to CGB-75/100 gas condensing boilers.

1.5 Acceptance

Within four weeks of commissioning of the burner the operator must notify the local

flue gas inspector accordingly. According to the Bundes-KÜO (German Federal

Sweeping and Inspection Act), tests and inspections are only required every 3 years

[Germany].

1.6 Recyclinganddisposal

- Old equipment may only be disconnected from the gas and electricity supply by a

qualiedcontractor.

- Always dispose of materials according to environmental, recycling and waste man-

agement standards.

- Old appliances, wearing parts, defective components and environmentally hazard-

ous liquids and oils must be disposed of or recycled according to applicable waste

disposal regulations without harming the environment.

Theymustnotbedisposedofashouseholdwaste.

- Disposeofpackagingmadeofcardboard,recyclableplasticsandsyntheticller

materials in an environmentally compatible manner through appropriate recycling

systems or a recycling centre.

- Please observe the applicable national and local regulations.

4 3062555_201804

2. Safetyinformation

Danger:ifyousmellgas

- Close the gas valve.

- Open the windows.

- Do not operate any electrical switches.

- Extinguish naked flames.

- From an external location, telephone the gas sup-

ply utility company and an approved contractor.

Danger:ifyousmelluegas

- Switch OFF the appliance.

- Open windows and doors.

- Notify an approved contractor.

Authorised personnel should read these instructions

beforeanyinstallation,commissioningorservicework.

Complywiththespecicationsinthisdocument.Failureto

observetheseinstallationinstructionsvoidsanywarranty

claimagainstWOLF.

Insomecountries,therelevantgassupplycompany

mustbenotiedoftheinstallationofagasboilerand

mustgivetheirapproval.

Pleasenotethatregionalpermitsmayberequiredfor

theuegassystemandconnectingthecondensate

draintothepublicsewer.

Beforestartinginstallationwork,thelocaluegasin-

spectorandwastewaterauthoritymustbeinformed.

Thegascondensingboilermustonlybeinstalled,commis-

sionedandservicedbyqualiedandtrainedpersonnel.

InaccordancewithVDE0105Part1,workonelectrical

components(e.g.controlunit)mayonlybecarried out

byqualiedelectricians.

VDE/ÖVE regulations [Germany/Austria] and those of

yourlocalpowersupplyutilitycompanyareapplicable

toelectricalinstallationwork.

Onlyoperatethegascondensingboilerwithintheoutput

range, which is stated in the technical documentation

suppliedby WOLF. Intendeduse of the boilerincludes

exclusiveuseforhotwaterheatingsystemsinaccordance

with DIN EN 12828.

Neverremove,bypassorotherwisedisableanysafetyor

monitoringequipment.Onlyoperatetheapplianceifitis

inperfecttechnicalcondition.

Anyfaultsordamagewhichimpactormightimpactsafety

mustberemediedimmediatelybyaqualiedcontractor.

Onlyreplacefaultycomponentsandequipmentwithorig-

inalWOLFspareparts.

Dangerfrom"live"electricalcomponents

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

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

Thereisadangerofelectrocution,resultingin

arisktohealthordeath.Themainterminalsare

'live',evenwhentheON/OFFswitchisintheOFF

position.

Riskofscalding

Boilersmaycontainhotwater.

Hotwatercancauseseverescalding.

Beforeworkingonpartswhichareincontact

withwater,allowtheappliancetocooltobelow

40°C,shutoffallvalvesand,ifnecessary,drain

theappliance.

Riskofburns

Boilercomponentsmaybeextremelyhot.

Hotcomponentscancauseburns.

Beforeworkingontheopenedupappliance,al-

lowittocoolbelow40°Corwearsuitablegloves.

Symbols

The following warning symbols are used in these instruc-

tions.

These relate to personal safety and operational reliability.

Instructions that must be followed precisely in order

to prevent risk and injury to persons.

Instructions that must be followed precisely in order

to prevent risk and injury to persons from live electri-

cal components.

Indicates technical instructions that must be

observed to prevent damage to the boiler and

malfunctions.

Note

53062555_201804

2. Safetyinformation

Risksfrompressurisedwater

Boilersaresubjecttohighwaterpressure.

Waterpressurecancausesevereinjuries.

Beforeworkingonpartswhichareincontact

withwater,allowtheappliancetocooltobelow

40°C,shutoffallvalvesand,ifnecessary,drain

theappliance.

Note:

Sensorscanbeincontactwithwaterandthere-

foreexposedtopressure.

Workingonthesystem

- Close the gas shut-off valve and secure it against uninten-

tional reopening.

- Isolate the system from the power supply (e.g. by remov-

ing a 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).

We recommend arranging a suitable maintenance con-

tract.

- The operator is responsible for the safety, environmental

compatibility and energy quality of the heating system

(German Immission Control Act/Energy Saving Ordi-

nance) [Germany].

- Use only genuine WOLF spare parts.

6 3062555_201804

2. Safetyinformation

Fig.: Terminal box: Danger from electrical voltage

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

exchanger

Danger from electrical voltage

Risk of burning through hot components

Fig.: Gas combination valve

Danger from electrical voltage

Escaping gas may cause poisoning or an explosion

Fig.: Gas connection

Escaping gas may cause poisoning or an explosion

73062555_201804

3. Standardsandregulations

Observeallstandardsandguidelinesapplicabletotheinstallationandopera-

tionofthisheatingsysteminyourcountry.

Observetheinformationontheboilertypeplate.

Thefollowinglocalregulationsmustbecompliedwithduringinstallationand

operationoftheheatingsystem:

• Siting conditions

• Ventilation and extract air facilities and connection to a chimney

• Electrical connection to the power supply

• Technical regulations of the gas supply utility company regarding the connection of

the gas appliance to the local gas mains

• Regulations and standards regarding the safety equipment of the water heating

system

• DHWinstallation

Thefollowinggeneralregulations,rulesandguidelinesmustbeobservedfor

installationinparticular:

• EN 806 Drinking water supply systems

• (DIN) EN 1717 Protection against pollution of potable water in water installations

• EN12831Heatingsystemsinbuildings–Methodforcalculationofthedesignheat

load

• (DIN)EN12828Heatingsystemsinbuildings-Designofwater-basedheating

systems

• (DIN)EN13384Chimneys–Thermalanduiddynamiccalculationmethods

• (DIN) EN 50156-1 (VDE 0116 Part 1) Electrical equipment in combustion systems

• VDE 0470/EN 60529 Degrees of protection provided by enclosures (IP rating)

• VDI 2035 Prevention of damage in hot water heating systems

- Scale formation (Sheet 1)

- Corrosion by water (Sheet 2)

 -Corrosionbyuegases(Sheet3)

8 3062555_201804

3. Standardsandregulations

Weacceptnoliabilityforlossescausedbytechnicalmodicationsmade

tothecontrolunitorthecontrolsystemcomponents.

Improperusemaycausearisktolifeandlimbordamagetotheappli-

anceorotherproperty.

Requirements

The installation of the boiler must be in accordance with the relevant requirements

of Gas Safety (Installation and Use) Regulations 1998, Health and Safety

Document No. 635 (The Electricity at Work Regulations 1989), BS 7671 (IEE

Wiring Regulations) and the Water Supply (Water Fitting) Regulations 1999, or The

Water Bylaws 2000 (Scotland). It should also be in accordance with the relevant

requirements of the Local Authority, Building Regulations, including amendments to

the Approved Documents Part L and J 2002, The Building Regulations (Scotland),

The Building Regulations (Northern Ireland) and the relevant recommendations of

the following British Standards:

BS5440: Fluesandventilationofgasredboilersnotexceeding70kWnet:

- Part 1: Flues

- Part 2: Ventilation

BS5449: Specicationforforcedcirculationhotwaterfordomesticpremises.

BS5546: Specicationforforcedcirculationhotwaterfordomesticpremises.

BS 6700: Services supplying water for domestic use within buildings and their

curtilages.

BS6798: Specicationforinstallationofgasredboilersnotexceeding60kW

input.

BS6891: Specicationforinstallationoflowpressuregaspipeworkupto28mm

(R1") in domestic premises (2

nd

family gas).

BS 7593: Treatment of water in domestic hot water central heating systems.

Institute of Gas Engineers Publication IGE/UP/7/1998:

"Guide for gas installations in timber framed housing"

Important: The appliance must be installed and serviced by a competent person

as stated in the Gas Safety (Installation and Use) Regulations 1998. In IE, the

installation must be in accordance with the current edition of I.S,813 "Domestic

Gas Installations", the current Building Regulations and reference should be made

to the current ECI rules for electrical installation.

When tightening or loosening threaded connections always use suitable open-ended

spanners (not pipe wrench, or extensions, etc.). Incorrect use and/or unsuitable

tools can lead to damage (e.g. gas or water leaks)!

93062555_201804

3. Standardsandregulations

GascondensingboilerCGB-...

Gas condensing boiler to DIN EN 437 / DIN EN 13203-1 /

DIN EN 15502-1 / DIN EN 15502-2-1 / DIN EN 60335-1 /

DIN EN 60335-2-102 / DIN EN 62233 / DIN EN 61000-3-2 /

DIN EN 61000-3-3 / DIN EN 55014-1, as well as 92/42/

EWG (Efciency Directive) / 2016/426/EU (GasApplianc-

es Directive) / 2014/30/EU (EMC Directive) / 2014/35/

EU (Low Voltage Directive) / 2009/125/EG (ErP Directive) /

2011/65/EU (RoHS-Richtlinie) /Regulation (EU) 811/2013 /

Regulation (EU) 813/2013, with electronic ignition and elec-

tronicue gastemperature monitoring,for lowtemperature

heatingandDHWheatinginheatingsystemswithowtemper-

atures up to 90°C and 3 bar permissible operating pressure in

accordance with DIN EN 12828. This WOLF gas condensing

boiler is also approved for installation in garages.

Open ue gas 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theinstallationandmaintenanceinstruc-

tionsbeforeinstallingtheboiler.Alsotakeinto

considerationalltechnicalinformation.

WhenoperatingtheboilerwithLPG useonly

propaneaccording to DIN 51 622,otherwise

faults may arise when starting and operating

thegascondensingboiler,whichmayleadto

damagetotheapplianceandpersonalinjury.

 ApoorlyventedLPGtankcanleadtoproblems

withignition.Insuchacase,contactthecom-

panythatllstheLPGtank.

Theadjustablecylinderwatertemperaturecan

exceed60°C.Forshorttermoperation above

60°Ctheboilermustbemonitoredinorderto

prevent scalding. For continuous operation,

appropriate precautions should be taken to

preventdraw-offtemperaturesabove60°C,e.g.

thermostaticvalves.

Fig.: Wolf gas condensing boiler

Toprotectagainstscaling,theDHWtemperatureshould

besettomax.50°Cifthetotalwaterhardnessis15°dH

(2.5 mol/m³) or above. Without an accessoryregulator,

thiscorrespondstoamaximumhotwaterrotaryselector

settingof6.Withatotalhardnessof20°dHorhigher,use

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

whenheatingDHWisnecessaryinordertoextendthe

maintenanceintervals.

Failuretotakesuchprecautionswillresultinpremature

scalingoftheapplianceandareductionintheconvenient

availabilityofdomestichotwater.Thecontractorrespon-

sibleshouldalwayscheckthelocalconditions.

10 3062555_201804

4. Control/Function/Operation

DHWtemperatureselection.

WhengascondensingboilersarecombinedwithaDHWcylinder,setting1-9corre-

spondstoacylindertemperatureof15-65°C.TheDHWtemperatureselectorsetting

becomes ineffective when the system is combined with a digital room thermostat or a

weather-compensated controller. The temperature will then be selected at the controller

(accessory).

Heatingwatertemperatureselection.

Settings 2 - 8 correspond, when factory-set, to a heating water temperature of 20-80 °C.

The heating water thermostat setting becomes ineffective when the system is combined

with a digital room thermostat or a weather-compensated controller.

ON/OFF switch

The condensing boiler is OFF in position 0.

Reset

A fault is reset by pressing the reset button which will also restart the system. Press-

ing the reset button re-activates the system, if there was no fault.

ON/OFF switch

ON/OFF

DHWtempera-

ture selector

Reset

button

Heatingwater

temperature

selector

Illuminated ring

Thermometer

Illuminatedringforstatusdisplay

Display Meaning

Flashing green Standby (power supply on; no heat demand)

Constant green light Heatdemand:pumprunning;burnerOFF

Flashing yellow Emissions test mode

Constant yellow light Burneron;amesteady

Flashing red Fault

113062555_201804

4. Control/Function/Operation

Note:

The number of times the condensing boiler can be started in heating mode is limited

electronically. This limit can be bypassed by pressing the reset button. Then, the boiler

starts immediately, as soon as there is a heating demand.

In summer mode, the circulation pump operates for approx. 30 seconds after a maxi-

mum idle period of 24 hours.

Anti-seizingpumpprotection

Setting

Wintermode (positions 2 to 8)

In winter mode, the boiler heats to the temperature selected at the heating water temper-

ature controller. According to the pump operating mode, the circulation pump operates

constantly (factory setting) or only in parallel with the burner activation / run-on period.

Summermode

Winter mode is disabled by rotating the heating water temperature selector into posi-

tion . In other words, the boiler will then operate in summer mode. Summer mode

(heatingOFF)meansonlyDHWheating.Frostprotectionfortheheatingsystemand

pump anti-seizing protection, however, remain enabled.

Emissionstestmode

The emissions test mode is activated by rotating the heating water temperature selector

into position

.Theilluminatedsignalringashesyellow.Aftertheemissionstestmode

has been activated, the boiler will heat with the selected maximum heating output. Any

previous cycle block will be cancelled. The emissions test mode terminates after 15

minutesorwhenthemaximumowtemperaturehasbeenexceeded.Toreactivate,turn

the heating water temperature selector anti-clockwise and then back into position

.

12 3062555_201804

5. Deliveredcondition/

standarddelivery

Deliveredcondition

Gascondensingboiler

The standard delivery includes:

 1 Gascondensingboilerreadytoconnectwiththecasingtted

1 Mounting bracket for mounting on the wall, with installation

accessories

1 Installation instructions

1 Operating instructions

1 Maintenance instructions

1 Trap with hose

1 Maintenance tools

Accessories

The following accessories are required for installation of the

gas condensing centre:

- Balancedueaccessories(seetechnicalinformation)

- Room temperature-dependent or weather-compensated

control

- Condensate drain outlet with hose retainer

- Gasballvalvewithreprotection

- Fittingassemblyforheatingow,heatingreturnandintegral

safety assembly

- Pump assembly with variable speed pump and integral safety

assembly

- Low loss header set for one or two appliances in a cascade

- Dirtlterintheheatingreturn

Boilerconnections

Fig.: Connections with heating circuit connection set (accessory)

Heatingow

G 1½"

Gas connection

R ¾"

Heatingreturn

G 1½"

Condensate

drain

Heatingcircuitpumpassembly(accessory)

Fig.: Pump assembly (accessory)

Heatingow

G 2"

Heatingreturn

G 2"

Trap

Gas tap

Connection

Expansion vessel 1"

Drain&llvalve

Pressure gauge

Safety valve

Modulating

pump

133062555_201804

CGB-75 / CGB-100

6. Layout

Quick-action air vent valve

Gas fan

Heatingwaterheat

exchangers

Condensate trap

Gas combination valve

Heatingreturn

Gas supply pipe

Flue gas temperature limiter

Combustion chamber casing

Return sensor

Combustion chamber

cover temperature limiter

Flue

Heatingow

Burner

Flow sensor

Temperature limiter

Flow

Intake pipe

Flue gas test point

Ventilation air test point

Gas:air mixing chamber

Flash trap

Displacement device

Water pressure switch

Gas restrictor

Monitoring electrode

Ignition electrode

Non-return valve

14 3062555_201804

First determine where the appliance is to be installed.

For this, take into account the ue gas connection, lateral

clearances towards walls and the ceiling, and any existing

connectionsforgas,heating,DHWandelectrics.

7. Sitinginstructions

Sound insulation: Under certain critical installation conditions

(e.g. installation on a drywall), additional measures may be

necessary to soundproof the boiler. In such conditions, use

anti-vibration rawl plugs and, if necessary, rubber mounts or

insulation strips.

When using a

low loss header set

Min. 830 mm

Min.

350 mm

Min.

350 mm

Electrical connection must be made on site.

Please maintain the 350 mm clearance to the ceiling to enable

inspection and maintenance work on the boiler to be carried

out, otherwise the necessary inspection and function tests

on components cannot be ensured during maintenance. The

drain hoses must be secured with the retainer above the drain

outlet (trap). The drain must be able to be easily inspected.

Theboilermaybeinstalledonlyinrooms

thatareprotectedfromfrost.

The temperature in the installation room must be be-

tween 0°C and 40°C.

Generalinformation

Clearancebetweentheboilerandcombustible

materials or components is not required, as

temperatureswillnotexceed85°Cattherated

boiler heating output. However, explosive or

readilyammablematerialsmustnotbeused

intheinstallationroomasthiswouldcreatea

riskofreorexplosion.

Duringboilerinstallation,ensurethatnocon-

taminants (e.g. drilling swarf) enter the gas

boiler,otherwisefaultsmaydevelop.

Note

Theinstallationroomandthecombustionair

supplied to the appliance must be free from

chemicals, e.g. uorine, chlorine or sulphur.

These substances are contained in sprays,

paints, adhesives, solvents and cleaning

agents.Underunfavourableconditions,these

mayleadtocorrosion,includingintheuegas

system.

153062555_201804

8. Installation

Initially, determine the location for the installation of the gas

condensing boiler.

For this, take into account the ue gas connection, lateral

clearances towards walls and the ceiling, and any existing

connectionsforgas,heating,DHWandelectrics.

Openingthecasingcover

We recommend you remove the casing cover during the

installation.

Release the casing cover with the l.h. and r.h. screw. Release

the bottom of the casing cover and unhook at the top.

Securingtheappliancewiththesuspensionbracket

Duringinstallationofthegascondensingboiler,

ensurethatallxingsarestrongenoughtocarry

itsweight.Alsotakeintoaccountthecondition

ofthewall,asanescapeofgasorwatermight

resultinariskofexplosionandooding.

Screws

Fig.: Undoing screws

Fig.: Drill holes for suspension bracket

Min. 446 mm

Ceiling

- Mark the holes to be drilled for the mounting bracket, taking

into consideration the minimum clearances.

-Inserttherawlplugsandtthemountingbracketwiththe

coach bolts and washers supplied.

- Hookthegascondensingboilerwiththemountingstaysinto

the mounting bracket.

Mounting stay

Fig.: Mounting brace on the condensing boiler

Aftercompletingservicing,closethefrontcasing

againandfastenthescrewstightly.Thereisa

riskofcarbonmonoxidepoisoningiftheue

systemisfaulty.

16 3062555_201804

9. Dimensions/installationdimensions

1 Heatingow

2 Heatingreturn

3 Condensate drain

4 Gas connection

min. 2200

830

138

Overpressure cascade DN 160 with low loss

header set

Ø 160/110

132,5

23

125 112,5 105 90

565

12,5

108 108350

104

236

925

96

1 4

173062555_201804

10.Installation

Heatingcircuitconnectionset

We recommend you connect the heating system with the aid

of a heating circuit connection set.

Connection set comprising: Connection to the appliance with

atgasket,connectiontoheatingow/returnwithballvalves

1" female thread.

Note:

Provideadrain&llvalveatthelowestpointinthesystem.

Fig.:Heatingcircuitconnectionset(accessory)

Fig.: Pump assembly (accessory)

TheCGB-75andCGB-100havenotbeenttedwithanex-

pansionvesselat the factory.Thismust bettedexternally

(available from the Wolf accessories range). The expansion

vesselmustbesizedsufciently,inaccordancewithDIN4807.

Theremustbenoshut-offvalve between the

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

otherwisethepressurebuild-upwouldperma-

nentlydamagetheboilerduringheating.There

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

risetoariskofscalding.

Thisdoesnotincludebutteryvalvesupstreamoftheexpan-

sionvessel.The pumpor tting assemblyincludes a 3bar

safety valve (6 bar safety valve is available as an accessory).

Route the discharge pipe line into a drain funnel. The mini-

mum system pressure is 1.0 bar. The boilers are approved

exclusively for sealed systems of up to 6 bar. The maximum

owtemperatureisfactory-setto80°Candmaybeadjusted

to 90°C if required.

Safetyequipment

18 3062555_201804

10.Installation

Note:

Provideadrain&llvalveatthelowestpointinthesystem.

InformationfromVDI2035

The way in which commissioning in particular is carried out

canhaveastronginuenceonscaling.Heatthesystematthe

lowest output with an even and adequate throughput. For mul-

ti-boiler systems it is recommended to commission all boilers

simultaneously to prevent the overall amount of lime concen-

trating on the heat exchanger surface of an individual boiler.

The minimum system pressure is 1.0 bar.

The gas condensing boiler is approved exclusively for sealed

systems of up to 6 bar. The maximum ow temperature is

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

Generally,theowtemperatureis80°CforDHWoperation.

Safetyequipment

Generalrequirements

Thereisariskofdamagetotheboilerresulting

fromwaterleaks,poorheattransferorcorro-

sion.

- Before connecting the gas condensing boiler, ush the

heating system to remove residues such as welding pearls,

hemp, putty, sludge sediments, etc. from the pipework

- Install a strainer/dirt trap in the return line and service the

strainer/dirt trap at regular intervals, see WOLF accessories

(500μm=0.5mm)

- The automatic air vent valve for the appliance must be

opened during operation

- Themax.owrateof100l/min(6000l/h)mustnotbeex-

ceeded

- Drinking water or desalinated domestic drinking water should

beusedasllwaterandtop-upwaterThehardnessofthe

systemwatermustbelessthan2dH.Thellandtop-up

waterqualitiesforthespecicsystemcanbefoundinthe

chapter “Technical information for water treatment”.

- If an ingress of oxygen cannot be ruled out, a system sep-

aration is advisable

- TheheatingwaterpHvaluemustbebetween8.2and8.5

- Ingeneral,llandtop-upwatermustbedesalinated;soften-

ing by means of a single stage de-ioniser is not permissible.

For this, the permissible methods and limits should be

obtained from the chapter “Technical information for water

treatment”(NOTEthelimitvaluesarespecictothesystem).

- Inhibitors and antifreeze are not permissible.

- A system log must be kept (see Technical information for

water treatment)

Aftercorrectllingofthesystem,thesystemmustbeheatedup

tothemaximumlevelandthenthetotalhardnessandpHvalue

must be measured again and adjusted as necessary. These

values must be checked and adjusted again after 6-8 weeks.

Heatingwater

Themaximumowratemustnotexceed

6000l/h(100l/min).

carryoutaleaktestonthepiping:

Testpressureonheatingwatersidemax.8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6bar.

Iftheapplianceisnotwatertight,thereisarisk

ofleaksandresultingmateriallosses.

Additionalrequirementsforoperationwithoutalowloss

header

- Systems with only one CGB-75/100

- Sludge separator in the boiler return of the CGB-75/100

- Desalinationoftheheatingwaterto2-3°dH

- Control of cylinder charging only via the MM module (con-

gurations1and10)

- Cylinder charging pump at least DN 25 with at least 6 m

head

- Themax.owtemperaturemustbeadjustedwithparameter

HG08to75°C

Thetechnicalinformationforwatertreatment

mustbeobserved,otherwisesystemdamage

duetowaterleaksmayoccur.

The manufacturer does not assume liability for any damage

to the heat exchanger caused by oxygen diffusion in the heat-

ing water. In the event of oxygen penetrating the system, we

recommend a system separation through the interconnection

of a heat exchanger.

For a specic system volume of >50 l/kW, adjust the total

hardnessto2-3°dHusingadesalinationprocess.

193062555_201804

10.Installation

Condensatedrainconnection

Connect the trap supplied to the connector on the combustion

chamber pan.

Note: Fill the trap with water prior to commissioning.

If condensate is directly routed to the drain pipe, ensure ventila-

tion, so that the drain pipe cannot affect the condensing boiler.

Fig.: Trap

Trap

Thetrapmustbelledwithwaterpriorto

commissioning.Operatingtheappliancewith

anemptytrappresentsariskofpoisoningor

asphyxiationduetotheescapeofuegases.

Undothetrap,removeandlluntilwaterruns

outofthedrainholeontheside.Retthetrap

andensurethegasketsealstightly.

The condensate must only be routed through pipes that are

resistant.

Observe the relevant instructions if you install a neutralising

system (accessory).

Fig.: Neutralising system (accessory)

Condensatepump

When using a condensate pump, the alarm output can be con-

nectedatconnectionE1.SettheboilerparameterHG13to"2".

The alarm output switches the appliance OFF if condensate

cannot be pumped out correctly.

20 3062555_201804

10.Installation

Gasconnection

Fig.: Straight-through gas ball valve (accessory)

Onlyalicensedgasttermayroutethegaspipe

andmakethegasconnections.Closethegas

ballvalveonthecondensingboilertopressure

testthegaspipe.

Removeallresiduesfromtheheatingpipework

andthegaspipepriortoconnectingthecon-

densingboiler,particularlyinoldersystems.

Priortocommissioning,testallgaspipesand

connectionsforleaksaccordingtoTRGI.Only

foaming leak detection sprays which are ap-

provedbytheDVGWshouldbeused.

Inappropriate installation or using unsuitable

components 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 Wolf

condensingboiler.Otherwiseexplosionsmay

occurifthereisare.Sizethegassupplypipe

in accordance with DVGW-TRGIregulations

[Germany].

Gasttingsontheappliancemayonlybepres-

sure-testedtoamaximumof150mbar.Higher

pressuremaydamagethegastrain,resultingin

ariskofexplosion,asphyxiationorpoisoning.

Closethegasballvalveonthegascondensing

centretopressuretestthegaspipe.

Mountthegasballvalveinaneasilyaccessible

place.

- Prior to installation, ensure that the boiler corresponds to the

local gas type. The factory settings for the particular type of

gas can be obtained from the following table.

Table: Factory setting according to gas type

1)

Not applicable for Austria/Switzerland

2)

Does not apply to Switzerland

NaturalgasE/H:

Ws=11.4-15.2kWh/m

3

=40.9-54.7MJ/m

3

NaturalgasLL:

1)

Ws= 9.5-12.1kWh/m

3

=34.1-43.6MJ/m

3

LPG P:

2)

Ws=20.2-21.3kWh/m

3

=72.9-76.8MJ/m

3

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Wolf CGB-100, CGB-75 Installation And Operating Instructions Manual

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