oil condensing boiler - centrogulf

Installation instructions and technical guideOil condensing boilerCOB Boiler for heatingCOB-CS Boilerwithstratificationcylinder

Document no.: 3062547_0311 Subject to modifications 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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IndexIndex ..................................................................................................................Page

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

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

3. Specification .........................................................................................................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/CS 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 flue 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/specification/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 flue system .........................................47-55

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

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

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

EC Declaration of Conformity ....................................................................................60

33062547_0311

1.SafetyinstructionsThefollowingsymbolsareusedinconjunctionwiththese important instructions concerning personal safety,aswellasoperationalreliability.

"Safety instructions" are instructionswith which you must comply exactly, toprevent risks and injuries to individuals andmaterial 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! Thisresultsinariskofelectrocutionthatmayleadtoinjuryordeath.

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 andmalfunctions.

NB

Diagram: Terminal box: Danger from electrical voltage

Diagram: Danger from electrical voltage and hot components

MaintenanceNB - only a heating contractor has thenecessaryknowledgeandexpertise!

- 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 refitted correctly.

- We recommend you arrange a maintenance contract with an approved heating contractor.

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2. COB/COB-CS installation/ standarddelivery

Oil condensing boilerConnection adaptor for flue gas with test nippleSiphon with hoseStainless steel cleaning brushMaintenance tool with setting gaugeProtective cap for maintenanceCOB/CS installation instructions COB/CS operating instructions COB/CS maintenance instructionsOil filter insert 40 μm

Oil condensing boilerStratification cylinderConnection adaptor for flue gas with test nippleSiphon with hoseStainless steel cleaning brushMaintenance tool with setting gaugeProtective cap for maintenanceCOB/CS installation instructionsCOB/CS operating instructions COB/CS maintenance instructionsOil filter insert 40 μm

COBstandarddelivery COB-CSstandarddelivery(notwithCOB-40)

The appliance is fully assembled with the casing fitted, 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 CS stratification cylinder, on the right, floorstanding

COB-15/20/29 oil condensing boiler with CS stratification cylinder, on the left, floorstanding

COB-15/20/29 oil condensing boiler with CS stratification cylinder, at the back, floorstanding

CO

B-1

5/20

/29:

129

0

5661210

CO

B-1

5/20

/29:

129

0

1132605

CO

B-1

5/20

/29:

129

0

6051132

CO

B-1

5/20

/29:

129

0C

OB

-40:

149

0

566605

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3.SpecificationBalanced flue connection

Opening the casing Closing the casing

Type plate

Return Optional fixing point for oil filter

Flow

Recesses for individual piping of the heating connections

Entries for oil hoses (optional)

Condensate drain level

1084

566

605

603

122

CO

B-1

5/20

/29:

129

0C

OB

-40:

149

0462

203

CO

B-4

0: 1

209

CO

B-1

5/20

: 919

194

516

26042

6

CO

B-2

9: 9

30

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3.SpecificationOil condensing boiler COB-15 COB-15/CS COB-20 COB-20/CSRated output at 80/60 °C, stage 1/2 kW 9.0 / 14.4 9.0 / 14.4 13.1 / 19.0 13.1 / 19.0Rated output at 50/30 °C, stage 1/2 kW 9.5 / 15.1 9.5 / 15.1 13.9 / 20.0 13.9 / 20.0Rated load, stage 1/2 kW 9.2 / 14.7 9.2 / 14.7 13.5 / 19.6 13.5 / 19.6Oil throughput, stage 1/2 kg/h 0.86 / 1.38 0.86 / 1.38 1.15 / 1.66 1.15 / 1.66Rated capacity CS (equivalent) Ltr - 160 (200) - 160 (240)Constant cylinder output CS kW/Ltr/h - 15 / 370 - 20 / 490Performance factor CS NL60 - 3,5 - 4.5DHW output CS l/10min - 250 - 280Standby input CS kWh/24h - 1.47 - 1.47Max. permissible cold water supply pressure CS bar - 10 - 10Minimum anode current, protective magnesium anode mA - > 0.3 - > 0.3External diameter, heating flow G 1½" 1½" 1½" 1½"External diameter, heating return G 1½" 1½" 1½" 1½"Condensate connection 1" 1" 1" 1"Oil connection, flow/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 1290Width mm 566 1132 566 1132Depth mm 605 605 605 605Boiler weight kg 92 92 92 92Cylinder weight kg - 76 - 76Balanced flue connection mm 80/125 80/125 80/125 80/125Balanced flue 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 standardNozzle* Danfoss

0.30 / 80°S LESDanfoss

0.40 / 80°S LEFuel oil filter Siku max. 40 μmCO2 setting stage 1 and stage 2 % 13.5 ± 0.3 13.5 ± 0.3 13.5 ± 0.3 13.5 ± 0.3Pump pressure stage 1 bar 5.0 ± 0.5 5.0 ± 0.5 8.5 ± 1 8.5 ± 1Pump pressure stage 2 bar 12.0 ± 1.0 12.0 ± 1.0 16.8 ± 2.5 16.8 ± 2.5Maximum negative pressure in oil lines bar -0.3 -0.3 -0.3 -0.3Flow temperature, factory setting °C 80 80 80 80Max. flow temperature °C 85 85 85 85Heating water pressure drop at Δ T=20 K mbar 3.6 3.6 6 6Heating water pressure drop at Δ T=10 K mbar 12 12 21 21Max. permissible boiler pressure bar 3 3 3 3Heating surface, heating water heat exchanger m² 2.55 2.55 2.55 2.55Heat exchanger water content Ltr. 7.5 7.5 7.5 7.5Seasonal efficiency [to DIN] at 40/30 °C (Hi / Hs) % 105 / 99 105 / 99 105 / 99 105 / 99Seasonal efficiency [to DIN] at 75/60 °C (Hi / Hs) % 101 / 96 101 / 96 101 / 96 101 / 96Efficiency at rated load at 80/60 °C (Hi / Hs) % 97 / 92 97 / 92 97 / 92 97 / 92Efficiency at 30% partial load and TR=30 °C (Hi / Hs) % 103 / 97 103 / 97 103 / 97 103 / 97Boiler standby loss qB at 70 °C (EnEv) % 0.75 0.75 0.75 0.75Rated heat input (stage 2): Flue gas mass flow 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 65Lowest heat input (stage 1): Flue gas mass flow 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 45Electrical connection V~/Hz 230/50 230/50 230/50 230/50Integral fuse (medium slow) A 5 A 5 A 5 A 5 APower consumption, stage 1 / stage 2 W 86/128 86/128 99/139 99/139Protection IP20 IP20 IP20 IP20 Condensate volume at 40/30 °C Ltr./h 1.2 1.2 1.6 1.6Condensate pH value approx. 3 approx. 3 approx. 3 approx. 3CE 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/CS COB-40Rated output at 80/60 °C, stage 1/2 kW 18.5 / 28.2 18.5 / 28.2 25.3 / 38.0Rated output at 50/30 °C, stage 1/2 kW 19.6 / 29.6 19.6 / 29.6 26.8 / 40.0Rated load, stage 1/2 kW 19.0 / 29.0 19.0 / 29.0 26.0 / 38.8Oil throughput, stage 1/2 kg/h 1.60 / 2.45 1.60 / 2.45 2.44 / 3.64Rated capacity CS (equivalent) Ltr - 160 (260) -Constant cylinder output CS kW/Ltr/h - 29 / 710 -Performance factor CS NL60 - 5.0 -DHW output CS l/10min - 300 -Standby input CS kWh/24h - 1.47 -Max. permissible cold water supply pressure CS bar - 10 -Minimum anode current, protective magnesium anode mA - > 0.3 -External diameter, heating flow G 1½" 1½" 1½"External diameter, heating return G 1½" 1½" 1½"Condensate connection 1" 1" 1"Oil connection, flow/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 1490Width mm 566 1132 566Depth mm 605 605 605Boiler weight kg 99 99 122Cylinder weight kg - 76 -Balanced flue connection mm 80/125 80/125 110/160Balanced flue 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 standardNozzle* Danfoss

0.55 / 80° S LEDanfoss

0.65/ 80°S LEFuel oil filter Siku max. 40 μmCO2 setting stage 1 and stage 2 % 13.5 ± 0.3 13.5 ± 0.3 13.5 ± 0.3Pump pressure stage 1 bar 8.5 ± 1 8.5 ± 1 9.8 ± 1Pump pressure stage 2 bar 16.8 ± 2.5 16.8 ± 2.5 18.0 ± 2.5Maximum negative pressure in oil lines bar -0.3 -0.3 -0.3Flow temperature, factory setting °C 80 80 80Max. flow temperature °C 85 85 85Heating water pressure drop at Δ T=20 K mbar 17 17 54Heating water pressure drop at Δ T=10 K mbar 55 55 205Max. permissible boiler pressure bar 3 3 3Heating surface, heating water heat exchanger m² 3.05 3.05 3.85Heat exchanger water content Ltr. 9.0 9.0 11.5Seasonal efficiency [to DIN] at 40/30 °C (Hi / Hs) % 105 / 99 105 / 99 105 / 99Seasonal efficiency [to DIN] at 75/60 °C (Hi / Hs) % 101 / 96 101 / 96 102 / 97Efficiency at rated load at 80/60 °C (Hi / Hs) % 97 / 92 97 / 92 98 / 93Efficiency at 30% partial load and TR=30 °C (Hi / Hs) % 103 / 97 103 / 97 103 / 97Boiler standby loss qB at 70 °C (EnEV) % 0.55 0.55 0.45Rated heat input (stage 2): Flue gas mass flow 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 150Lowest heat input (stage 1): Flue gas mass flow 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 72Electrical connection V~/Hz 230/50 230/50 230/50Integral fuse (medium slow) A 5 A 5 A 5 APower consumption, stage 1 / stage 2 W 129 / 178 129 / 178 126 / 205Protection IP20 IP20 IP20Condensate volume at 40/30 °C Ltr./h 2.2 2.2 2.8Condensate pH value approx. 3 approx. 3 approx. 3CE ID CE-0085BS0326

3.Specification

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7

8

9

1011

2

3

6 5

4

1

COB-CS oil condensing boiler with stratification cylinder

Cold water

DHW

DHW circulation

Oil condensing boiler Stratificationcylinder

1 Cylinder heating from above with deflector 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)

CSstratificationcylindercannotbeinstalledwithCOB-40NB

4.Layoutofcomponents

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5. Description of components

Automatic air vent

Regulated stratification pump

Blast tube connection

Plate-type heat exchanger

Oil pump motor

Immersion pipe, cylinder sensor

Two-stage oil pump

Stratification 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 flow 1"

Drain valve

DHW circulation (accessory)

Drain

Protective anode (under cover)

Flame monitor

Fan

Cold water connection ¾" (optional accessory)

COB component description

CS component description

Hot water connection ¾"

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To save energy and protect against scalingif the total hardness is greater than 15 °dH (2.5mol/m³),theDHWtemperaturemaybesetto a maximum of 50 °C.

If the total hardness is greater than 20 °dH (3.58mol/m³),we recommendusing awatertreatmentfacilityinthecoldwatersupplylineforDHWheating,toprolongthemaintenanceinterval(descalingDHWheatexchanger).

COB / COB-CS oil condensing boiler

Two-stage oil condensing boiler with electronic ignition and electronic flue gas monitoring, for low temperature heating and DHW heating in heating systems with flow 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 Efficiency 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

Stratification cylinder type CS 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.

Openflueoilcondensingboilersmustonlybeinstalled in a room which complies with the appropriate ventilation requirements. Otherwise there is a riskof asphyxiationor 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. Thiscutsthelevelofmaintenanceandenergyinput.

6. Standards and regulations

ObtainthepermissionofyourlocalfluegasinspectorandthelowerwaterauthoritypriortotheinstallationofWolfoil 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.

Thefollowingregulations,rulesandguidelinesmustbeobserved 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: Pleasereadtheseinstructionscarefullybeforethe installation and keep them in a safe place. Please also note the technical information in the appendix.

Anydamageor loss resulting from technicalmodificationstothecontrolunitortothecontrolcomponentsareexcludedfromourliability.

- 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 flow temperatures of up to 95 °C

- DIN 18160 Domestic chimneys

- 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 flue 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 instructionsTransport Boiler/stratificationcylinder

- The boiler and the stratification 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 stratification cylinder, secure with a strap and transport to the installation location

The COB and CS 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 stratification cylinder horizontally using adjustable feet.

Adjustable feet

- Remove strap and packaging

- Remove the four fixing screws on the pallet

- Lift the boiler and/or stratification cylinder off the pallet

COB with CS behind

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

NB

NB

NB

COB with CS rightor left

COB-40 minimum

room height

COB

70 cm 70 cm

70 c

m

70 c

m

70 c

m

190

cm

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8. Installation - general notesNote:Provide a fill and drain valve at the lowest point in the system.

SafetyequipmentThe COB has not been fitted with an expansion vessel at the factory. This must be fitted 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 expansionvesselandtheoilcondensingboiler,because otherwise the pressure build-up would permanentlydamagetheboilerduringheating.Thereisariskofsystemcomponentsrupturing,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 flow temperature is factory-set to 80 °C and may be adjusted to 90 °C if required. Generally, the maximum flow 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°dHSystem volume: 1 m³This 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 "Megafill Alu" cartridges from Taconova for the first fill, and later as and when required.- Topping up with distilled water.

Tota

l har

dnes

s in

°dH

System volume in m3

Water treatment necessary

Water treatment not necessary

0.3 m3

Inhibitors (substances to prevent corrosionand limescale deposits) and antifreeze arenot permitted. There is a risk of damage to the boiler resulting from poor heat transfer or corrosion.

Heating waterThe 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 fill 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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Wehighlyrecommendthatyouuselowsulphurfueloilto 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-oilquality

The bio-oil must comply with EN 14213 when the customer tank is filled.

3. Oil storage tanks

The customer must obtain written confirmation from the manufacturer or supplier regarding the suitability of the tank for the use of bio-oils, giving the maximum permitted FAME percentage. It is important to ensure that the tank fittings and gaskets are 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 filling 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.

6.Oilsupplytotheboiler

The oil line system mustbesetupasasinglelinesystem in order to avoid oxidising effects resulting from the introduction of air-borne oxygen into the oil tank.The oil lines must be made of plastics suitable for use with bio-oils, or stainless steel. Copper pipes and brass components, as well as galvanised pipes (damage to the bio-oil caused by zinc oxide coating), should also be avoided to prevent premature ageing of the oil.

Information from VDI 2035The 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 barPrior 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.Themaximumflowratemustnotexceed6000l/h(100l/min).

8. Installation - general notes

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9. Installation - accessoriesWe recommend making the connection to the heating system with the following parts from the Wolf accessories range.

COBconnectionsetadjacenttothewallcomprising:2 cross pieces, each with one connection2 clips1 corrugated stainless steel pipe 1", length 1 300 mm1 corrugated stainless steel pipe 1", length 800 mm1 silicon grease tubeCOBconnectionsetwithCSadjacenttothewallcomprising:2 cross pieces, each with two connections4 clips3 corrugated stainless steel pipe 1", length 1 300 mm1 corrugated stainless steel pipe 1", length 800 mm2 corrugated stainless steel pipes ¾", length 800 mm1 silicon grease tube1 trimming set ¾"

COBconnectionsetadjacent to thewall fora freestandingcylinderuptoSEM-1-750andSE-2-750comprising:2 cross pieces, each with two connections3 corrugated stainless steel pipe 1", length 1 300 mm1 corrugated stainless steel pipe 1", length 800 mm4 clips 1 silicon grease tube 6 flat packings 1"1 pipe bend 2 flat packings 1½" EPDM1 pump 1 adaptor fitting G1½" (fem.)2 double nipples G 1" (male) - G 1" on G1" (male)1 elbow with air ventCSaccessorysetforcoldwatercomprising:1 expansion vessel 8 l1 cold water connection pipe to the expansion vessel2 double nipples ¾"1 trimming set ¾"

Pipeassemblycomprising:1 circulation pump2 thermometers in flow and return2 ball valves in flow and return- Incl. / excl. mixer- With manifold for 2 or 3 pipe assemblies

For further accessories, such as a safety assembly 1" or wallmounting bracket for pipe assembly, etc., see "Heatingsystems"pricelist

CSDHWcirculationpumpaccessorysetcomprising:1 analogue DHW circulation pump1 corrugated stainless steel pipe ¾"1 trimming set ¾"

Neutralisationbox,incl.plinthcomprising:1 granulate fill1 installation accessories set(for standard fuel oil EL (sulphur content > 50 ppm), neutralisation of the condensate is required).

Condensate lifting systemwith a zero-volt alarm outputcomprising:1 condensate lifting pump with a zero volt alarm output1 condensate tank with cover and wall mounting bracket1 PVC hose, 10 mm (6 m long)1 non-return valve1 condensate inlet adaptor

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10.Installation-boiler/CScylinderExample: COB-15/20/29 oil condensing boiler with CS stratification cylinder on the right,

floorstanding (when looking at front of boiler). The pipework for the heating flow and heating return, as well as the heating water flow and heating water return, are connected to the stratification cylinder with corrugated stainless steel pipes (accessories) (see chapter 9 "Installation - accessories").

Diagram: Cold water connection to DIN 1988

Non

-ret

urn

valv

e (in

divi

dual

ly te

sted

)

Dra

in

Shu

t-off

valv

e

Pres

sure

redu

cing

va

lve

Shu

t-off

valv

e

Col

d w

ater

inle

t

Pre

ssur

e ga

uge

port

DH

W fi

lter

Saf

ety

valv

e (in

divi

dual

ly te

sted

)

Dra

in

Above top edge of the cylinder

Boiler flow

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 certified 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

Pipeassemblyfortwoheatingcircuitswithmanifoldforsafetyassemblyinstallation

Pipeassemblyforoneheatingcircuitforsafetyassemblyinstallation

Safety assembly for fixing to thecorrugated stainless steel pipes of heatingflowandreturn

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.

Pipeassemblyforthreeheatingcircuitswithmanifoldforsafetyassemblyinstallation

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12.Oilconnectioninasinglelinesystem

Assumptions:Kinematic viscosity 6 mm²/s at 20 °C, oil temperature = 10 °CAdditional pressure drops: 4 elbows 90°, 1 non-return valve, 1 shut-off valveIn view of possible outgassing of the oil, an inlet height of more than 4 m should be avoided.

Singlelinesystem

Secure the oil filter 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), and up to 50 cm when fed in from the bottom.

Oilfilter

Oil filter fitted inside the boiler

Oil filter fitted on the outside of the boiler

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 fitting 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 difficult 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 insinglelinesystems

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 filter 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 flushed prior to commissioning.

The system must be connected as a single line system. A filter/air vent valve combination from the Wolf product range must be installed. Older two-line systemsmustbeconvertedtosinglelinesystems.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 filter using a suitable manual pump.

Output Throughput Internal line Ø Inlet height H (m)

kg/h mm 4 3 2 1 0 -1 -2 -3COB-15COB-20COB-29

to 2.54 77 68 58 49 40 31 22 13

6 100 100 100 100 100 100 87 64

COB-40 2.5 to 5.04 39 34 29 25 20 16 11 66 100 100 100 100 100 79 56 32

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13. Siphon/neutralisation/condensate pumpCondensate 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.

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 flexible 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 flexible 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 flue gases. For this reason, the siphon must be filled with water prior to commissioning. Undo, remove and fill the siphon until water runs out of the side drain. Refit 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 > 50ppm),neutralisation of the condensate is required.

Note:Thesiphonandtheneutralisationboxmustbefilledwith water prior to commissioning.

Observe the neutralisation box installation instructions.

NB

SiphonDrain hose, siphon

SiphonCondensate pump

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14.Installationofabalancedfluesystem

Diagram: Example of a C93x balanced flue system

InstallationofthebalancedfluesystemForfluesandconcentricbalancedfluesystems,useonlyoriginalWolfcomponents.Please observe the technical information regarding balanced flue systems priorto 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 flue gas inspector prior to installation.

Between the flue 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° (6cm/m) to the oilcondensing boiler. Spacer brackets should be fittedtosecuretheequipmentinposition.In theworst case scenario, a smaller slopeforthebalancedfluemayleadtocorrosionoroperating faults.

Generally bevel or deburr trimmed flues to ensure a gas tight installation of pipe joints. Ensure that gaskets are properly fitted. Remove all contamination prior to installation - never fit faulty parts.

The localfluegas inspectormusthaveclearaccesstothefluegastestnipples.

Route the balanced flue over the appliancein such away that the displacement devicecan be removed (minimum clearance via COB-15/-20/-29 is 30 cm; for COB-40 it is 40cm).

C93x

NB

NB

NB

NB

20 3062547_0311

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 flange (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 figure.

- 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 profile, then compare with the table below.

Displacement device distance to ridged profile (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.

Beforeconnectingtheboiler,flushtheheatingsystemtoremoveresiduessuchasweldingpearls,hemp,putty,etc.fromthepipework.

- 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, fill slowly via the inspection/fill & 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, briefly 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, five times in succession.

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

Air vent valveFillingtheheatingsystem

15.Fillingtheheatingsystem

Diagram: Venting the COB

Checking the position of the displacement device

Diagram: View of COB displacement device

Displacement device distance

Achtung

Unplug the central connector

Burner in the maintenance position

213062547_0311

16. Electrical connectionGeneral notes

Thepowersupplyterminalsare'live'evenwhenthe ON/OFF switch has been switched OFF.

The installationmust be carried out by alicensed electrical contractor. Observe VDE regulationsaswellasall localregulationsbyyourpowersupplyutility.

Fuse M 5A

Power supply 230 V / 50 Hz

Two-wire eBUS connection

Replacement fuse

Outside temperature sensor

Cylinder sensor

Programmable input E1 (24 V), zero-voltRemove jumper a/b when making the connection

Heating circuit pump


Terminal box

Power plug, condensate pump

CS stratification pump Stratification sensor

Control signal, stratification pump

Alarm switch, condensate pump

Programmable output A1 (230 VAC; 200 VA)

Output A1 to DHW circulation


Control signal, stratification pump

Cylinder sensor

Stratification pump


Terminal boxThe terminal box is supplied fitted to the back panel of the boiler. If necessary, the terminal box can be mounted on the wall to the right, to the left or above the boiler.The control, regulating and safety equipment are fully wired and tested.

PowersupplyIn the case of a permanent connection, provide the power supply via a mains isolator (e.g. fuse, heating system emergency stop), which ensures at least 3 mm contact separation for all poles. Connecting cable, flexible, 3 x 1.0 mm² or rigid, max. 3 x 1.5 mm².The maximum current carrying capacity of the outputs is 2 A, but a total of 5 A must not be exceeded.

Installationinformation,electricalconnectionIsolate the system from the power supply before opening the casing.Unclip the terminal box from the holder.Open the terminal box.Insert the strain relief into the holes provided.Strip approx. 70 mm off the power cable insulation.Push the cable through the strain relief and secure the strain relief.Terminate the appropriate cores at the Rast-5 plug.Push the inserts back into the terminal box casing.Insert the Rast-5 plug.Fit the cover.

Isolate the boiler from the power supplybefore changing the fuse. The ON/OFF switch on the boiler does not provide separation from thepowersupply.Danger through 'live'electrical components. Never touch electrical components or contacts as long as the boiler hasnotbeenisolatedfromthepowersupply.Danger to life.

22 3062547_0311

0I

0 °C

20

40

60

80

100

120

ON/OFF switch DHW temperature

selector

Reset button Heating water temperature

selector

Illuminated signal ring

Thermometer

17. Control unit

ON/OFF switchThe condensing boiler is OFF in position 0.

Reset A fault is reset by pressing the reset button which will also restart the system. If the boiler is in a cycle block, this is reset by pressing the button (2 seconds)

Heating water temperature selectorSettings 2-8 correspond, when factory-set, to a heating water temperature of 20-80 °C. Combined with a BM programming module, the adjustment at the heating water temperature selector is disabled.

DHW temperature selectorWhen oil condensing boilers are combined with a DHW cylinder, setting 1-9 corresponds to a cylinder temperature of 15-65 °C. DHW temperatures of over 60 °C are not permissibleinconjunctionwithaCSstratificationcylinder. In combination with a BM programming module, adjustment at the DHW temperature selector is disabled. The temperature is set at the BM programming module.

Illuminated signal ring as status indicator

Display ExplanationFlashing green Stand by (ON/OFF switch ON, no heat demand,

pump OFF)Constant green light Heat demand: Pump running; burner OFFFlashing yellow Emissions test modeConstant yellow light Burner ON; flame steadyFlashing red Fault

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In summer mode, the circulation pump operates for approx. 30 seconds after a maximum idle period of 24 hours.

Anti-seizing pump protection

Summer modeWinter mode is disabled by rotating the heating water temperature selector into position. The boiler then operates 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.

Setting Winter mode (settings 2 to 8)In winter mode, the boiler heats the flow temperature to the value set on the thermostat. According to the pump operating mode, the circulation pump operates constantly (factory setting) or only in parallel with the burner activation / run-on period.

Emissions test modeThe emissions test mode is activated by rotating the heating water temperature selector into position. The illuminated signal ring flashes yellow. After the emissions test mode has been activated, the boiler will heat with the selected maximum output. Any previous cycle block will be cancelled. The emissions test mode terminates after 15 minutes or when the maximum flow temperature has been exceeded. To reactivate, turn the heating water temperature selector anti-clockwise and then back into position .

0I

0 °C

20

40

60

80

100

120

ON/OFF switch Reset button BM programming module

Illuminated signal ring

Thermometer

Control unit with BM programming module

17. Control unit

24 3062547_0311

18. Displaying/modifyingcontrolparametersThecontrolparameterscanonlybemodifiedordisplayedviaWolfcontrolaccessorieswitheBUScapability.Forinstallationandprocedures,checktheoperatinginstructionsoftherelevantaccessories.

Pressing the r.h. rotary selector leads to control level 2, where you can select the menu levels shown in the overview by turning the rotary selector clockwise.Pressing the Info key takes you back to the standard display, irrespective of which submenu is currently displayed.The system automatically also returns to the standard display when no adjustment is made for more than one minute.All available set and actual temperatures, burner starts and hours run as well as other system values can be displayed. This scan is identical to that initiated via the Info key.

Parameter overview / settings report(settings and functions on the following pages)

Parameter Setting range Factorysetting Individual settingsA09 Frost protection limit -20 to +10 °C +2 °CA10 Parallel DHW operation 0 / 1 0A14 Maximum DHW temperature 60 to 80 °C 65 °C

HG00 Matching the pipe length 1 to 5 3HG01 Burner switching differential 1 to 20 K 10 KHG06 Pump operating mode 0 to 3 0HG07 Boiler circuit pump run-on time 0 to 30 min 3 minHG08 Maximum limit, boiler circuit TV-max. 40 to 90 °C 75 °CHG09 Burner cycle block 1 to 30 min 7 minHG13 Programmable input E1 1 to 11 1HG14 Programmable output A1 0 to 14 0HG15 Cylinder hysteresis 1 to 30 K 5 KHG16 N / AHG17 N / AHG19 Cylinder primary pump run-on time 0 to 10 min 5 minHG20 Maximum cylinder heating time 0 to 5 h 2 hHG21 Minimum boiler water temperature TK-min. 20 to 90 °C 20 °CHG22 Maximum boiler water temperature TK-max. 50 to 90 °C 80 °CHG25 Boiler overtemperature during DHW cylinder heating 0 to 40 K 10 KHG28 Burner operating mode 1 to 4 2HG31 Blocking time burner stage 2 0 to 40 min 4 min

A: - System parametersHG: - Boiler parameters

Topreventdamagetotheheatingsystem,cancelnight setback when outside temperatures fall below -12°C. If this rule isnotobserved, icemaybuildupontheflueoutletwhichmaycauseinjuryormateriallosses.

Modificationsmustonly thecarriedoutbyarecognisedheatingcontractororby theWolfcustomer service.

BM programming moduleL.h. rotary selector - program selection Display

R.h. rotary selector - temperature selection

Info key Single cylinder heating key

Setback keyHeating key

NB

253062547_0311

19. Contractor level parametersContractor level Press the r.h. rotary selector to change to control level 2. Turn the r.h. rotary selector

clockwise to select the contractor level and confirm the selection by pressing the r.h. rotary selector again.The display shows the code scan.

Heating contractor

The correct code is set by pressing (display indication flashes) and then turning the r.h. rotary selector from 0 to 1. After changing the code from 0 to 1, pressing the r.h. rotary selector again confirms the setting; you are then at the contractor level.

Code scan

code NO

- - - -

Factory setting: 1

Maximum DHW temperatureParameter A14

65

Factory setting: 65 °CSetting range: 60 to 80 °C

A14

The maximum DHW temperature is factory-set to 65 °C. If, for commercial reasons, a higher DHW temperature is required, a maximum temperature of up to 80 °C is enabled.If pasteurisation has been activated (BM), the DHW cylinder will be heated to the selected maximum DHW temperature during the first cylinder heating of the day.

Take adequate measures to prevent scalding.Parameter HG22 (maximum boiler water temperature) should be set at least 5 K higher than the selected maximum DHW temperature.DHWtemperaturesofover60°CarenotpermissibleinconjunctionwithaCSstratificationcylinder.

The boiler circuit pump operates constantly if the outside temperature stays below the selected value. The burner starts and heats the boiler to at least 20 °C if the boiler water temperature falls below +5 °C.

Note:Only change the factory setting if you can ensure that the heating system and its components will not freeze up at low outside temperatures.

Frost protection limitParameter A09

2.0

Factory setting: 2 °CSetting range: -20 to +10 °C

Incorrect operation can lead to system faults.Please note when adjusting parameter A09 (frost protection / outside temperature), that frost protection is no longer safeguarded if you set temperatures lower than 0 °C. This can lead to heating system damage.

A09

The heating circuit pump is switched OFF during cylinder heating with DHWpriority(0). The boiler energy will then be used exclusively for DHW heating. The cylinder primary pump will only start if the boiler water temperature is 5 °C higher than the current cylinder temperature. The burner shuts down and the heating circuit pump is started as soon as the cylinder has reached its set temperature. The cylinder primary pump runs on for, at most, the period selected under parameter HG19 (cylinder primary pump run-on time).The heating circuit pump continues to operate in parallelDHWmode(1). The cylinder primary pump starts if the boiler water temperature is 5 °C hotter than the cylinder temperature. Cylinder heating ends when the cylinder reaches the set water temperature. The cylinder primary pump runs on for, at most, the period selected under parameter HG19 (cylinder primary pump run-on time).

In parallel DHW mode (1), the heating circuit can temporarily be operated at a higher temperature.Parallel operation in conjunction with a stratification cylinder is not recommended.

Parallel DHW operationParameter A10

A10

Factory setting: 0Setting range: 0 / 1

0

NB

NB

NB

26 3062547_0311

19. Contractor level parameters

The burner switching differential regulates the burner temperature within a set range by switching the burner ON and OFF.The switching differential between burner stage 1 and burner stage 2 is always half the switching differential.See also parameter HG31 diagram.

Burner switching differentialParameter HG01

HG01

10

Factory setting: 10 KSetting range: 1 to 20 K

This parameter shifts the minimum and maximum fan speed parallel downwards or upwards.

This enables the CO2 value for burner stages 1 and 2 to be adjusted at the same time. See also chapter 22 "CO2 adjustment by matching the pipe lengths"

One unit = 120 r.p.mSetting 3 = set value, burner control unit

Matching the pipe lengthParameter HG00

HG00

3

Factory setting: 3Setting range: 1 to 5

Pump operating mode 0:Heatingcircuitpumpforheatingsystemswithoutcascadecontrolandwithoutlow loss headerThe heating circuit pump runs constantly when there is a heat demand. The heating circuit pump will be switched OFF during cylinder heating if DHW priority has been selected.

Pump operating mode 1:Feedpumpforheatingsystemswithcascadecontroland/orlowlossheaderHeating circuit pump becomes the feed pump.The header sensor affects the heating operation as well as cylinder heating. The feed pump runs only when there is a burner demand. Pump run-on in accordance with parameter HG07.

Hydraulic scheme:

Pump operating modeParameter HG06

HG06

0

Factory setting: 0Setting range: 0 / 1 / 2

ZUP = Feed pumpSPL = Cylinder primary pumpSF = Cylinder sensorSAF = Header sensorKF = Boiler sensorMKP = Mixer circuit pumpM = Mixer motorMM = Mixer module Oil condensing boiler

CylinderLow loss header or buffer

M

MM

SAF

ZUP

MKP

SPL

SF

KF

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Pump operating mode 2:BufferprimarypumpforBSPcylinderHeating circuit pump become the buffer primary pump.The manifold sensor (buffer) only affects the heating operation. In case of cylinder heating, the reference temperature is provided by the internal boiler sensor. In heating mode, the buffer primary pump runs only when there is a burner demand. Pump run-on in accordance with parameter HG07.

Subject to there being no heat demand from the heating circuit, the boiler circuit pump will run on in accordance with the set time, to prevent a boiler safety shutdown at high temperatures.

Boiler circuit pump run-on timeParameter HG07

HG07

3

Factory setting: 3 minSetting range: 0 to 30 min

Each time the burner is shut down in heating mode, it will be blocked for the duration of the burner cycle block.The burner cycle block is reset by switching the ON/OFF switch OFF and ON or by briefly pressing the reset button.

BurnercycleblockParameter HG09

HG09

7



SPL = Cylinder primary pumpPLP = Buffer cylinder primary pumpSF = Cylinder sensorSAF = Header sensorKF = Boiler sensorMKP = Mixer circuit pumpM = Mixer motorMM = Mixer module

Wood boiler

Buffer cylinder

Oil condensing boiler

Solar thermal system integration

Hydraulic scheme:

M

J

SAF

SFPLP

KF

SPL

MKP

MM

This function limits the boiler water temperature upwards in heating mode, and the burner shuts down. This parameter has no function during cylinder heating, and the boiler water temperature may also be higher during this time. "Reheating effects" can result in the temperature being slightly exceeded.

Maximum limit boiler circuit TV-max.Parameter HG08

HG08

75


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The functions of input E1 can only be scanned and adjusted with Wolf control accessories with eBUS capability.The following functions can be allocated to input E1:

Programmable input E1Parameter HG13

HG13

1


Explanation

1

Room thermostat Closed contact is a prerequisite for enabling the burner in heating mode. No function for DHW mode. No function for emissions test mode and frost protection, no error message. Open contact blocks the enabling of the heating and the heating circuit pump (pump run-on).

2

Maximumthermostat/systempressureswitch Closed contact is a prerequisite for enabling the burner in heating and DHW mode. When the contact is opened, the burner switches off and the pump run-on begins - no error message. Applies to all pumps. When the mains power is on and the contact is open, there is only a pump kick, no run-on.

5

Flue gas/ventilation air damper Function monitoring of the flue gas/ventilation air damper with zero volt contact. Closed contact is a prerequisite for enabling the fan and burner in heating, DHW, cascade and emissions test mode. Output A1 must be programmed for flue gas/ventilation air damper function.If output A1 is controlled and does not close input E1 within two minutes, Fault Code 8 is issued.If output A1 is not controlled, input E1 must also open within two minutes. Otherwise FC8 is generated. With FC8, the fan is controlled with 65% of speed stage 1.

6DHW circulation pushbutton After the DHW circulation pushbutton is activated, output A1 is switched on for 5 minutes, if output A1 is programmed as DHW circulation pump (A1 = 13).

7 Header sensor A header sensor (5 K-NTC) is connected at E1; observe parameter HG 06.

8

Burner blocking Operation without burner. Closed contact, burner blocked. Heating circuit pump and cylinder primary pump run in standard mode. In emissions test mode and frost protection, the burner is enabled. Open contact enables the burner again.

10

External burner demand Closed contact, TKset is set to TKmax -5 K. Demand also functions in standby; cycle block active (control of output A1 when parameter output A1 = 14).

0,3,4,9,11arewithoutfunction.


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The functions of output A1 can only be scanned and adjusted with Wolf control accessories with eBUS capability.

The following functions can be allocated to output A1:

Programmable output A1Parameter HG14

HG14

0


Explanation1 DHW circulation pump 100%

Output A1 is switched by control accessories (BM) if DHW circulation has been enabled. Output A1 is constantly enabled when no accessory controller is installed.

2 DHW circulation pump 50% Output A1 is switched by control accessories (BM) if DHW circulation has been enabled. 5 minutes ON and 5 minutes OFF. Output A1 constantly cycled in 5 minute cycles when no accessory controller is installed.

3 DHW circulation pump 20% Output A1 is switched by control accessories (BM) if DHW circulation has been enabled. 2 minutes ON and 8 minutes OFF. Output A1 cycles constantly when no accessory controller is installed.

4 Alarm output Output A1 is controlled after a fault and expiry of 4 minutes.

5 Flame detector Output A1 is controlled after a flame has been recognised.

7 Flue gas/ventilation air damper Output A1 is always controlled before the fan starts. The feedback is checked via input E1. If input E1 does not close, the fan and burner will not start, and after two minutes FC8 will be generated. The flue gas/ventilation air damper is controlled until the fan starts. If input E1 is interrupted during burner operation, the burner shuts down. In case of a fault, e.g. pressure switch, flame failure during operation etc., the flue gas damper is closed after the flushing time has expired. Input E1 must be programmed as flue gas/ventilation air damper. With FC8, the fan is controlled with 65% of speed stage 1.

8 External ventilation Output A1 is controlled inverted to the burner. Switching OFF external ventilation (e.g. extractor fan) during burner operation is only required, if the boiler is operated as open flue system.

9 Oil shut-off valve Output A1 switches simultaneously to the oil pump.

11 External pump Output A1 switches simultaneously with the heating circuit pump. Use with, for example, system separation.

12 Diverter valve Synchronous control with input E1 (E1 = 8, burner blocking).

13 DHW circulation pump DHW circulation pump ON for 5 mins if input E1 (E1 = 6) is programmed as DHW circulation pushbutton and input E1 Key is closed.

14 Pump with external burner demand Simultaneous control with input E1 (E1 = 10, ext. burner demand).0,6,10,15arewithoutfunction.


30 3062547_0311

After completing cylinder heating (the cylinder has reached the set temperature), the cylinder primary pump will run on up to the maximum set run-on time. The cylinder primary pump will switch OFF prematurely if, during the run-on time, the boiler water temperature cools down to a differential between boiler and cylinder water temperature of 5 K, to prevent the boiler cooling down too severely.

Cylinderprimarypump run-on timeParameter HG19

HG19

5


Cylinder heating commences as soon as the cylinder temperature sensor demands heat. The heating circuit pumps would be constantly switched off if the boiler was undersized, the cylinder was scaled-up or if DHW was constantly drawn off during DHW priority mode. The accommodation cools down significantly. One option enables a max. cylinder heating time to be specified to limit this effect. If the set maximum cylinder heating time has expired, error message FC52 appears on the BM module. The control unit reverts to heating mode and cycles in the selected rhythm (HG20) between heating and cylinder heating mode, irrespective of whether the cylinder has reached its set temperature or not. This function remains enabled even in parallel mode (parameter A10 set to 1). It is only disabled if it is set to 0.Set this parameter to 0 in heating systems with a high DHW consumption, e.g. hotels, sports facilities, etc.

Max.cylinderheatingtimeParameter HG20

Factory setting: 2 hSetting range: 0 to 5 h

HG20

2

The control unit is equipped with an electronic boiler thermostat, with an adjustable minimum switch-ON temperature. The burner is switched on subject to the cycle block if this temperature is not achieved when heat is demanded. The minimum boiler water temperature TK-min. is also not necessarily achieved when there is no heat demand.

Minimum boiler water temperature TK-min.Parameter HG21

HG2120


19. Contractor level parametersThe cylinder hysteresis regulates the start point for cylinder heating. The higher the setting, the lower the start point for cylinder heating.

Example: Set cylinder temperature 60 °C Cylinder hysteresis 5 K

Cylinder heating commences at 55 °C and ends at 60 °C.

CylinderhysteresisParameter HG15

HG15

5


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Boiler overtemperature during cylinderheatingParameter HG25

The excess temperature differential between the cylinder temperature and the boiler water temperature during cylinder heating is selected with parameter HG25. The boiler water temperature continues to be limited by the maximum boiler water temperature (parameter HG22). This ensures that, even in spring and autumn, the boiler water temperature is higher than the cylinder temperature, thereby ensuring short heating times.

HG25


10

Burner operating modeParameter HG28


You can select any burner operating mode. Control unit is set at the factory for two-stage burner operation.

Setting "1": single stage burner operation, stage 1

Setting "2": two-stage burner operation, stages 1 + 2

Setting "3": single stage burner operation during cylinder heating two-stage burner operation in heating mode

Setting "4": N / A

HG28

2

19. Contractor level parametersMaximum boiler water temperature TK-max. Parameter HG22


The control unit is equipped with an electronic boiler thermostat which has an adjustable maximum shutdown temperature (maximum boiler water temperature). The burner is switched off if this temperature is exceeded. The burner will be started again when the boiler water temperature has fallen by as much as the burner switching differential.

If the boiler water temperature exceeds 95 °C (possible effect of reheating), the boiler circuit pump and cylinder primary pump (if installed) will also be started in "summer mode". These pumps are stopped again when the boiler water temperature falls below 92 °C. This prevents the boiler overheating.

HG22

80

Blocking time burner stage 2Parameter HG31


4

Burner stage 2 is started when there is stage 2 demand and after the blocking period has expired (factory setting 4 min). It is stopped once a temperature of approx. 5 °K above the set value has been reached. Once the stage 2 has been enabled, it will be started as soon as the set temperature has been reached or is no longer achieved. Enabling is removed when burner stage 1 is shut down.During cylinder heating and emissions test mode, this parameter is disabled.

TimeBlocking period, factory setting 4 min

Boi

ler

tem

pera

ture

°C Burner stage 1

Burner stage 1Burner OFF

Burner stage 1

Burner stage 2 Burner stage 2

Burner OFF

Set value

Demandstage 2

HG31

32 3062547_0311

SettingtheeBUSaddressforcascade mode(seeinstallationinstructionsforKMmodule)

The eBUS address is set by pressing the reset button for at least 5 seconds after the appliance has been switched on. After 5 seconds, the corresponding flashing code appears (in accordance with the table) at the illuminated signal ring. Select the corresponding eBUS address with the DHW temperature rotary selector. Your selection of the required eBUS address is saved by releasing the reset button. No address can be allocated more than once.

20. Cascade operation Control/specification/notes

Cascadetype 2 x COB-29

3 xCOB-29

4 xCOB-29

2 x COB-40

3 xCOB-40

4 xCOB-40

Rated output at 80/60 °C kW 56.4 84.6 112.8 76.0 114.0 152.0Rated output at 50/30 °C kW 59.2 88.8 118.4 80.0 120.0 160.0Rated heat input kW 58.0 87.0 116.0 77.6 116.4 155.2Lowest output at 80/60 °C Stage 1 kW 18.5 25.3Lowest output at 50/30 °C Stage 1 kW 19.6 26.8Lowest output kW 19.0 26.0

Specification

Heating circuit To ensure the heating water flow rate through every condensing boiler is as even as possible, the following connection types are recommended:

1. For precise hydraulic balancing, a line regulating valve can be fitted in the supply line to every appliance.

2. Design the flow and return lines with the same length for the flow and return according to the Tichelmann system, to ensure the pressure drop in every line is equally high.

These oil condensing boilers have control PCBs with functions that are optimally matched to the digital controller type KM for cascade control. Up to four COB-29 or COB-40 oil condensing boilers (with the same output) with an output range of 18.5 kW to 112.8 kW (cascade COB-29) or 25.3 kW to 152.0 kW (cascade COB-40) can be linked together to form a single cascade. Subject to load, this digital cascade controller KM can control the header flow, a mixer circuit and a DHW cylinder circuit. The digital controller type MM from the WOLF range of control accessories can be connected to regulate an additional mixer circuit and radiator circuit. Furthermore, a BM can be used in each case as a remote control.For a detailed description, see also the installation instructions for the individual modules.

General

Low loss header It must not be possible for the on-site heating circuit pumps or primary pumps to influence the function of the condensing boilers. A low loss header should therefore be installed upstream of the heating water circuit or DHW cylinder circuit. Furthermore, ensure that the heating water flow rate through the condensing boilers is set lower than that through the subsequent heating circuit. The flow rate should therefore be set upstream of the low loss header via a line regulating valve or butterfly valve.

Systemseparation Instead of the low loss header, a heat exchanger can be installed. If pipes are used which are not impermeable to oxygen, this is a requirement in any case.

DHWcylinder A DHW cylinder is generally connected downstream of the system separation (e.g. via a low loss header).Cylinder heating is controlled via the cascade controller type KM, to which a cylinder primary pump and the electronic cylinder sensor are connected.

*Factory setting (individual boiler without cascade mode)

Boiler in cascade operation

eBUSaddress

Rotaryselector,DHW temperature

selection

Illuminated signal ring indication

Boiler 1 1* 1* flashing red

Boiler 2 2 2 flashing yellow

Boiler 3 3 3 flashing yellow/red

Boiler 4 4 4 flashing yellow/green

333062547_0311

21. Cascade operation Fluesystemdesign

Balancedfluerouting Oil condensing boilers with a separate, concentric, balanced flue outlet (DN 80/125 or DN 110/160) above the roof, type C33x, may only be installed in attics, or in rooms where the ceiling also forms the roof, or where only the roof construction is located above the ceiling.

If the pipework for the combustion air supply and flue gas routing crosses different floors in the building, route the pipes outside the boiler room inside a duct with a fire resistance of at least 90 minutes, and in living spaces of low height with a resistance of at least 30 minutes.

Topreventfluegasbeingdrawnbackthroughadjacentroofoutletswhereseveralflueoutletsarearrangednexttoeachother,arrangetheoutletsatapproximatelythesameheightandwithatleast600mmbetweenthem.

The maximum permissible straight length for concentric balanced flue routing must not exceed 16 m with an internal diameter DN 80/125, or 21 m with DN 110/160. The calculated length of the balanced flue routing comprises the straight pipe length and the length of the pipe bends. In this calculation, an 87° bend is calculated as being 1.5 m and a 45° bend as being 1 m.

Cascade control with separate, vertical, concentric balanced flue routing, type C33x.

min. 600min. 600min. 600

KM module

34 3062547_0311

22. Cascade operation Flue gas header design

For open flue operation, there must be an aperture in the boiler room that opens to the outside and has a clear cross-section of at least 150 cm².Where necessary, adapt the installation examples to the relevant Building Regulations and requirements of your country/region. Discuss any questions relating to the installation, particularly of inspectioncoversandventilationapertures(ventilationgenerallyrequiredabove50kWoutput)with your local heating engineer.

Flue gas routing with header Oil condensing boilers with common flue routing - open flue operation in installation type B23.

Number 2 x COB-29

2 x COB-29

3 xCOB-29

4 xCOB-29

2 x COB-40

3 xCOB-40

4 xCOB-40

Installation Art B23Flue internal diameter DN110 DN160 DN160 DN160 DN160 DN160 DN160Total flue gas mass flow rate g/s 26.6 26.6 40.0 53.3 35.0 52.5 70.0Max. flue gas temperature °C 76 83Max. effective building height m 30

Cascade control with header

DWTK

min. 600

max. 1000

min. 605

max. 2000

min. 600

max. 1000

min. 600

max. 1000

KM module

Flue cascades are only suitable in balanced flue operation. They must be designed to EN 13984-1. To prevent flue gas escaping, a flue cascade is only permitted with a tested

flue gas damper.

Flue cascade

Cei

ling

heig

ht a

t lea

st 2

500

mm

The effective heights specified are only valid on the condition that the length of the flue between the individual appliances and downstream of the last appliance does not exceed 2 m. 325 m was assumed as the geodetic height. If the conditions at the installation site are different, an individual calculation is required.

353062547_0311

The maximum horizontal length of the flue gas header is 1.5 m between the appliances and 1.5 m downstream of the last appliance. In addition to the boiler connection bend, a maximum of two 87° diverters may be installed.

Pipe length calculation: The calculated length of the flue comprises the straight pipe length and the length of the pipe bends.

Minimum cross-section of the duct: With a round duct, the clear distance from the flue to the duct wall must be at least 3 cm and with an angular duct, at least 2 cm.

The flues must be installed in ducts and channels in such a way that it is possible to inspect and, if necessary, clean the ventilated cross-section. Close cleaning apertures in ducts with chimney cleaning covers which have been assigned a test mark.

The distance from the cleaning and inspection aperture in the duct/channel to the front edge of the flue can be twice the diameter of the flue, up to a maximum of 35 cm, as long as cleaning and inspection do not take place at the outlet.

Flues in ducts should be designed at the outlet in such a way that no precipitation can enter the space between the flue and duct, and the secondary ventilation can escape freely.

Removable covers must be able to be removed without tools and be secured to prevent them falling.

Retaining straps and spacers must be designed in such a way that it is possible to inspect and, if necessary, clean the free duct cross-section.

Provide sufficient cleaning and inspection apertures.

Installation in an existingchimney/duct

23. Cascade operation Flue gas header design / notes

Component Calculated length87° bend 1.5 m45° bend 1 m

87° tee with inspection aperture 2 mStraight pipe Subject to length

36 3062547_0311

In the vertical part of the flue, a cleaning and inspection aperture is required immediately above or below the flue diverter if the distance from the centre of the cleaning and inspection aperture in the horizontal part of the flue to the vertical axis of the flue is greater than 30 cm.

The distance can be up to 1 m if the inspection aperture in the horizontal part of the flue is arranged on the front and if there are no diverters in the flue from this cleaning and inspection aperture to the vertical part.

In the upper part of the flue arranged inside the building (< 5 m), a cleaning and inspection aperture is required if cleaning or inspection cannot be carried out from the roof.

Before commissioning the combustion system, have the safe usability of the flue system confirmed by the local flue gas inspector [in Germany; check local regulations].

Installingtheflue

23. Cascade operation Flue gas header design / notes

2616

23

24

25

26

27

33

3737373738

32

26

35

34

2

32

26

35

34

2

32

26

35

34

2

32

26

35

34

2

36

1 Oil condensing boiler

2 Connection adaptor with test nipple for air and flue gas (included in COB standard delivery)

16 Rose

23 Support rail

24 87° support bend

25 Spacer

26 PP pipe

27 Cowl

33 PP outlet

34 Electricalfluegasdamper

35 Extension(whererequired)

36 Siphon

37 PP header

38 End piece with inspection aperture and condensate drain

Secondary ventilation

Example of an open flue cascade design according to type B23

1 1 11

373062547_0311

24. Cascade operation Flue gas damper installation

- Push flue gas damper as far as it will go onto connection adaptor (with test nipple) on the boiler.

- Push the flue as far as it will go onto the flue gas damper.- Correctly route the limit switch cable and motor cable from

the flue gas damper to the terminal box and to the cable (programmable output A1).

In the delivered condition, the terminal box is fitted to the back panel of the boiler. If required, the terminal box can be mounted on the wall to the right or left of the boiler, or above it.The control, regulating and safety equipment are fully wired and tested.

Installation information regarding electrical connection of inputE1andoutputA1forthefluegasdamper

- Isolate the system from the power supply before opening.- Unclip the terminal box from the holder.- Open the terminal box.- Insert the strain relief into the holes provided.- Strip approx. 70 mm off the power cable from the limit

switch.- Push the cable through the strain relief and secure the strain

relief.- Connect the wires from the limit switch to input E1 (see chapter 25 "Wiring diagram cascade operation").- Connect motor cable from the flue gas damper via an on-

site junction box with programmable output A1 (see chapter 25 "Wiring diagram cascade operation").- Fit the cover.

Proceed with chapter 26 "Flue gas damper tightness test" and "Commissioning".

Terminal box

Flue gas damper installation

Flue gas damper

COB

Programmable output A1(230 VAC; 200 VA)

COB back view

Flue gas damper installation information

Electrical connection installation information

38 3062547_0311

25. Cascade operation Flue gas damper installation / wiring diagram

M

230 V ~

Netz KKP LP

N

N

NL1L1 L1

L1 L1L1 N NN

AF SFE1 eBUS

+ - 1 12 2a b

1 2 1 2 1 21 2

COB terminal box

Flue gas damper with servomotor

Limit switch

COB-15/20/29/40

Programmable output A1(230VAC; 200VA)

NB:Flue gas damper limit switch must be zero volt. Otherwise the COB control unit will be destroyed.

Note:Contractor parameter HG13 (input E1) must be set to 5 and HG14 (output A1) must be set to 7.

Power supply (230 VAC; 200 VA)

Flue gas damper wiring diagram

Junction box on site

393062547_0311

26. Cascade operation Flue gas damper tightness test

Testingadjacentappliances for tightness

1 2 3 4

1. ON OFF OFF OFF2. OFF ON OFF OFF

As part of the annual boiler test, the cascade damper in overpressure boiler systems must be tested for tightness to ensure no CO2 can escape into the boiler room; risk of poisoning or suffocation.The check must be carried out with the appliance closed.

We recommend proceeding as follows:

Testingadjacentappliancesfortightness

- Set the program selector (l.h. rotary selector) to “Standby” on the BM program-ming module.

- Then turn the first COB to position 1 “Emissions test” by means of the heating water temperature selector è COB starts.

- Operate the first COB for at least 5 minutes.

- On all other appliances, check the CO2 contents at the air connector:

- If the CO2 value exceeds 0.2% within 15 minutes, the leak must be found and remedied.

- Subsequently close all test apertures again. When doing so, ensure the caps are seated firmly.

TestingthefirstCOBfortightness

- Turn the temperature selector for heating water on the first COB to its centre posi-tion è COB shuts down.

- Turn the second COP to position 1 “Emissions test” by means of the heating water temperature selector è COB starts.

- Operate the second COB for at least 5 minutes.

- Carry out the CO2 test on the first COB.

- If the CO2 value exceeds 0.2% within 15 minutes, the leak must be found and remedied.

- Subsequently close all test apertures again. When doing so, ensure the caps are seated firmly.

40 3062547_0311

27. Commissioning with Wolfcontrolaccessories(BM)

0I

0 °C

20

40

60

80

100

120

ON/OFF switch Program selector switch

"Inlet air" test port

"Flue gas" test port

Ifnocontrolaccessoryisinstalled,seechapter28"CommissioningwithoutWolfcontrolaccessories(BM)".

Commissioning Only qualified personnelmust carry out the commissioning andoperationoftheboiler,aswellasinstructtheuser.

- Checktheboilerandsystemforleaks.Normaloperatingpressure whensystemiscold1.5-2.0bar.Preventwaterleaks.

- Check location and seating of the installation. (e.g. displacement deviceposition)

- Check the fuel level in the oil tank and water level in the siphon or neutralisation box.

- Checkallconnections,includingthosebetweencomponents,forleaks.

- If tightness cannot be ensured then there is a danger of water damage.

- Fit casing.

- Check that all flue gas accessories have been correctly installed.

- Open the shut-off valves on flow and return.

- Open oil shut-off valves (tank, oil line, filter).

- Switch ON the heating system emergency stop switch.

- Switch ON the system ON/OFF switch on the control unit.

- Remove cap from r.h. test port (inlet air).

- Insert test probe 2 cm.

- Turn the program selector switch on BM module to "Emissions test" .

(Illuminated signal ring flashes yellow)

- After a pre-purge time of approx. 25 seconds, the pump starts up and opens the solenoid valve. The supplied fuel oil reaches the nozzle and a flame is established.

- The burner enters a fault state if, during commissioning, the oil pump does not supply sufficient oil during the pre-purge time. Repeat the burner start by pressing "Reset".

- Measure temperature and CO2 in the inlet air and enter the values in the commissioning report in chapter 29.

- The flue is not gas tight if the CO2 content > 0.2%; rectify the leak.

- Terminate the emissions test mode by turning the program selector switch on the programming module to the required operating mode.

- If emissions test mode is not reset manually, the appliance switches back to the original operating mode automatically after 15 minutes.

- Remove the test probe and close the test port. Ensure the cap is seated firmly.

413062547_0311

- Measure the flue gas, CO2 content, flue gas temperature and soot value and enter them in the commissioning report (chapter 29).

- Modifying the parameter HG00 has also adjusted the speed for stage 1. For checking purposes, the boiler must be set to stage 1.

- Switch HG28 burner operating mode from 2 (two-stage) to 1 (single stage).

- Measure the CO2 content and compare it against the values given in the stage 1 table adjacent.

- If the value is outside the set value, the CO2 value must be adjusted via the pump pressure (see chapter 28 "Commissioning without Wolf control accessories").

- Reset HG28 burner operating mode from 1 to 2.

- Terminate the emissions test mode by turning the program selector switch on the BM programming module to the required operating mode. If emissions test mode is not reset manually, the appliance switches back to the original operating mode automatically after 15 minutes.

- Remove the test probe and close the test port.

27. CO2check/adjustmentbymatchingthe pipe lengths

CO2adjustmentbymatching the pipe lengths

WithcontractorparameterHG00(seechapter19"Contractorlevelparameters"),theappliancescanbematchedtothefluegassystembychangingthespeedfor both stages.

- The casing must be closed for this setting.

- Remove the cap from the l.h. "flue gas" test port.

- Insert the test probe of the CO2 measuring instrument into the "flue gas" test port (approx. 70 mm).

- Turn the program selector switch on BM module to "Emissions test". (Illuminated signal ring as status indicator flashes yellow.)

- Measure the CO2 content and compare it against the values given in the Stage 2 table adjacent.

- If required, alter the CO2 content with parameter HG00.

Completingtheadjustments - Check the control parameters and match them to the system if necessary.

- Check the condensate drain.

- Instruct the customer in the operation of the boiler, with the aid of the operating instructions.

- Complete the commissioning report (chapter 29) and hand over the instructions to the customer.

- Instruct the customer about the need for annual servicing.

- Instruct the customer about energy saving options.

- Refer your customer to section "Information regarding energy efficient operation" in the operating instructions.

CO2 check in the lower load (stage1)

CO2setvalue,boilerclosedstage113.5 ± 0.3%

AdjustingtheCO2 value in the upperloadrange(stage2)(emissionstestmode)

CO2setvalue,boilerclosedstage2

13.5 ± 0.3%

HG 00 CO2 settings

Factory setting: 3

1 2 3 4 5

Lower CO2 valueHigher CO2 value

42 3062547_0311

28. Commissioning without Wolf control accessories(BM)

0I

0 °C

20

40

60

80

100

120

ON/OFF switch

Heating water temperature selector

DHW temperature selector

Commissioning Only qualified personnelmust carry out the commissioning andoperationoftheboiler,aswellasinstructtheuser.

- Remove front and top casing.

- Pivot the control unit downwards.

- Insert the oil pressure gauge into the pump's pressure gauge test port.

- Remove the cap from the l.h. "flue gas" test port.

- Insert the test probe of the CO2 measuring instrument into the "flue gas" test port.

(approx. 70 mm).

- Turn the heating water temperature selector to "Emissions test"

(illuminated signal ring as status indicator flashes yellow.)

- Measure the CO2 content and compare it against the values given in the stage 2 table adjacent.

- If required, set the CO2 content with the stage 2 pressure regulating screw using a 4 mm Allen key in accordance with the table.

Turn clockwise - higher CO2 value

Turn anti-clockwise - lower CO2 value

CO2 settings via pump pressure

IfnocontrolaccessoryisconnectedtotheapplianceortheCO2 set value is not achievedbymatchingthepipelengths,thesettingismadeviapumppressurecontrol:

"Inlet air" test port

"Flue gas" test port

- Checktheboilerandsystemforleaks.Normaloperatingpressure whensystemiscold1.5-2.0bar.Preventwaterleaks.

- Check location and seating of the installation.- Check the fuel level in the oil tank.- Check all connections and component links for leaks.- If tightness cannot be ensured then there is a danger of water damage.- Fit casing.- Check that all flue gas accessories have been correctly installed.- Open the shut-off valves on flow and return.- Open oil shut-off valves (tank, oil line, filter).- Switch ON the heating system emergency stop switch.- Switch ON the system ON/OFF switch on the control unit.- Remove cap from r.h. test port (inlet air).- Insert test probe 2 cm.- Turn DHW temperature selector to 1.- Turn heating water temperature selector to "Emissions test" (illuminated signal ring flashes yellow).- After a pre-purge time of approx. 25 seconds, the pump starts up and opens the

solenoid valve. The supplied fuel oil reaches the nozzle and a flame is established.- The burner enters a fault state if, during commissioning, the oil pump does not supply

sufficient oil during the pre-purge time. Repeat the burner start by pressing reset.- Measure temperature and CO2 in the inlet air and enter the values in the commissioning

report in chapter 24.- The flue is not gas tight if the CO2 content > 0.2%; rectify the leak.- Terminate the emissions test mode by turning the temperature selector back to its

original position.- If emissions test mode is not reset manually, the appliance switches back to the

original operating mode automatically after 15 minutes.- Remove the test probe and close the test port. Ensure the cap is seated firmly.

AdjustingtheCO2 value in the upperloadrange(stage2)(emissionstestmode)

Pressure regulating screw, stage 1

NB

Vacuum test connection

Vacuum test connection

Oil pressure test connection

Oil pressure test connection



Pump Danfoss

Pump Suntec

433062547_0311

Completingtheadjustments - Shut down the boiler and close the test ports again.- Check the control parameters and match them to the system if necessary.- Check the condensate drain.- Instruct the customer in the operation of the boiler, with the aid of the operating instructions.- Complete the commissioning report (chapter 29) and hand over the instructions to the customer.- Instruct the customer about the need for annual servicing.- Instruct the customer about energy saving options.- Refer your customer to section "Information regarding energy efficient operation" in

the operating instructions.

- Check whether the pump pressure is still within the tolerance range. If not, then check the nozzle and mixer head.

- Terminate the emissions test mode by turning the DHW temperature selector back to its original position.

- Press the reset button.- Set the heating water temperature selector to 8.- Approx. 60 seconds after the burner start, check the CO2 content with the CO2

measuring instrument.- If required, alter the CO2 content with the stage 1 pressure regulating screw using a

4 mm Allen key.

Testing must be carried out within 240 seconds of the burner start. If necessary, repeat the start phase for setting procedures by turning back the heating water temperature selector and pressing the reset button.

Turn clockwise - higher CO2 value Turn anti-clockwise - lower CO2 value

28. CO2check/adjustmentviapumppressure

- After completing the work, refit the casing lid and check the CO2 value with the boiler closed.

Observe the CO emissions whilst making CO2adjustments.TheCOvalue should be < 50 ppm if the CO2 value is correct.

- The condensing boiler is correctly adjusted when the CO2 values correspond to those in the adjacent table.- If the CO2 value increases too greatly, the balanced flue must be checked.- Enter the flue gas values of CO2, flue gas temperature and soot value in the

commissioning report in chapter 29.

Checking the CO2adjustment

AdjusttheCO2 value in the lowerload(stage1)

- Check whether the pump pressure is still within the tolerance range. If not, then check the nozzle and mixer head.

- Terminate boiler operation by turning the heating water temperature selector back to its original position.

- Remove the oil pressure gauge and close the aperture again.

Appliance open COB-15 COB-20 COB-29 COB-40Stage 2 CO2 set value 13.2 ± 0.3% 13.2 ± 0.3% 12.7 ± 0.3% 12.7 ± 0.3%Stage 1 CO2 set value 13.2 ± 0.3% 13.2 ± 0.3% 12.7 ± 0.3% 12.7 ± 0.3%

Appliance open COB-15 COB-20 COB-29 COB-40Stage 2 Pump pressure 12.0 ± 1.0 bar 16.8 ± 2.5 bar 16.8 ± 2.5 bar 18.0 ± 2.5 barStage 1 Pump pressure 5.0 ± 0.5 bar 8.5 ± 1.0 bar 8.5 ± 1.0 bar 9.8 ± 1.0 bar

Thepumppressureinstage2mustalwaysbegreaterthanthatinstage1

Appliance closed COB-15 COB-20 COB-29 COB-40Stage 2 CO2 set value 13.5 ± 0.3%Stage 1 CO2 set value 13.5 ± 0.3%



Pump Danfoss

Pump Suntec

44 3062547_0311

29. Commissioning report

Commissioning steps Testvalueorconfirmation

1.) Fuel oil Standard EL

Low sulphur EL

Bio-oil B10

2.) Oil leak test carried out?

3.) Balanced flue system checked?

4.) Water connections checked for leaks?

5.) Siphon filled?

6.) Boiler and system vented?

7.) Function test carried out?

8.) Function test carried out?

9.) Flue gas test:

Flue gas temperature gross

Inlet air temperature

Flue gas temperature net

Carbon dioxide content (CO2) or oxygen content (O2)

Carbon monoxide content (CO)

__________________ tA [°C] __________________ tL [°C] __________________ (tA - tL ) [°C] __________________ % __________________ ppm

10.) Casing fitted?

11.) Control parameters checked?

12.) System user trained, documentation handed over?

13.) Confirm commissioning? Date: ____________________________

Signature: ________________________

453062547_0311

30. Maintenance and design dataNTC sensor resistances

Boiler sensor, cylinder sensor, outside temperature sensor, header sensor, DHW heating sensor

Pressure drop on the heating water side COB-15

Watervolume(l/h)

Pressuredrop(m

bar)

Temp. °C Resist. Ω Temp. °C Resist. Ω Temp. °C Resist. Ω Temp. °C Resist. Ω-21 51393 14 8233 49 1870 84 552-20 48487 15 7857 50 1800 85 535-19 45762 16 7501 51 1733 86 519-18 43207 17 7162 52 1669 87 503-17 40810 18 6841 53 1608 88 487-16 38560 19 6536 54 1549 89 472-15 36447 20 6247 55 1493 90 458-14 34463 21 5972 56 1438 91 444-13 32599 22 5710 57 1387 92 431-12 30846 23 5461 58 1337 93 418-11 29198 24 5225 59 1289 94 406-10 27648 25 5000 60 1244 95 393-9 26189 26 4786 61 1200 96 382-8 24816 27 4582 62 1158 97 371-7 23523 28 4388 63 1117 98 360-6 22305 29 4204 64 1078 99 349-5 21157 30 4028 65 1041 100 339-4 20075 31 3860 66 1005 101 330-3 19054 32 3701 67 971 102 320-2 18091 33 3549 68 938 103 311-1 17183 34 3403 69 906 104 3020 16325 35 3265 70 876 105 2941 15515 36 3133 71 846 106 2852 14750 37 3007 72 818 107 2773 14027 38 2887 73 791 108 2704 13344 39 2772 74 765 109 2625 12697 40 2662 75 740 110 2556 12086 41 2558 76 716 111 2487 11508 42 2458 77 693 112 2418 10961 43 2362 78 670 113 2359 10442 44 2271 79 670 114 228

10 9952 45 2183 80 628 115 22211 9487 46 2100 81 608 116 21612 9046 47 2020 82 589 117 21113 8629 48 1944 83 570 118 205

200 400 600 800 1000 1200 1400 1600 1800 20000

0

5

10

15

20

25

30

COB-1520K-spread

COB-1510K-spread

46 3062547_0311


Watervolume(l/h)

Pressuredrop(m

bar)

200 400 600 800 1000 1200 1400 1600 1800 20000

0

5

10

15

20

25

30

0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000

0

5

10

15

20

25

30

35

40

45

50

55

60

65

70

75

80

0 400 800 1200 1600 2000 2400 2800 3200 3600 4000 4400 4800 5200 5600 6000

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160160

170

180

190

200

210

COB-2020K-spread

COB-2010K-spread

COB-2920K-spread

COB-2910K-spread

COB-4020K-spread

COB-4010K-spread

Watervolume(l/h)

Pressuredrop(m

bar)

Watervolume(l/h)

Pressuredrop(m

bar)



30. Maintenance and design data

473062547_0311

31. Design information

1) Marking "x" indicates that all components of the flue are surrounded by combustion air and meet increased requirements for gas tightness.2) For types B23 and B33, the combustion air is drawn from the installation room (open flue combustion equipment). For type C, the combustion air is drawn through a sealed system from the outside (balanced flue combustion equipment).

Connectiontypes

The following balanced flue or flues with CE-0036-CPD-9169003 certification may be used:

Flue DN 80Concentric balanced flue DN 80/125Flue DN 110Concentric balanced flue (on an external wall) DN 80/125Flue (flexible) DN83, DN110Concentric balanced flue (on an external wall) DN 110/160Flue DN 160 (for cascade)

The necessary type plates and certificates are included with the relevant Wolf accessories. Observe all additional installation instructions included with accessories.

Boiler type

Appliance type 1), 2)

Operating mode Can be connected toOpen flue Balanced

flueMoisture-resistant

chimneyBalanced flue

chimneyBalanced flue Certified

balanced flueMoisture-

resistant flueCOB-15/20/29/40

B23, B33, C53, C33x, C43x, C53x, C63x, C83x, C93x

Yes Yes B33, C53, C83x C43x C33x, C53x, C93x

C63x B23, C53x, C83x

I IIII IIIII IIIII IIII IIIII IIII IIIII IIIII IIII IIIII IIIII IIII IIIII IIII IIIII IIIII IIII IIIII IIIII IIII IIIII IIIII

I IIIII IIII IIIII IIIII III

IIIIIIIIIII

I

I

II

II

II

IIII

I

IIII

IIII

IIIIIIII

IIIIIIIIIC83x

C33x

C53x

B33C83x C93x

C33x

C93x C43xC53

B23

B33

C33x

48 3062547_0311

1) Available fan draught: COB-15: 32-65 Pa / COB-20: 45-65 Pa / COB-29: 55-105 Pa / COB-40: 70-150 Pa (the maximum length corresponds to the total length from the appliance to the flue terminal)

2) Vertical flue for installation in a duct, flexibleandrigidwith horizontal concentric connection line Calculation to DIN EN 13384 (balanced flue manufacturer)

Note: Systems C 33x and C 83x are also suitable for installation in garages.Where necessary, adapt the installation examples to the relevant Building Regulations and requirements of your country/region. Discuss any questions relating to the installation, particularly regarding the inspection components and ventilation apertures, prior to installation with your local flue gas inspector.Thelengthdimensionsrefertoconcentricbalancedflueandflues,andonlytooriginalWolfcomponents.

Balancedfluerouting

CalculatingthebalancedfluelengthThe calculated length of the balanced flue system or the flue is derived from the straight pipe length and the length of the pipe bends.Example:

Length of straight balanced flue 1.5 m

Inspection tee 87° = 2 m

2 x 45° bends = 2 x 1 m

L = 1.5 m + 1 x 2 m + 2 x 1 m

L = 5.5 m


Table: Pipe length calculation

Component Calculated length87° bend 1.5 m45° bend 1 m

Tee 87° with inspection aperture

2 m

Straight pipe Subject to length

Versions as condensing boilers Max. length, vertical 1)

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

B23 Flue in a duct and combustion air directly via the boiler (open flue) 30 30 30 30

B33 Flue in a duct with horizontal, concentric connection line (open flue) 30 30 30 30

B33 Connection to a moisture-resistant flue gas chimney with a horizontal concentric connection line (open flue)

Calculation to DIN EN 13384(balanced flue manufacturer)

C33x Vertical concentric roof outlet through a pitched or flat roof, vertical concentric balanced flue for installation in a duct, (balanced flue)

20 20 16 21

C43x Connection to a moisture-resistant balanced flue chimney, maximum pipe length from centre of boiler bend to connection 2 m (balanced flue)


C53 Connection to the flue in a duct and ventilation air line through an external wall (balanced flue)

30 30 30 30

C53x Connection to a flue on an external wall (balanced flue) 30 30 30 30

C83x Connection to the flue in a duct and ventilation air through an external wall (balanced flue)

30 30 30 14

C83x Concentric connection to a moisture-resistant flue gas chimney and combustion air through an external wall (balanced flue)


C93x Vertical flue for installation in a duct, flexibleandrigidwith horizontal concentric connection line

rigidflexible

2719

2719

22 16

202)

493062547_0311

Balancedfluerouting,rigidandflexibleinaduct

Minimum duct sizesRequiredsecondaryventilationtoDIN18160

C93x

Minimum duct sizes forbalancedflueoperationC93x

B23, B33 open flue in a DN80 duct

B23/B33 open flue in a DN80 duct

Assumptions: In the installation room, 2 x tee, 1 x 87° bend + 1.5 m horizontal with 87° support bend

C93x balanced flue

MinimumductsizesforopenflueoperationB23,B33and balancedflueoperationC53(x),C83(x)


C93x

Round Ø SquareDN 80 150 mm 130 mm DN 110 190 mm 170 mm

10

8110 120 130 140 150 160

12

14

16

18

20

22

24

26

28

30

32

COB-29

COB-15/-20

COB-40

Square duct a x a (mm)

Max

. ver

tical

leng

th (m

)

Flue DN80 (COB-15/20/29), DN110 (COB-40)

10

8

12

14

16

18

20

22

24

26

28

30

32

120 130 140 150 160 170 180

COB-40

COB-29

COB-15/-20

Round duct Ø (mm)

Max

. ver

tical

leng

th (m

)Flue DN80 (COB-15/20/29), DN110 (COB-40)

50 3062547_0311

2617

18

20

18

17

18

19

20

18

4 5 4 1610

4 16

23

24

25

26

1

2

16

23

11

4

4

33 33

27 27

510

1

2

16

8

4

5

S

S

16 16 4 55 2829 10

2

4 16

23

24

25

26

27

1

33

ConcentricbalancedflueC33x,C83x,C93xandflueonanexternalwallC53x(examples)DN80/125andDN110/160



4 Balancedflue 500 mm 1000 mm 2000 mm

5 Spacer clip

7 Balancedflue,vertical (roof outlet for flat or pitched roofs)

8 Separator (slide coupling), if required

10 Inspection tee 87°

11 87° bend

16 Rose

17 External wall connection with smooth ends on both sides of the air pipe

18Airinlet,externalwall

19Balancedflue,externalwall

20Walloutlet,externalwall

21 Twin coupling

23 Support rail

24 Support bend 87°

25 Spacer

26PPflue 500 mm 1000 mm 2000 mm

27 Cowl

28 Air pipe

29 Air inlet pipe

33 PP outlet

Install the horizontal flue with approx. 3° fall (6 cm/m) towards the boiler. Route the horizontal air supply with a 3° fall towards the outside – install the air inlet with wind protection; permissible wind pressure at the air inlet 90 Pa. The burner will not operate with higher wind pressure. In a duct, after the support bend (24), a rigid or flexible flue in DN80 can be connected.

Flue on an external wall

C53x C33x, C93x

C83x


approx.1500 mm

513062547_0311

33

8

8

44

4

9

9

3

5

5

10 4 5 11

12

13

6

14

S

S

6 6 6

4

5

4

7 7 7

1

2

1

2

1

2

VerticalconcentricbalancedflueC33x(examples)systemDN80/125andDN110/160



3 Balancedflueincl.inspectionaperture (250 mm long)

4 BalancedflueDN80/125 500 mm 1000 mm 2000 mm

5 Spacer clip

6 Mounting bracket for roof outlet

7 Balancedflue,vertical (roof outlet for flat or pitched roofs)

8 Separator (slide coupling), if required

9 45° bend

10 Inspectiontee,87°

11 87° bend

12 Universaltilefor pitched roof 25° - 45°

13 "Klöber" adaptor 20° - 50°

14 Flat roof collar

Please note: Install the horizontal flue with approx. 3° fall (6 cm/m) towards the boiler. During installation, slide the separator (8) fully into the coupling. Push the next balanced flue (4) 50 mm (dim. "S") into the coupling of the separator, and secure in this location, e.g. with pipe clips DN 125 (5) or a fixing screw on the air side.

Lubricate the pipe ends and gaskets for easier installation (use only grease without silicone).

Determine the required inspection piece (3) (10) with your local flue gas inspector prior to installation.

C33x C33xC33x


NB

52 3062547_0311

32 26 16

23

24

25

26

27

33

1

2

29

31 3230 26 161616

23

24

26

27

1

2

33

33

Balancedfluerouting,openflueB33andB23(examples)DN80/125andDN110/160



4 Balancedflue 500 mm 1000 mm 2000 mm

5 Spacer clip (only if required)

10 Inspection tee 87°

16 Rose

22 Connection to fluegaschimneyB33 length 250 mm with air aperture

23 Support rail

24 87° support bend

25 Spacer

26 PPflue 500 mm 1000 mm 2000 mm

27 Cowl

29 Balancedfluedistributor 80/80 mm

30 Air inlet pipe

31 87° bend

32 Tee 87° with inspection aperture

33 PP outlet

Install the balanced flue distributor eccentrically (29) for separate balanced flue on the oil condensing boiler.Install the horizontal flue with approx. 3° fall (6 cm/m) towards the boiler. Route the horizontal air supply with a 3° fall towards the outside – install the air inlet with a cowl; permissible wind pressure at the air inlet 90 Pa. The burner will not operate with higher wind pressure.

Eccentricbalancedflue(examples)DN80andDN110


C53


B23


B33


approx.1500 mm

1622

23

24

25

26

27

4 510

1

2

33

533062547_0311

SupplementaryinstallationinstructionsforbalancedflueDN80/125

During installation, slide the separator (8) fully into the coupling. Push the next balanced flue (4) 50 mm (dim. "S") into the coupling of the separator, and secure in this location, e.g. with pipe clips DN 125 (5) or a fixing screw on the air side.

Flat roof: Affix the ceiling outlet approx. Ø 130 mm (14) in the roof cover.Pitched roof: At (12), observe the installation instructions on the

cowl regarding roof pitches.

If an inspection aperture is required for the balanced flue, insert a balanced flue with inspection aperture (3) (250 mm long).

Insert the roof outlet (7) from above through the roof and secure vertically with (6) to a rafter or brickwork.Installtheroofoutletonlyinitsoriginalcondition.Modificationsare not permissible.


Wet or lubricate all air/flue gas joints prior to installation, e.g. using a grease without silicone.NB

Fit connection adaptor with test nipple (2) to the oil condensing boiler connection.

Separate the flue via a slide coupling (8)

For inspection purposes, undo and move the inspection piece clamp. Undo and remove the inspection pipe cover.

Inspection piece (3)

Determine distance A. Length of balanced flue (4) always approx. 100 mm longer than distance A. Always trim the flue on the smooth side, never on the coupling side.Chamfertheflueaftertrimming.

Distan

ce A

Offset

11

10

11

11

4

4

Distance A

Distance A

Slide coupling (isolating appliance) (8)

Connection adaptor with test nipple (2)

Bends Offset87° min. 204 mm45° min. 93 mm

7

650

550-1

050

1250

1750-2

300

8

4

5

S

S

4

54 3062547_0311

General notes

Particularly for safety reasons, useonlyoriginalWolfcomponents for flues and concentric balanced flue systems.

Where necessary, adapt the installation examples to the relevant Building Regulations and requirements of your country/region. Discuss any questions relating to the installation of inspection covers and ventilation apertures with your local flue gas inspector.

The electronic flue gas temperature limiter switches the oil condensing boiler off when the flue gas temperature exceeds 120 °C.

The boiler restarts when the reset button is pressed.

Flue gas temperature limiter

The clear cross-section of flues must be able to be inspected. Therefore, install an inspection and/or test aperture inside the boiler room; agree suitable arrangements with your local flue gas inspector.


At low outside temperatures, the water vapour contained in the flue gas may condense and freeze on the balanced flue. This ice may fall from the roof causing injuries or material losses. Prevent ice from falling through on-site measures, e.g. the installation of a snow catcher grille.

Secure the balanced flue or flue outside ducts with spacer brackets with a minimum clearance of 50 cm from the flue outlet or upstream/downstream of diverters to prevent the pipe joints being pulled apart. If this is not observed, there is a danger of poisoning caused by escaping flue gas. Furthermore, equipment damage may result.

A clearance between the concentric balanced flue and combustible materials or components is not required, as temperatures are limited to 85 °C at the rated boiler output.If only a flue is installed, maintain the clearances specified by DVGW/TRGI 86/96 [or local regulations].

Balanced flues without ducts must not be routed through other installation rooms, as there is a risk of fire spreading, and mechanical protection is not ensured.

The combustion air must not be drawn from chimneys that used to carry flue gases from oil or solid fuel boilers.

If the balanced flue crosses different floors, route the pipes outside the installation room inside a duct with a fire resistance of at least 90 min, and in low residential buildings with a resistance of at least 30 min. Fire may spread if these instructions are not observed.

The following applies to boilers with a balanced flue above the roof, where only the roof structure lies above the ceiling:

If fire resistance is required for the ceiling, the pipes for combustion air supply and flue gas exhaustion running between the top edge of the ceiling and the roof skin must be run inside a liner that provides the same fire resistance and is constructed from non-combustible materials. There is a risk of fire spreading if these requirements are ignored.

If fire resistance is not required, route the pipes for combustion air supply and flue gas exhaustion between the top edge of the ceiling and the roof skin inside a duct made from non-combustible, rigid materials or inside a protective metal pipe (mechanical protection). There is a risk of fire spreading if these requirements are ignored.

Condensing boilers with a balanced flue outlet above the roof may only be installed in attics, or in rooms where the ceiling also forms the roof, or where only the roof construction is located above the ceiling.

Connectiontothebalancedflue

Ducts which were previously connected to an oil or solid fuel boiler must be thoroughly cleaned by the flue gas inspector. There must be no dust, sulphur or soot residues left on the inner surface of the chimney. If this is not possible, use a separate ventilation supply. If the combustion air is drawn in via the cleaned duct, the prior use can cause odours in the boiler room.

Flue cascade

Flue cascades are only suitable in balanced flue operation. They must be designed to EN 13984-1.

To prevent flue gas escaping, a flue cascade is only permitted with a tested flue gas damper.

NB

NB

553062547_0311

Connectiontoamoisture-resistantbalancedfluechimneytypeC43x

Straight balanced flues must be no longer than 3 m when connecting the system to a balanced flue chimney. In addition to the boiler connection tee, up to two 90° diverters may be installed.The balanced flue chimney must be CE-designated.

Connectiontoamoisture-resistantfluetypeB23foropenflueoperation

The straight, horizontal flue must be no longer than 3 m. In addition to the boiler connection tee, up to two 90° diverters may be installed in the horizontal flue.The flue gas chimney must be CE-designated.

The straight, horizontal flue must be no longer than 3 m. For horizontal air supply pipes, a maximum length of 3 m is recommended. Observe special requirements for flues that are not surrounded by combustion air in accordance with locally applicable combustion regulations.

Connectiontoamoisture-resistantfluetypeC53,C83xforbalancedflueoperation

Connection to a combustion air andflue system typeC63x that is not tested together with the oil combustion equipment

Original Wolf components are designed for long-term use and are matched for use with Wolf oil condensing boilers. When using CE-designated third party equipment, the installer is responsible for the correct sizing and perfect function of such systems. Faults, material losses and injuries resulting from incorrect pipe lengths, excessive pressure drop, premature wear with escaping flue gas and condensate or incorrect function, e.g. through components working themselves loose, are excluded from our warranty if non-approved third party equipment is used.

Straight balanced flues must be no longer than 3 m, when connectingthesystemtoacombustionairsupplyandaseparateflue.In addition to the boiler connection tee, up to two 90° diverters may be installed. The chimney must be free from contamination if the combustion air is drawn from the chimney.

Connectiontoamoisture-resistantfluegaschimneyorafluesystemtypeB33foropenflueoperation

Straight balanced flues must be no longer than 3 m when connecting the system to a flue gas chimney. In addition to the boiler connection tee, up to two 90° diverters may be installed.The flue gas chimney must be CE-designated.If necessary, the flue outlet should be obtained from the chimney manufacturer.The air apertures to the boiler room must be completely free from obstruction.


56 3062547_0311

32. Wiring diagram

SF

12

gn

/ge

br

bl

32

1

LN

NL

NN

NL

LN

LN

LL

NN

+-

~+

+-

-+

-~

~~

~~

+-

++-

++

+-

--

~~

++

-

eBUS

eB

US

gn

ge

rt

GND

GND

R6

80

12V

+

+

-

-

GND0,5..4,5V

GND5V

>

X1

X2

X3

X6

X4

X7

X5

X8

br

wsgn

br

gnrt

gews

br

gnbr

br

gn

gews

gn

sw

bl

br

rt

rt

bl

br

sw

br

br

bl

bl

br

br

vio

br

sw

or

gn

bl

rt

ge

ws

ge

gn br

A2

A1

AF

E1

eB

US

+-

12

ab

L1

oo

oo

oo

oo

oo

12

12

12

12

rt

gn

sw

bl

or

vio

br

ge

rt

L1

L1

rt

sw

>

ws g

e

gn

br

S4

>

ge

gn

ws

br

ge

5 4 3

3

2

2

1

1

br rt gn

345 2 1

P

gra

u

Ne

tzK

KP

LP

N

N

NL

1L

1M

T

5A

F1

br

bl

gn/ge

sw

ws

L1

NL1

NN

L1

NN

XXX

12

34

56

bl

br

gn

/ge

12

3

PE

PE

PE

PE

NN

NL

LL

br

bl

gn

/ge

PW

M

N-Klemme

Term

inal

box

:M

ains

23

0 VA

C 5

0 Hz

LP

Externalprim

arypu

mp

23

0 VA

CE1

Pr

ogra

mm

able

inpu

teB

US

BUSconn

ectio

nfore

xternal

co

ntro

l acc

esso

ries

KK

P H

eatin

g ci

rcui

t pum

pA

F O

utsi

de te

mpe

ratu

re s

enso

rSF

Cylinders

ensor

Mains

Accessories

Primary pumpOutput A1

Heating circuit pump

Stratification pump

Oil pumpN terminal

Ignition

Oil preheater

L valves

Valve 1Valve 2

Input E1Outside temperature sensor

PWM stratification pump


Flow sensor

Speed

TW flowTW flue gas

External boiler monitoring

Cylinder sensor

Fan

X10

(ear

th

cond

ucto

r te

rmin

al)

X9

boile

r cod

ing

card

eBU

S p

lug

PW

M s

tratifi

catio

n pu

mp

Faul

t mes

sage

, co

nden

sate

pum

p

B1

(flow

sen

sor)

E1

(igni

tion

trans

form

er)

Y2

(val

ve 2

)Y

1 (v

alve

1)

Out

put A

1

M3

(oil

pum

p)

Bur

ner

M4

(fan)

S4

(wat

er p

ress

ure

switc

h)

S2

(TW

flue

gas

)

S1

(TW

flow

)

Stra

tifica

tion

sens

or

Jum

per

M1

(stra

tifica

tion

pum

p)

B3

(IRD

)

eBUS

grey

GND5 V

0.5..4.5 VGND

Mai

ns

bn

bu

gn/ye

wh

bk

rd

yebkog

vt

bngn

rd

bu

gn ye rd GND

bn

bl

bn

bl

rd

bn

bk

bn

rd

bl

bn

rd

rd

bn

bl

bk

og

vt

bkyebn

gn

blrd

gn

bngnbngn

bnwhye

rd

gnbn

whgn

wh

gn

bn

ye

ye bn gn wh

bn rd gn

bngn

/ye

bl

bn bl

gn/y

e

bn bl

gn/y

e

wh

ye gn bn

wh

ye gn bn

573062547_0311

33. ResetReset Observe the following steps to implement a reset:

- The ON/OFF switch must be set to O (OFF).- Press and hold down the reset button on the standard control unit whilst setting the ON/OFF switch to I (ON).- Hold down the reset button again for at least 2 seconds after switching on the system.

All parameters (individual settings) are returned to their factory settings by a reset.

0I

0 °C

20

40

60

80

100

120

ON/OFF switchReset button

58 3062547_0311

34. TroubleshootingAny faults will be displayed as fault code by Wolf control accessories with eBUS capability. The cause and remedy for a fault can be established using the following table. This table is designed to allow your local heating contractor to trace the fault more easily.

Fault code

Fault Cause Remedy

1 Excess temperature (high limit safety cut-out)

The flow temperature has exceeded 110 °C Test heating circuit pump, vent system, press reset, clean heat exchanger

4 No flame established

No flame at burner startInspection window for flame monitor/mixer head contaminated Faulty flame monitor Air in oil line Negative pressure at oil pump too high, max. 0.3 bar Overpressure at oil pump too high, max. 0.5 bar

Check oil line, if necessary check fuel level, check ignition electrode and ignition transformer, press reset Check inspection window for flame monitor/mixer head Check flame monitor and leadSiphon backpressure

5 Flame failure during operation

Flame failure during safety time Negative pressure at oil pump too high, max. 0.3 bar, flue gas recirculation (flue gas in the ventilation air)

Check CO2 values, check flame monitor and lead, press reset, check flue system for leaks

6 TW excess temperature The flow has exceeded the limit of the temperature limiter (100 °C)

Vent the system, check the heating circuit pump

7 Flue gas sensor excess temperature

The flue gas temperature has exceeded 120 °C Clean heat exchanger, check whether all displacement devices are installedCheck the flow through the boilerCheck boiler flow / boiler returnpress reset

8 Flue gas/ventilation air damper does not move

Flue gas/ventilation air damper contact (E1) fails to close or open when there is a demand

Check flue gas/ventilation air damper and wiring

11 Flame pretence A flame is recognised before the burner starts Press the resetCheck solenoid valve for oil pump

12 Faulty boiler sensor Faulty boiler sensor or lead Check sensor and lead14 Faulty cylinder sensor

SFFaulty cylinder sensor or lead Check sensor and lead

15 Faulty outside temperature sensor

Faulty outside temperature sensor or lead Check sensor and lead

25 Fan fault The fan does not reach the set speed Check power cable to fan and check fan;Check that the condensate can drain off freely from the balanced flue systempress reset

26 Fan fault The fan does not stop Check power cable to fan and check fan; press reset

27 Faulty stratification sensor

Faulty stratification cylinder sensor or lead Check sensor and lead

40 Insufficient water pressure

The pressure switch does not switch on, water pressure is too low (< 0.8 bar)

Check system pressure >1.5 bar Check water pressure switch, check lead, press reset

593062547_0311

34. Troubleshooting

Fault code

Fault Cause Remedy

42 Condensate pump is not pumping anything out

Faulty condensate pump, drain line blocked, no power supply to pump

Check pump, check drain line, check mains plug and fuse

52 Max. cylinder heating time exceeded

Set cylinder temperature is not being reached, insufficient flow

Vent cylinder, increase cylinder heating time (HG20), check cylinder sensor assembly

78 Header sensor fault Faulty header sensor or lead Check sensor and leadInsufficient heating system heating, frequent cycling

Air in the heating or cylinder system Vent radiators, vent cylinder primary circuit, vent heating circuit pumps, vent boiler

No DHW heating Sensor is not detected by the boiler Switch boiler off and on; sensor will be detected on restarting

Gerdewan JacobsTechnical Management

Mainburg, 21 April 2010

DECLARATION OF CONFORMITY(to DIN EN ISO/IEC 17050-1)

Number: 3062547

Issued by: Wolf GmbH

Adress: Industriestraße 1, D-84048 Mainburg

Product: Oil condensing boiler COB/COB-CS

Theproductdescribedaboveconformstotherequirementsspecifiedinthefollowingdocuments:

DIN EN 230, 10/2005DIN EN 303, 12/2003DIN EN 304, 01/2004DIN EN 15034, 01/2007DIN EN 15035, 05/2007DIN EN 12828, 06/2003DIN EN 61000-3-2, 03/2010DIN EN 61000-3-3, 06/2009DIN EN 61000-4-3, 06/2008DIN EN 55014-1, 02/2010DIN EN 60335-1, 02/2007DIN EN 60335-2-102, 04/2007DIN EN 60529, 09/2000

In accordance with the following Directives

92/42/EWG (Efficiency Directive)2004/108/EG (EMC Directive)2006/95/EG (Low Voltage Directive)

thisproductisidentifiedasfollows:

Klaus GrabmaierProduct approval

0085

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

oil condensing boiler - centrogulf

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