Installation and maintenance instructions Wall mounted gas ... condensing boiler 2... · CGU-2 -...

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Installation and maintenance instructions

Wall mounted gas fired combi boilers and wall mounted gas fired boilers with integral cylinder connection

Wolf GmbH • Postfach 1380 • D-84048 Mainburg • Tel. +49-8751/74-0 • Fax +49-8751/741600 • Internet: www.wolf-heiztechnik.deArt.-Nr.: 3062347_201507 Subjecttomodifications GB

CGU-2-18/24CGG-2-18/24CGU-2K-18/24CGG-2K-18/24

2 3062347_0309

General information

Safety instructions / Standards and regulations ..................................................................... 3-5

Installation and commissioning

Dimensions ............................................................................................................................... 6 Layout / Equipment code........................................................................................................ 7-9 Positioning information / Installation dimensions................................................................ 10-11 Installation on finished walls / Installation on unfinished walls ................................................................................................ 12 General boiler installation ........................................................................................................ 13 Electrical connection ......................................................................................................... 14-17 Fill / Vent the system. .............................................................................................................. 18 Guidelines for commissioning ................................................................................................. 19 Control / Function / Commissioning ................................................................................... 20-21

Setting and adjusting the boiler

Displaying / Modifying control parameters ........................................................................ 22-30 DHW connection versions / Resetting control unit .................................................................. 31 Setting the eBUS address for cascade mode ......................................................................... 32 Commissioning gas connection............................................................................................... 33 Conversion to other gas types / Nozzle change ...................................................................... 34 Setting the control unit after converting the gas type .............................................................. 35 Checking nozzle pressure .................................................................................................. 36-37 Resetting gas valve / Setting nozzle pressure ........................................................................ 38 Adjusting the flue lengths CGG-2(K) ....................................................................................... 39 Flue gas test CGU-2(K) CGG-2(K) ......................................................................................... 40

Limiting the maximum output .................................................................................................. 41 Selecting the pump stage / Bypass .................................................................................... 42-43 Checking the flue gas monitoring CGU-2(K) ........................................................................... 44 Notes on planning ventilation / Flue gas system CGU-2(K) ................................................................................................ 45-49 Commissioning report ............................................................................................................. 50

Maintenance and additional information

Inspection and maintenance steps .......................................................................................... 51 Service report .......................................................................................................................... 52 Maintenance ....................................................................................................................... 53-57 Wiring diagram CGU-2(K) ....................................................................................................... 58 Wiring diagram CGG-2(K) ....................................................................................................... 59 Specification ....................................................................................................................... 60-61 Fault / Cause / Remedy........................................................................................................... 62 Resistance table ...................................................................................................................... 63 Product data sheet according to EU regulation no. 811/2013 ................................................. 64 Technical parameters according to EU regulation no. 813/2013 ............................................. 65 Keyword index .................................................................................................................... 66-67 EC declaration of conformity ................................................................................................... 68

Contents

33062347_0309

"Safety instructions" are instructions with which you must comply exactly, to prevent risks and injuries to individuals and material losses.

The following symbols and reference symbols are used in this description. These important instructions concern personal safety, as well as operational reliability.

"Note" indicates technical instructions that you must observe to prevent material losses and boiler malfunctions.

Note

D a n g e r t h r o u g h ' l i v e ' e l e c t r i c a l components.Please note: Switch OFF the ON / OFF switch before removing the casing.

Never touch electrical components or contacts when the ON / OFF switch is in the ON position. This results in a risk of electrocution that poses a danger of injury or death.

The main supply terminals are 'live' even when the ON / OFF switch is in the OFF position.

Fig.: Terminal box: Danger from electric current

Fig.: Gas connection: Escaping gas may cause poisoning or the risk of explosion

Fig.: Ignition transformer, high voltage ignition electrode, combustion chamberRisk through 'live' electrical components, risk of burning through hot components

Fig.: Gas combination valve:Danger from electric currentEscaping gas may cause poisoning or the risk of explosion

Balanced flue operated gas boilers must only be installed in a room that complies with the appropriate ventilation requirements. Otherwise there is a risk of asphyxiation or poisoning. Read these installation and maintenance instructions before installing the boiler. Also take the technical guide into consideration.

Safety instructions / Standards and regulations

4 3062347_0309

Safety instructions / Standards and regulationsPlease follow these safety instructions closely to prevent accidents and material losses.

Commissioning - Commissioning must only be carried out by the system installer or a commissioning engineer designated by him. All actual values must be recorded in a commissioning/service report that should be kept with these instructions.

Safety regulations - Observe all national safety regulations and installation requirements.

- Installation, commissioning, inspection, maintenance and repairs must only be carried out by a competent person (heating engineer / installation contractor).

- Before working on the equipment / heating system, switch OFF the power supply (e.g. by removing a separate mains fuse or by means of a main electrical isolator) and safeguard against unauthorised reconnection.

- Disconnect the system by means of an appliance that isolates all non-earthed conductors simultaneously with at least 3 mm contact separation.

- It is not permitted to carry out repairs on parts that fulfil a safety function.

- Use only original WOLF replacement parts or those that are equivalent and that have been approved by the manufacturer.

Instructing the system user

- The system installer must hand the operating instructions to the system user and instruct them in the operation of the system.

Only use propane compliant with local regulations, otherwise faults may arise with the starting characteristics and operation ofthewallmountedgasfiredboiler;thisinturn,mayleadtoboiler damage and risk of injury.

Poorly vented LPG tanks can lead to ignition problems. In such cases, contact your local LPG supplier.

Note: Please read these instructions carefully before the installation and keep them in a safe place. Please also note the technical information in the appendix.

Anydamageorlossresultingfromtechnicalmodificationstothe control unit or to the control components are excluded from our liability.Incorrect use can lead to a risk to life and limb or to a risk of material losses.

Obtainthepermissionofyourgassupplyutility,thefluegasinspectorand the lower water authority [where appropriate] prior to the installation ofWolfgasfiredboilers.

53062347_0309

Safety instructions / Standards and regulationsStandards and regulations

Category: II2ELL3P<DE> and II2H3P<AT>NOx class: 5Flue types: CGG-2: C12x, C32x, C42x, C52, B32 CGU-2: B11BSOperating mode: open / balanced flueTo be connected to: chimney, flue chimney / balanced flue system

- Obtain the permission of your mains gas supplier and all relevant authorities prior to the installation of Wolf gas fired combi boilers.

- Open flue gas fired boilers must only be installed in a room that complies with the appropriate ventilation requirements.

- in accordance with the Directive 2009/125/EC (Ecological Design Directive) applies from 26/09/2015 for the CGU-2K:

This boiler with natural draught is intended for connection exclusively to a flue gas system in existing buildings to which several dwellings are connected and which removes the combustion residues from the installation room into the open air. It draws its combustion air directly from the installation room and is equipped with a draught safeguard. Due to lower efficiency, every other use of this boiler is to be avoided - it would lead to higher energy consumption and higher operating costs.

- Boiler room guidelines or Building Regulations relating to the construction and installation of central boiler rooms and fuel storage facilities

- Technical regulations for gas and DHW installations DVGW-TRGI 1996 and TRF 1996

(in the currently applicable form)

Thegasfiredboilermeetswiththefollowingregulations

EC Directives- 2006/95/EC Low Voltage Directive- 2004/108/EC EMC Directive- 90/396/EEC Gas user equipment- 92/42/EEC Efficiency directiveDIN / EN Standards- EN 297; EN298; EN 483; EN 625;

EN 55014-2; EN 60335-1; EN 60335-2-102; EN 60529; EN 61000-3-2; EN 61000-4-3

The following regulations, rules and guidelines must be observed during installation:

DIN / EN Standards- EN 437 Test gases; test pressures;

appliance categories- DIN EN 1283 Procedure for calculating the

standard heating load- DIN EN 12828 Heating systems in buildings- DIN EN 1717 Protection of DHW against

contaminations in DHW installations

- DIN EN 50156-1 (VDE 0116 part 1) Electrical equipment for combustion systems

- On site regulations from building and industry regulatory agencies (mainly covered by the emission test switch)

- On site regulations from the gas supply utility

6 3062347_0309

440

Dimensions

Gas fired combi boilers

Gas fired boilers

1 Heating flow Heating flow2 DHW DHW flow3 Cold water DHW return4 Heating return Heating return5 Gas connection Gas connectionInstallation inside a cupboardFor installation of the gas fired boiler inside a cupboard note the following:

Never install the gas fired boiler on the back wall of the cupboard, as it may not be substantial enough to take the boiler's weight. This would create the risk of water and gas leaks which in turn would result in a risk of explosion and flooding.

- Removing the rear wall of the cupboardMinimum lateral clearance between the gas fired boiler and the cupboard sides 25 mm.

A cutout of 410 x 550 mm is required in the cupboard top. Otherwise there is a risk of suffocation and poisoningWith open flue gas fired boilers the ventilation grill in the cupboard door must be installed with a free minimum diameter of 600 cm2

Otherwise there is a risk of suffocation and poisoning

3

12

4

5

31 2 4 5

Min

.400

Min

.400

>25

694

366

CG

U-2

(K) 1

8

380

CG

U-2

(K) 2

4

258

CG

G-2

(K) 1

8/24

344

120176

170

3949

855

393

190226

(CGG-2)(CGU-2)

73134

73062347_0309

Layout CGU-2(K) 18/24

Combustion chamber

Internal fillingequipment (optional)not <DE><AT>

Gas combination valve

Expansion vessel

Three-waydiverter valve

Flow sensor 2

Limit thermostat

Monitoring electrode

Ignition electrode

Heating water heat exchanger

Safety valve

Drain valve

DHWFlow & temperature sensor

Flow sensor 1

Draught hood

Gas burner

Heating circuit strainer

Cold water strainer with throughput

limiter

Heating circuit pump

Air vent

Bypass

Flue gas temperature limiter

HZ - VL HZ - RL

8 3062347_0309

Layout CGG-2(K) 18/24

Flue gas fanwith speed regulation

Combustion chamber

Internal fillingequipment (optional)not <DE><AT>

Gas combination valve

Expansion vessel


Flow sensor 2

Limit thermostat

LAF connection

Monitoring electrode

Ignition electrode


Differential pressure switch

Safety valve

Drain valve

DHWFlow & temperature sensor

Flow sensor 1

Flue gas collector

box

Gas burner


Cold water strainer with throughput

limiter


Air vent

BypassHZ - VL HZ - RL

93062347_0309

Layout / Equipment code


Gas burner

Gas combination

valve

Expansion vessel

Air vent


DHW heat exchanger

Safety valve

Drain valve


Cold water strainer with throughput limiter

Limit thermostatflow

Flow sensor 2

Flow sensor 1


DHW flow& temperature sensor(only combi boilers)Bypass valve

Hydro Tec system(integrated components)

Overflow valve

Flue gastemperature limiter

Wolf Low NOx unit with hydro tec system (plug-in technology for quick installation) compactlydesignedforlowemissions,highenergyefficiency.

DHWheatexchangerandDHWflowtemperaturesensoronly with combi boilers

CGU-2 - 18/24 Open flue gas fired boiler with integrated cylinder connectionCGU-2 K - 18/24 Open flue gas fired combi boilerCGG-2 - 18/24 Balanced flue gas fired boiler with integrated cylinder connectionCGG-2 K - 18/24 Balanced flue gas fired combi boiler

Equipment codes

10 3062347_0309

Balancedfluegasfiredboilersmustonlybe installed in a room that complies with the appropriate ventilation requirements. Otherwise there is a risk of asphyxiation or poisoning. Read these installation and operating instructions before installing thegasfiredboiler.Alsotakethetechnicalguide into consideration.

Sound insulation:Under certain critical installation conditions (e.g. installation on a drywall) additional measures may be necessary to soundproof the boiler. In this case use soundproof plugs and, if necessary, rubber buffers or insulation strips.

Positioning information / Installation dimensions

l.h. turnbuckle r.h. turnbuckle

Fig.: Opening the turnbuckle

- Determine the installation location for the gas fired boiler; maintain the specified minimum clearances (see dimensions).

- Fit the supplied installation template (paper poster) to the wall.

- Transfer the fixing hole and connection positions marked on the installation template to the wall (e.g. with a power drill).

- Remove the installation template.- Drill Ø 12 mm holes for the mounting bracket and

secure the bracket using the rawl plugs and screws supplied. (Before securing the bracket, check that the rawl plugs are suitable for the wall construction.)

- Remove the casing lid of the gas fired boiler. For this, pivot the control unit lid down, hook in the r.h. and l.h. turnbuckle, undo the bottom of the casing lid and unhook at the top.

- Hang the gas fired boiler with the hook-in brace on the back of the boiler onto the mounting bracket.

General

The gas fired boiler may only be installed in rooms that are protected from frost.

During the boiler installation ensure that all fixings are sufficiently strong to carry its weight. Also consider the wall consistency, otherwise gas or water may escape which could lead to explosions and flooding. It can also lead to noise developing.During the boiler installation, ensure that no contaminants (e.g. drilling swarf) enter thegasfiredboilerotherwise faultsmaydevelop.The combustion air supplied to the boiler must be free from chemicals, e.g. fluoride, chlorine or sulphur. Such materials are contained in sprays, solvents and cleaning agents. Under the most unfavourable conditions, these may lead to corrosion, even in the flue gas system.

Note

500

25 25

(CGU-2-18) Ø110 (CGU-2-24) Ø130

(CG

U-2

) min

.400

(CG

G-2

) m

in.2

00

(CGG-2-18) Ø100

1212

344

min

.200

1478

113062347_0309

Positioning information / Installation dimensions

Installation dimensions of the boiler with freestanding cylinder SW-120 / CSW-120Installationonunfinishedwalls

Installation dimensions of the boiler with freestanding cylinder SW-120 / CSW-120Installationonfinishedwalls

1754

- 19

04

790

270

- 420

694

5

100

100547

1143

CG

U-2

(K) 1

811

57 C

GU

-2(K

) 24

1035

CG

G-2

(K) 1

8/24

393

1754

- 19

04

790

270

- 420

694

5

100

100547

1123

CG

U-2

(K) 1

811

37 C

GU

-2(K

) 24

1015

CG

G-2

(K) 1

8/24

393

12 3062347_0309

Installationonfinished/unfinishedwalls

Fig.: View from below, connection set for installation on finished walls

Installationonunfinishedwalls(accessory)

Fig.: Front view, connection set for installation on unfinished walls

Fig.: View from below, connection set for installation on unfinished walls

Installationonfinishedwalls(accessory)

Fig.: Front view, connection set for installation on finished walls

Heating flow Rp ¾" DHW Rp ¾" (gas combi boilers) Cold water Rp ¾" (gas combi boilers) Heating return Rp ¾" Gas connection Rp ½"Drain for safety valve R 1"

With boilers that are not used for DHW, seal the cold and DHW connections with locking cap G ¾" (accessory).If this is not done then the building and equipment may be damaged through uncontrolled water leakages.

Heating flow R ¾" DHW R ¾" (gas combi boilers) Cold water R ¾" (gas combi boilers) Heating return R ¾" Gas connection R ¾"Drain for safety valve R 1"

50

180

73

164

94 84

120

200

164

120

200

19010

7

6 662 57

133062347_0309

General boiler installation

Gas connection

Laying the gas pipe, as well as making the gas connections, must only be carried out by a licensed gas fitter. Close the gas ball valve on the gas fired combi boiler to pressure test the gas pipe.Remove all residues from the heating pipework and the gas pipe prior to connecting the gas fired boiler, particularly in older systems.Prior to commissioning, test all pipe and gas connections for leaks.Inappropriate installation or using unsuitable components or assemblies may lead to gas escaping, which results in a risk of poisoning and explosion.

The gas valve can be subjected to a maximum pressure of 150 mbar. Higher pressure may damage the gas valve, resulting in a risk of explosion, asphyxiation or poisoning. Close the gas ball valve on thegasfiredboiler to pressure test thegas pipe.

Install a tested and certified pressure reducer, if the cold water supply pressure is above the maximum permissible operating pressure of 10 bar. Otherwise water could escaperesultinginariskofflooding.

Fig.: Cold water connection

Cold water and DHW connection

For the cold water and DHW connection, we recommend installation in accordance with the diagram below.

- Wolf connection sets (accessories) are available for installation on finished and unfinished walls. The connection pipes are Cu 18x1.

Hydraulic connections

Note: As standard, a combined cold water strainer with throughput controller is fitted at the cold water connection of the boiler (see Fig.).

Fig.: Throughput controller with cold water strainer

Installation inside a cupboard

For installation of the gas fired boiler inside a cupboard note the following:

Never install the gas fired boiler on the back wall of the cupboard, as it may not be substantial enough to take the boiler's weight. This would create the risk of water and gas leaks which in turn would result in a risk of explosion and flooding.Removing the rear wall of the cupboardMinimum lateral clearance between the gas fired boiler and the cupboard sides 25 mm.

A cutout of 410 x 550 mm is required in the cupboard top. Otherwise there is a risk of suffocation and poisoningWith open flue gas fired boilers the ventilation grille in the cupboard door must be installed with a free minimum diameter of 600 cm2.Otherwise there is a risk of suffocation and poisoning.

As the cold water strainer may need to be cleaned, provide a facility for its removal in site.

Otherwise there is a risk of faults.

Dra

in

Dra

in

Shu

t-off

valv

e

Pre

ssur

e re

duci

ng v

alve

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

Note

[2]

[1]

14 3062347_0309

Electrical connection CGU-2(K) / CGG-2(K)

General notes

The installation must be carried out by a licensed electrical contractor. Observe the regulations of the relevant authorities and the local regulations of the power supply company.

The power supply terminals are 'live' even when the ON/OFF switch has been switched OFF.

Terminal box

Terminal box

The control, regulating and safety equipment are fully wired and tested.You only need to connect the power supply and the external accessories.

Power supply connection

Connect the power supply permanently or with a safety plug (no plug connection in protective areas 1 and 2, i.e. near a bath or shower).

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.Connection cable flexible, 3 x 1.0 mm² or rigid, max. 3 x 1.5 mm².The plug must be accessible when using a power supply cable with safety plug. Flexible power supply cable 3 x 1.0 mm².

No further loads may be connected to the connecting cable. The appliance may be connected only via a residual current circuit breaker in rooms with a bath tub or shower.

153062347_0309

Fluegasdamperconnection(230V;max.200VA)

Insert the cable glands into the terminal box. Insert and secure the connecting cable through the cable gland. Connect the connecting cable to terminals L1, N, and .

In order to prevent overtemperatures in the flue gas collection box, the flue gas flap is closed with a delay of 30 seconds each time after the burner is switched off.

Fig.: Flue gas damper connection

Changing a fuse

Isolate the boiler from the main supply prior to changing a fuse. The ON/OFF switch on the boiler does not provide separation from the power supply.

Danger through 'live' electrical components. Never touch electrical components or contacts if the boiler has not been isolated from the power supply. Danger of death.

Fig.: Pivot the control unit forward, terminal box cover open

Fuse

Electrical connection CGU-2(K)

Connection to OutputA1(230VAC;max.200VA)

Insert the cable glands into the terminal box. Insert and secure the connecting cable through the cable gland. Connect the connecting cable to terminals L1, N and .

Fig.: Connection output A1

Installation information, electrical connection

- Isolate the system from the power supply before opening the casing.

- Pivot the control unit to the side.- Open the terminal box.- Insert the strain relief into the holes provided.- Strip approx. 70 mm off the power supply cable

insulation.- Push the cable through the strain relief and

secure the strain relief.- Pull the Rast-5 plug.- Terminate the appropriate cores at the Rast-5 plug.- Push the inserts back into the terminal box casing.- Push the Rast-5 plugs back into the correct

positions.

A Mains connection 230 VAC/50 HzC Programmable output A1G Flue gas damper connectionD Programmable input E1 zero voltE 2-wire eBUS connection, digital Wolf control

accessoriesF Outside temperature sensor

A C G D E F

.

230 V < 24 V

230 V < 24 V

16 3062347_0309

Electrical connection CGU-2(K)

Fig.: Connection DHW circulation pump / external accessories

Changing a fuse

Isolate the boiler from the main supply prior to changing a fuse. The ON/OFF switch on the boiler does not provide separation from the power supply.

Danger through 'live' electrical components. Never touch electrical components or contacts if the boiler has not been isolated from the power supply. Danger of death.

Fig.: Pivot the control unit forward, terminal box cover open

Fuse

ConnectiontoOutputA1(230VAC;max.200VA)

Insert the cable glands into the terminal box. Insert and secure the connecting cable through the cable gland. Connect the connecting cable to terminals L1, N and .

Fig.: Connection output A1

Installation information, electrical connection

- Isolate the system from the power supply before opening the casing.

- Pivot the control unit to the side.- Open the terminal box.- Insert the strain relief into the holes provided.- Strip approx. 70 mm off the power supply cable

insulation.- Push the cable through the strain relief and

secure the strain relief.- Pull the Rast-5 plug.- Terminate the appropriate cores at the Rast-5 plug.- Push the inserts back into the terminal box casing.- Push the Rast-5 plugs back into the correct

positions.

Power supply for external accessories (230VAC;max.200VA)

Insert the cable glands into the terminal box. Insert and secure the connecting cable through the cable gland.Connect the connecting cable to terminals L1, N and .

Netz Z A1

N

N

NL1L1 L1

L1 L1L1 N NN

3

Z A1

N

N

NL1L1 L1

L1 L1L1 N NN

3

Netz

A Mains connection 230 VAC/50 HzB Power supply, ext. Accessories

230 VAC/50 Hz/max. 200 VAC Programmable output A1D programmable input E1 zero voltE 2-wire eBUS

connection, digital Wolf control accessoriesF Outside temperature sensor

A B C D E F

230 V < 24 V

230 V < 24 V

173062347_0309

Connection, analogue outside temperature sensorThe analogue outside temperature sensor for digital control accessory (e.g. BM) may be connected to the terminal strip of the gas fired boiler at the connection AF or the terminal strip of the BM.

Fig.: Connection, analogue outside temperature sensor

Connection of digital Wolf control accessories (e.g. BM, MM, SM1, SM2, KM)

Only connect control units from the Wolf accessory range. Each accessory is supplied with its own connection diagram.Use a 2-core cable (cross-section > 0.5 mm²) as the connecting cable between the control unit accessory and the gas fired boiler. Fig.: Digital Wolf control accessories connection (eBUS

interface)

Electrical connection CGU-2(K) CGG-2(K)

Fig.: Connection, programmable input

Connection, programmable input E1 (<24 V)

Connect the connecting cable for input 1 at terminals E1 in accordance with the wiring diagram; first remove the jumper between a and b from the respective terminals.

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

DHW tank sensor connection

- When a cylinder is to be connected, the blue socket of the cylinder sensor must be connected to the blue plug of the control unit.

- Observe the cylinder installation instructions.

Fig.: Blue plug, cylinder sensor connection

Blue plug

NotePay attention + , -to polarity

18 3062347_0309

Fill / vent the system

Procedure for boilers withinternalfillingfacilitynot for <DE> <AT>

- Filltheentireheatingsystemandboilerviathefillingfacilityoranon-sitefill&drainvalveuptoapprox.0.5-1bar,whilstsimultaneouslyventingtheheating system.

- Close the shut-off valves on the heating water side of the boiler (flow and return).

- Push the drain hose onto the drain valve of the hydraulic assembly.

- Clean theheatexchangerbyopening the internalfilling facilityand thedrain valve simultaneously on the hydraulic assembly (make sure there is no air remaining in the heat exchanger).

Procedure for boilers withoutinternalfillingfacility

Filling the system Fill the system and vent it thoroughly to safeguard the perfect functionofthegasfiredboiler. Otherwise there is a risk of faults.

Theheatingwatermustnotbemixedwithinhibitorsorantifreeze;otherwiseleaksandfloodingcouldresult.

- Close the gas ball valve.

- Beforeconnectingthegasfiredboilertotheheatingsystem,flushtheentiresystem to remove residues such as welding pearls, hemp, putty, etc. from the pipework and to remove air that may have collected.

- Fill the DHW system of the boiler until water flows out of a DHW draw-off point.

- To fill the heating system use the fill & drain connections. Open the cap of the automatic air vent valve on the heating circuit pump by approx. 2 revolutions, but do not remove the cap.

- Open all radiator valves and the shut-off valves on the heating water side of the boiler.

- Fill theentireheatingsystemandboilerviathefill&drainvalves(Wolfaccessory) up to approx. 0.5 bar, whilst simultaneously venting the heating system.

- Close the return shut-off valve on the heating water side of the boiler.

- Attach drain hose to the drain valve on the hydraulic assembly (alternative, if only a fill & drain connection is provided).

- Cleantheheatexchangerbyopeningthefill&drainvalveand/orthedrain valve simultaneously on the hydraulic assembly (make sure there is no air remaining in the heat exchanger).

- Remove the drain hose and open the boiler shut-off valve(s) on the heating water side again.

- After venting, raise the system pressure to 2.5 bar.

- Start the boiler, set the heating water temperature selector to position "2" (pump running, illuminated signal ring (status display) constantly green).

- Ventthepump;forthis,brieflyopenandthenretightentheairventscrew, optimum venting in pump stage 3.

Top up with water when the system pressure falls severely.

- Open the gas shut-off valve. Press the reset button.

- When in constant use the heating circuit vents automatically via the heating circuit pump, venting optimum at pump stage 3. After venting set to pump stage 1 or 2 for reduced noise, depending on customer preference.

- At system pressure below 1.0 bar the boiler may experience faults. If necessary fill on heating side.

Internal filling facility not for <DE><AT>

Drainvalve

Fig.: Shut off valves (accessory)

Gas shut-off valve

Heating flow(incl. fill & drain connection)

Heating return(incl. fill & drain connection)

Automaticair-vent valve

Fill & drain Connection

Note

193062347_0309

- Instruct the customer about energy-saving options.Saving energy

Commissioning guidelines Onlyqualifiedpersonnelmustcarryoutthecommissioningandinitialstart-up of the boiler as well as instruct the user.

Guidelines for commissioning

- Flushandventboiler(useshut-offvalvewithfill&drainvalvefromWolfaccessoryrange),fillboilerandsystemandtestfortightness.Normaloperating pressure when system is cold 1.5 bar. Prevent water leaks.

- Check location and seating of the installation.

- Check the gas supply pressure.

- Check all connections and component links for leaks.

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

- Checkthatallfluegasaccessorieshavebeencorrectlyinstalled.

- Openthewaterandshut-offvalvesonflowandreturn.

- Open gas connection.

- Switch ON emergency heating switch and switch ON the ON/OFF switch on the control unit.

- Checktheadjustmentofthefluelength,resettingifrequired. Seechapter"Adjustingthefluelength".

- Checktheignitionandflamestructureoftheburner.

- The illuminated ring shows a yellow colour, if the boiler starts correctly.

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

- Complete the commissioning report and hand over the instructions to the customer.

- Implement the "Installation" and "Electrical connection" of the boiler and all extension and programming modules in accordance with the instructions in the associated manuals.

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

Step 7

Step 8

Step 9

Step 10

Step 11

Step 12

Step 13

Step 14

Step 15

Note Otherwise there is a risk of faults.

20 3062347_0309

Control / Function / Commissioning

ON / OFF switch DHW temperature

selectorPressure

gauge

Reset button

Heating water temperature

selector

Illuminated signal ring

Thermometer

91

2 8

3 7

4 65

DHW temperature selectorSettings 1-9 correspond with a DHW temperature of 40-65 °C with gas combi boilers, or 15-65 °C with gas boilers with a cylinder. Combined with a control thermostat for wall mounted gas fired boilers, the adjustment at the DHW temperature selector is disabled; instead the temperature is selected at the boiler control thermostat.

2 8

3 7

4 65

Heating water temperature selectorSettings 2-8 correspond to a heating water temperature of 40-80 °C. Combined with a temperature controller for wall mounted gas fired boilers, the adjustment at the heating water thermostat is disabled; instead the temperature is selected at the boiler temperature controller.

Signal ring asstatus display

Display ExplanationFlashing green Standby (power supply ON, burner OFF)Constant green light Heat demand: pump running, burner OFFFlashing yellow Emissions test modeConstant yellow light Burner ON, flame steadyFlashing red Fault

Reset A fault is reset by pressing the reset button which will also restart the system. Pressing the reset button reactivates the system, if there was no fault.

213062347_0309

In conjunction with the accessory controllers BM / AWT / ART, the settings at the boiler relating to DHW and heating water are disabled.

Note:

Setting Winter mode (position 2 to 8)In winter mode, the boiler heats to the temperature selected at the heating water temperature controller. According to the pump operating mode, the circulation pump operates constantly (factory setting) or only in parallel with the burner activation / run-on period.

Summer modeThe winter mode is deactivated by rotating the heating water temperature selector into position . In other words, the boiler will then operate in summer mode. Summer mode (heating OFF) means, only DHW heating. Frost protection for the heating system and pump anti-seizing protection, however, remain enabled.

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

Anti-seizing pump protection

ThermomanometerThe current heating water temperature is displayed in the upper area.The water pressure in the heating system is displayed in the lower area. In normal use, the water pressure should be between 2.0-2.5 bar.

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

Control / Function / Commissioning

22 3062347_0309

Parameter overview / setting reportColumn 1 settings apply to control accessories ART, AWTColumn 2 settings apply to Wolf control system with BM programming module(Setting and function of the most important functions on the following pages, further description, see BM installation instructions.)

Parameters Setting range Factory setting Individual settingsColumn 1 Column 2

HG00 Adjusting flue lengths 1 to 5 4GB05 A09 Frost protection limit -20 to +10 °C +2 °CGB01 HG01 Burner switching differential 5 to 25 K 8 K

HG02 Lower burner output heating 1 to 100% 1%HG03 Upper burner output DHW 1 to 100% 100%

GB04 HG04 Upper burner output heating 1 to 100% 100%GB06 HG06 Pump operating mode 0 to 2 0GB07 HG07 Boiler circuit pump run-on time 0 to 30 min 1 minGB08 HG08 Maximum boiler temperature, heating 40 to 90 °C 80 °CGB09 HG09 Burner cycle block 1 to 20 min 7 min

HG10 eBUS address (display only) 1 to 4 1HG11 DHW quick start temperature 10 to 60 °C 10 °CHG12 Gas type, 1=natural gas 0=LPG 0 to 1 1HG13 Programmable input E1 1 to 11 1HG14 Programmable output A1 0 to 15 6HG15 Cylinder hysteresis 1 to 30 K 5 KHG16 Pump rate HC, minimum 20 to 100% 45%HG17 Pump rate HC, maximum 20 to 100% 80%HG20 No function 0HG21 Minimum boiler water temperature TK-min >40 °C* 40 to 60 °C 40 °CHG22 Maximum boiler water temperature TK-max. 50 to 90 °C 80°C

A14/HG23 Maximum DHW temperature 60 to 80 °C 65 °CHG25 Boiler overtemperature during DHW cylinder heating 0 to 40 K 20 KHG70 Manifold sensor (display only)

HG80-89 Fault history

ThecontrolparameterscanonlybemodifiedordisplayedviaWolfcontrolaccessorieswitheBUScapability. For installation and procedures, check the operating instructions of the relevant accessories.

To prevent damage to the heating system, cancel night setback when outside temperatures fall below -12 °C. If this rule is not observed, ice may form on theflueoutletwhichmaycauseinjurytoindividuals or material losses.

Modificationsmustonlybecarriedoutbya recognised heating contractor or by the Wolf customer service.

L.h. rotary selectorProgram selection

Display R.h. rotary selectorTemperature selection

Info key Single cylinder heating key

Setback keyHeating key

NoteBM programming module

Displaying / modifying control parameters with Wolf control accessories

* To prevent damage to the boiler TK min must be set > 40 °C

233062347_0309

Press the r.h. rotary selector to change to control level 2. Turn the r.h. rotary selector clockwise to select the menu level Contractor and confirm the selection by pressing the r.h. rotary selector again.The display shows the code scan.

Contractor level

expert

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

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 TK-min., 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

A09

2.0

Factory setting: see tableSetting range: -20 to +10 °C

Note 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.

Displaying / modifying control parameters with Wolf control accessories

The control parameter should be set according to the table opposite, subject to the calculated length of the balanced flue routing. The calculated length will be rounded up or down accordingly.

(Also see chapter "Adjusting the flue length".)

Matching the pipe lengthParameter HG00

HG00

4

Factory setting: see tableSetting range: 1 to 5

HG00Adjusting pipe

lengths

Calculated length (m)

1 1.3 - 1.52 1.5 - 2.53 2.5 - 3.54

(factory setting) 3.5 - 4.0

5 4.0 - 5.0

The burner switching differential regulates the burner temperature within a set range by switching the burner ON and OFF.The higher the ON / OFF temperature differential, the higher the boiler temperature fluctuation around the set temperature.

Burner switching differentialParameter HG01

HG01

8

Factory setting: see tableSetting range: 5 to 25 K

The lower burner output in heating mode can be adjusted within the modulation range. The setting relates to the maximum heating output in kW (see table "Limiting maximum heating output").

Lower burner output HzParameter HG02

HG02

1


24 3062347_0309

JJ

J

Displaying / modifying control parameterswith Wolf control accessories

The higher burner output in DHW mode can be adjusted within the modulation range. The setting relates to the maximum heating output in kW (see table "Limiting maximum heating output").

Upper burner output DHWParameter HG03

HG03

100


The higher burner output in heating mode can be adjusted within the modulation range. The setting relates to the maximum heating output in kW (see table "Limiting maximum heating output").

Upper burner output HzParameter HG04

HG04

100


Pump operating mode 0:Heating circuit pump for heating systems without cascade control and without low loss headerThe boiler pump runs constantly when there is a heat demand. When the heat has been switched off via the room thermostat or remote control, the boiler pump runs for the set time (pump run-on Hz, parameter HG07).

Pump operating modeParameter HG06

HG06

0

Factory setting: see tableSetting range: 0 / 1 / 2

Pump operating mode 1:For heating systems with a low-loss header or heating buffer (header sensor mandatory on input E1)Boiler pump becomes the feed pump.The manifold sensor affects the heating operation as well as the cylinder heating (please note: only cylinder mode possible). The boiler pump will not run for a general heat demand, but rather only when there is a burner demand in the heating operation, with pump run-on according to parameter HG07.

VL Sensor 1

Three-way valve

Header

Manifold sensor E1

VL Sensor 2 A1 as heating circuit pump

A1 as primary cylinder pump

DHW cylinder

Hydraulic scheme:

Gas fired boiler

Boiler pump or

253062347_0309

Subject to there being no heat demand from the heating circuits, 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

1

Factory setting: see tableSetting range: 0 to 30 min


J

J

J

J

Hydraulic scheme:

VL Sensor 2VL Sensor 1

Three-way valve

Manifold sensor E1

A1 as heating circuit pump

Cylinder sensor

Buffer

DHW cylinder

Gas fired boiler

Boiler pump

Pump operating mode 2:Appliance pump becomes feed pump for heating.For heating systems with a hydraulic low-loss header or heating buffer with hot water generation at the heater (collector sensor on input E1 only optional)

Function without header sensor(e.g. when using a cascade module)The appliance pump runs in heating mode only in case of burner operation and with pump overrun in accordance with parameter HG07.When domestic hot water is drawn off (vertical calorifier or combi boiler) the appliance pump runs in normal mode.

Function with header sensorThe header sensor on input E1 affects only the heating mode.The appliance pump runs in heating mode only in case of burner operation and with pump overrun in accordance with parameter HG07.When domestic hot water is drawn off (vertical calorifier or combi boiler) the appliance pump runs in normal mode.

26 3062347_0309

The eBUS address can only be displayed here. The setting is done as described in "Conversion/eBUS address in cascade operation" and is only required in cascade operation with several boilers.

eBUS addressParameter HG10

HG10

1


Gas type set according to the following table:1 = Natural gas0 = LPG

The modulating current for the gas combi valve is adjusted to fit with the relevant setting.The conversion of the gas type can also be carried out through the selector or the heating temperature selector (see control settings after gas type conversion).

Gas typeParameter HG12

HG12

1


Outside of the DHW switching times (in the control accessories) and in summer mode, water can be heated to and kept at a certain temperature in the flat-plate heat exchanger.10 °C = DHW quick start disabled40-60 °C = DHW quick start enabled

DHW Quick StartParameter HG11

HG11

10



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.

Burner cycle blockParameter HG09

HG09

7

Factory setting: see tableSetting range: 1 to 30 min

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 exceeded a little.

Maximum limitBoiler circuit TV-max.Parameter HG08

HG08

80

Factory setting: see tableSetting range: 40 to 90 °C

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Explanation

1Room thermostat Closed contact is a pre-requisite to enable the burner in heating mode. No function (blocked) for DHW mode. No function (blocked) for emissions test mode and frost protection, no error message.Open contact blocks the enabling of the heating and the boiler pump (pump run-on time)

2Maximum thermostat / system pressure switch Closed contact is a prerequisite for enabling burner in central heating, DHW and emissions test mode. When the contact is opened the boiler switches off and the pump run-on begins. A fault message is generated.

5Ventilation damper Function monitoring of the ventilation damper with zero volt contact Closed contact is a prerequisite for enabling burner in central heating, DHW and emissions test mode Output A1 must be programmed to 7, ventilation damper function

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

Manifold sensor A manifold sensor (5 K-NTC) is connected at E1. The flow temperature control in heating and DHW mode (pump operating mode 1) or only in heating mode (pump operating mode 2) no longer relates to the flow sensor but rather the manifold sensor. Safety functions and emissions test mode remain at the flow sensors. In case of break or short circuit of the manifold sensor, the flow sensor takes on the temperature control. Observe parameter HG 06

8

Burner block (BOB) Operation without burner Closed contact, burner blocked Heating circuit pump and cylinder primary pump run in normal operation In emissions test mode and frost protection the burner is enabled Open contact enables the burner again

10External burner demand Closed contact, set FT is set to TKmax flow hysteresis Demand also functions in standby; cycle block active (Control of output A1 when parameter output A1 = 14)

0, 3, 4, 9, 11 are without function

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:

ProgrammableInput E1Parameter HG13

HG13

1



The electrical control to input E1 must be made with a zero volt contact. Otherwise, use an on-site relay for potential separation.

28 3062347_0309

Explanation0 No function

Output A1 is not enabled1 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.

6 Cylinder primary pump Output A1 always closes along with the boiler pump in DHW operation. Both with 3-way valve idle period protection and with pump kick.

7 Ventilation damper Output A1 is activated before each burner start. The burner will, however, only be enabled after input E1 has been closed.

Important: In any case, input E1 must also be programmed as "Ventilation damper"!

Otherwise there is a risk of faults.

The feedback to input E1 must be made with a zero volt contact. Otherwise, use an on-site relay for potential separation.

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 External LPG valve Output A1 switches with the gas combi valve

10 Direct heating circuit pump Pump switches in accordance with the enabling of the direct heating circuit

11 External pump Output A1 switches synchronously with the heating circuit pump (HKP). Use with, for example, system separation.

12 Diverter valve If E1 is programmed for burner blocking (option 8) and closed, A1 switches ON. If E1 is not programmed as burner blocking, A1 always stays OFF.

13 DHW circulation pump DHW circulation pump ON for 5 mins, if input E1 is programmed as DHW circulation pushbutton and input E1 Key is closed.

14 Pump with external burner demand Synchronous control with input E1 (E1 = 10, ext. burner demand)

15 Constant voltage for accessories A1 is always closed (constant voltage 230 VAC)

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:

ProgrammableOutput A1Parameter HG14

HG14

6



Note

230

V A

C<

24 V

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The cylinder hysteresis regulates the start point for cylinder heating. The greater the hysteresis, the lower the start temperature.Example: Set cylinder temperature 60 °C Cylinder hysteresis 5 K

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

Cylinder hysteresisParameter HG15

HG15

5


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 temperatureTK-min.Parameter HG21

HG21

40


In heating mode the internal appliance pump does not regulate above this adjusted value (no function with 3-stage pump).

Pump rate HC, maximumParameter HG17

HG17

70

Factory setting: see tableSetting range: 20 to 100%

In heating mode the internal appliance pump does not regulate below this adjusted value (no function with 3-stage pump).

Pump rate HC, minimumParameter HG16

HG16

45

Factory setting: see tableSetting range: 20 to 100%


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The excess temperature differential between the cylinder temperature and the boiler water temperature during cylinder heating is selected with parameter HG25. This ensures that, even in spring and autumn, the boiler water temperature is higher than the cylinder temperature, thereby ensuring short heating times.

Boiler overtemperature during DHW cylinder heatingParameter HG25

HG25

20



HG70

54

Display only:

With parameter HG70 analogue input E1 is displayed, if a manifold sensor is connected (display only).

ParametersHG 80 Fault 1HG 81 Fault 2HG 82 Fault 3HG 83 Fault 4HG 84 Fault 5HG 85 Fault 6HG 86 Fault 7HG 87 Fault 8HG 88 Fault 9HG 89 Fault 10

HG80

04

Display only:

Fault historyParameter HG80

This temperature can be enabled at 80 °C, if for commercial reasons a higher DHW temperature is required. If pasteurisation (BM) has been enabled, the DHW cylinder will be heated to 65 °C during the first cylinder heating of the day, subject to parameter HG23 being set to this temperature or higher.

Take adequate measures to prevent scalding.

Maximum DHW temperatureParameter A14 / HG23

HG23

65


Note

“The controller is equipped with an electronic boiler temperature controller whose max. switch-off temperature is adjustable (maximum boiler temperature).If this is exceeded, the burner is turned off. If a reclosure of the burner when the boiler temperature has fallen to the burner switching differential.

Maximum DHW temperatureParameter HG22

HG22

90


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DHW connection versions / Resetting control unit

With boilers CGU-2 / CGG-2 there are 3 possible boiler versions.

A VL sensor 2B VL sensor 1C Boiler pumpD Three-way valveE Flow rate sensorF Cylinder sensor

Legend

Reset Observe the following steps to implement a reset:

- The operating mode switch must be set to O (OFF).- Press the reset button on the control unit and hold it down.- Switch on ON/OFF switch in I position.- After 5 seconds the signal ring will illuminate and flash yellow/green and

red every 1 second.- Then release the reset button again.

All parameters (individual settings) are returned to their factory settings by a reset, except for gas type settings and adjustments to pipe lengths.

ON / OFF switch

Press reset button

Note

The DHW circuit is bridged and is not usedBoilerA

B

CD

When drawing DHW the flow rate sensor recognises the DHW demand. The burner is fired-up and regulated to the set DHW outlet temperature (adjusted via rotary selector or control accessories)

Combination boiler A

B

CD

E

When drawing DHW, the temperature falls below the set DHW temperature. The burner fires up and regulates the boiler flow temperature and boiler excess temperature when preparing DHW

Boiler with cylinder

F

AB

CD

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Boiler in cascade operation eBUS address

Position Rotary selector,

DHW temperature selection

Illuminated ring display

1 (factory setting) 1 1 flashing red

2 2 2 flashing yellow

3 3 3 flashing yellow/red

4 4 4 flashing yellow/green

ON / OFF switch DHW temperature selector

Pressure gauge

Reset button


selector


Thermometer

- At the system ON / OFF switch, switch the boiler first OFF and then ON again. There must not be any fault present at the boiler.

- Press reset button for between 30 and 60 seconds after turning on the mains and keep pressed down during the next step. Setting the address is only possible during this time window.

- After 10 seconds the illuminated signal ring indicates the currently selected gas type (see table: eBUS address).

- Turn the DHW temperature selector towards the required address and check the setting by means of the colour of the illuminated signal ring.

- The adjustment will only be activated when the reset button is released.

- A successful setting of the eBus address is indicated by a triple flashing yellow/red (0.4 s ON / 1.0 s OFF) of the signal ring.

Setting the eBUS address for cascade mode

When operating several boilers (up to 4 control units) in conjunction with a cascade controller KM, adjust the eBUS address of the boilers in accordance with the table, below.

Table: eBUS address

333062347_0309

Start-up gas connectionOnlyqualifiedpersonnelmustcarryoutthecommissioning and boiler operation as well as the user instruction to prevent dangers and injuries as well as material losses.

- The boiler and system must be fully vented and must be absolutely tight.

- If the system water pressure falls below 1.5 bar, top up with water until a pressure of 1.5 to max. 2.5 bar has been achieved.

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

- The gas fired boiler must be switched OFF. Open the gas shut-off valve.

- Remove the casing cover.

- Release the plug at test nipple and vent the gas supply pipe.

Check test nipple for gas-tightness, otherwise gas may escape, resulting in a risk of explosion, asphyxiation or poisoning.

Prior to commissioning, ensure that the boiler corresponds to the gas type available.

Gas type Wobbe index WskWh/m³ MJ/m³

Natural gas H 11.4 - 15.2 40.9 - 54.7LPG P 20.3 - 21.3 72.9 - 76.8

Commissioning gas train:

- Pull the hose off and tighten the test nipple again.

- Retighten the plug.

- Start the boiler.

- Check the ignition and the regular flame structure of the burner.

Never take the boiler into use if the actual value falls outside the specified limits. → Notify gas supply utility.

Gas type Nominal supply pressure, Permissible range

Natural gas H 20 mbar 18 - 25 mbarLPG P 50 mbar 43 - 57 mbarLPG P 37 mbar 25 - 45 mbarLPG P 29 mbar 25 - 35 mbar

- Connect the hose to the pressure test appliance at test nipple and check against atmosphere.

- Read off value and enter in the commissioning report.

34 3062347_0309

- Continue with adjusting of the control unit subject to gas type

- Adjusting the nozzle pressure

- Identification

1. Nozzle change:

- Switch OFF the boiler at the ON/OFF switch and isolate it from the power supply

- Remove the casing lid of the gas fired boiler. For this, pivot the control unit lid down, hook in the r.h. and l.h. turnbuckle, undo the lower casing lid and unhook at the top

- Close the gas valve, observe all safety instructions and crack open the gas fittings at the gas manifold

- Remove fixing screw

- Pull out the gas manifold

- Undo all burner nozzles (spanner size 7) at the gas manifold

- Insert new burner nozzles with new gaskets

- Reassemble the boiler in reverse order

Table: Number of nozzles, nozzle size

Boiler No. of nozzles Natural gas H LPG/propaneNozzle ID Nozzle

Ø mmNozzle ID Nozzle

Ø mmCGU-2(K) 18 090 0.90 060 0.60CGU-2(K) 24 090 0.90 060 0.60CGG-2(K) 18 087 0.87 057 0.57 CGG-2(K) 24 087 0.87 057 0.57

Conversion to other gas typesCGU-2(K) / CGG-2(K)

Fixing screwsGas fitting

Gas manifold

The conversion to other gas types is made in four steps:

1. Nozzle replacement2. Adjusting the control unit after converting the gas type3. Checking and adjusting the nozzle pressure4. Identification

Note Carry out all steps, otherwise there is a risk of incorrect functions or system damage.

353062347_0309

Control unit settings aftergas type conversion


Pressure gauge

Reset button


selector


Thermometer


- Press the reset button within the following 30 seconds and hold it down during the next steps.

- On (CGU) after 5 seconds the currently set gas type is displayed at the signal ring, see table: Setting gas type. On (CGG) after 5 seconds the currently set pipe length is displayed at the signal ring.

- Turn the heating water temperature selector towards the required gas type and check the setting by means of the colour of the illuminated signal ring (see table adjusting the gas type).


- A successful conversion of the gas type is indicated by a triple flashing yellow/red (0.4 s ON / 1.0 s OFF) of the signal ring.

Table: Adjusting the gas type

2. Adjusting the control unit:

Check the nozzle pressure after converting the gas type, otherwise material losses and incorrect functions can occur.

Gas type Natural gas LPGIlluminated ring display quickly flashing yellow quickly flashing redHeating water temperature adjustment l.h. closing r.h. end stop

Note: The adjustment of the gas type can also be done with the BM accessory controller (Contractor parameter HG12, description see chapter "Displaying / modifying control parameters with Wolf control accessories").

Note

36 3062347_0309

Check nozzle pressure3. Checking and adjusting the nozzle pressure:

- The gas fired boiler must be switched OFF.

- Open the gas shut-off valve.

- Remove boiler casing cover and move the control unit to the front.

- Undo the plug at the test nipple [2].

- (+) Connect the differential pressure tester with a hose at test nipple [2].

- (-) Connect the differential pressure tester with a hose at test port [3] of the combustion chamber casing (only CGG-2(K)).

- Start the boiler by turning the heating water temperature selector to position 8.

- Read off the nozzle pressure Pmin (at minimum boiler output) within 180 seconds of ignition (soft start phase = minimum output).

- Turn the heating water temperature selector further to the emissions test position [chimney symbol].

- Read off the nozzle pressure Pmax (at maximum boiler output) within the 15 minute test phase.

- Compare the actual values with those in the table.

- Close the plug again.

[2]

[3]

Gas pressures for gas throughput adjustment according to the nozzle pressure method

Table: Nozzle pressure table

Nozzle pressure in mbar (1013 ±0.5 mbar; 15 °C)Gas fired boilers(gas fired combi boilers)

Rated output P in kW

Rated thermal load

Q in kW

Natural gas HW1= 45.7 MJ/m³= 12.7 kWh/m³

LPG PW1= 70.7 MJ/m³= 19.6 kWh/m³

CGU-2(K) -18 18.0 20.2 12.7 26.715.3 17.3 9.5 20.013.0 14.8 7.1 14.810.9 12.5 5.2 10.78.0 8.8 3.2 5.8

CGU-2(K) -24 24.0 26.5 12.9 25.420.4 22.5 9.4 18.716.0 18.1 6.3 12.313.0 14.9 4.4 8.510.9 12.0 3.1 6.0

CGG-2(K) -18 18.0 19.7 15.9 36.015.3 16.7 11.4 25.913.0 14.2 8.8 19.310.9 12.0 6.3 14.18.0 8.5 3.3 7.5

CGG-2(K) -24 24.0 26.5 16.8 35.820.4 22.5 12.2 26.116.0 17.7 7.5 15.913.0 14.0 4.8 10.010.9 11.7 3.4 7.3

373062347_0309

The gas fired boiler corresponds to protection level IP X4D and can be installed in bathrooms in safety zone 1 and more widely in accordance with VDE 0100 Part 701.

Boiler certification

1) Balanced flue B32 required

Gas throughput table for gas volume adjustment according to the volume flow method

If the actual values fall outside these limits, readjust the gas valve (see the respective chapter), otherwise material losses at the boiler and incorrect functions can result. Otherwise continue under the point "Removing the test equipment again".

Note

Gas volume adjustment check

If the actual net calorific value is known, the gas volume can be checked with a stop watch and a gas meter according to the following formula:

Gas throughput [l/min] =Rated thermal load [kW] x 1 000

Net calorific value Hi [kWh/m³] x 60

Check nozzle pressure

Boiler Type Category Operating mode To be connected to

Open flue

Openbalanced

flueChimney

Air / flue gas chimney

Balanced flue system

CGU-2(K) B11BS II2H3P X X

CGG-2(K)B32, C12x, C32x, C42x

II2H3P X 1) X X 1) X X

Gas fired boilers

(gas fired combi

boilers)

Thermaloutput

kW

Rated thermal

loadkW

Gas throughput in l/min (1013 mbar; 15 °C)Natural gas H

with an operational net calorific value of Hi in MJ/m³ (kWh/m³)25.9(7.2) 27.4(7.6) 28.8(8.0) 30.2(8.4) 31.7(8.8) 33.1(9.2) 34.6(9.6) 36.0(10.0) 37.4(10.4) 38.9(10.8) 40.3(11.2)

equivalent of a gross calorific value of HS in MJ/m³ (kWh/m³)28.8(8.0) 30.2(8.4) 31.7(8.8) 33.8(9.4) 35.3(9.8) 36.7(10.2) 38.1(10.6) 40.0(11.1) 41.8(11.6) 43.2(12.0) 4.6(12.4)

18.0 20.2 47.0 44.5 42.3 40.3 38.4 36.8 35.2 33.8 32.5 31.3 30.215.3 17.2 40.0 37.9 36.0 34.3 32.8 31.3 30.0 28.8 27.7 26.7 25.7

CGU-2(K) -18 13.0 14.8 34.3 32.5 30.8 29.4 28.0 26.8 25.8 24.7 23.7 22.8 22.110.9 12.5 28.9 27.4 26.0 24.8 23.7 22.6 21.6 20.9 20.0 19.3 18.68.0 8.8 21.3 20.2 19.2 18.3 17.4 16.7 16.0 15.4 14.7 14.2 13.724.0 26.5 61.3 58.1 55.2 52.6 50.2 48.0 46.1 44.3 42.4 40.8 39.520.4 22.5 52.8 40.0 47.5 45.2 43.2 41.3 39.7 38.0 36.5 35.1 34.0

CGU-2(K) -24 16.0 18.1 41.9 39.7 37.7 35.9 34.3 32.8 31.5 30.2 29.0 27.9 27.013.0 14.9 34.5 32.7 31.0 29.6 28.2 27.0 25.9 24.8 23.9 23.0 22.210.9 12.0 28.9 27.4 26.0 24.8 23.7 22.6 21.8 20.9 20.0 19.3 18.618.0 19.7 45.6 43.5 41.0 39.9 37.3 35.7 34.1 32.8 31.5 30.4 29.315.3 16.7 38.6 36.6 34.8 33.1 31.7 30.2 29.0 27.8 26.7 25.8 24.8

CGG-2(K) -18 13.0 14.2 32.8 31.1 29.6 28.2 26.9 25.8 24.8 23.7 22.8 21.9 21.2

10.9 12.0 27.8 26.3 25.0 23.8 22.7 21.8 20.6 20.0 19.3 18.5 17.98.0 8.5 19.6 18.6 17.7 16.8 16.1 15.4 14.8 14.2 13.6 13.1 12.724.0 26.5 61.3 58.2 55.2 52.6 50.2 48.0 49.0 44.2 42.5 40.9 39.420.4 22.5 52.1 49.3 46.9 44.6 42.6 40.8 39.1 37.5 36.6 34.8 33.5

CGG-2(K) -24 16.0 17.7 41.0 38.8 36.9 35.1 33.5 32.1 30.8 29.5 28.4 27.4 26.313.0 14.0 32.4 30.7 29.2 27.7 26.5 25.4 24.3 23.3 22.4 21.6 20.910.9 11.7 27.0 25.6 24.4 23.2 22.1 21.2 20.3 19.5 18.8 18.1 17.4

38 3062347_0309

Readjusting the gas valve:

Carry out the nozzle pressure adjustment in the following order:

- Remove transparent plastic cap [4] from the gas combination valve.

- Operate the boiler in emissions test mode (Pmax).

- Adjust the maximum pressure at nut [5] (spanner size 10).

- Tightening increases the pressure.

- Releasing reduces the pressure.

- Pull the cable from the gas valve. The boiler goes to minimum output (Pmin).

- Adjust the minimum pressure at screw [6] in accordance with nozzle pressure table (Philips screwdriver 6x1); during this adjustment, hold nut [5] tightly.

- Turning right increases the pressure.

- Turning left reduces the pressure.

- Replace the plastic cap [4].

- Reconnect the cable.

[4]

[6][5]

4.Identification:

Carry out the re-designation of the gas type in accordance with the instructions supplied with the conversion kit.

Remove the test equipment:

Readjust the gas valveChecking / adjusting the nozzle pressure

- Shut down the boiler. Close the gas shut-off valve.- Pull the hoses off and retighten the test nipple [2] and

the test port [3]. Open the gas shut-off valve.

Check gas tightness of the test nipple, otherwise there is a danger of gas escaping and consequent damage to health.

[2]

393062347_0309

Flue gaspipe lengthCGG-2(K)

Position Rotary selector

Temperature selection

DHW

Illuminated ring display(green)

Calculated length(m)

1 1 1x0.4 s ON/OFF 1x1.5 s pause 1.3 - 1.5

2 2 2x0.4 s ON/OFF 1x1.5 s pause 1.5 - 2.5

3 3 3x0.4 s ON/OFF 1x1.5 s pause 2.5 - 3.5

4*(factory setting) 4 4x0.4 s ON/OFF

1x1.5 s pause 3.5 - 4.0

5* 5 5x0.4 s ON/OFF 1x1.5 s pause 4.0 - 5.0


Pressure gauge

Reset button


selector


Thermometer


- Press the reset button within the following 30 seconds and hold it down during the next steps.

- After 5 seconds, the illuminated signal ring indicates the currently selected gas type (see table: Pipe length adjustment).

- Turn the DHW temperature selector towards the required pipe length and check the setting by means of the flash sequence of the illuminated signal ring.


- A successful conversion of the gas type is indicated by a triple flashing green (0.4 s ON / 1.0 s OFF) of the signal ring.

AdjustingthefluelengthsCGG-2(K)

Note: The adjustment of the flue pipe length can also be done with the BM accessory controller (Contractor parameter HG12, description see chapter "Displaying / modifying control parameters with Wolf control accessories").

* Operation only with condensate drain pipe in the balanced flue routing (see accessories)Table: Pipe length adjustment

40 3062347_0309

Flue gas test CGU-2(K) / CGG-2(K)The flue gas emissions must be tested with the boiler closed.

- Remove the screw from the test port "inlet air".

- Insert the test probe until it bottoms out.

- Start the boiler and turn the heating water temperature selector to emissions test [chimney sweep symbol]. (The illuminated status display ring flashes yellow).

- Test the temperature and CO2 or O2 value.

The balanced flue is not gas-tight if the CO2 content ≥ 0.3%; rectify the leak.

- After the test has been completed, switch the boiler OFF, remove the test probe and close the test port. Ensure the screws are seated firmly.

Testing the combustion air CGG-2

Vertical boiler flue connection

- Remove the screw from the test port "flue gas".

- Insert the test probe into the centre of the pipe.

- Start the boiler and turn the heating water temperature selector to emissions test [chimney sweep symbol]. (The illuminated status display ring flashes yellow).

- Test the temperature and CO2 value.

The CO2 value should be tested at maximum heat output. Take the values from the table on the right.

- After the test has been completed, switch the boiler OFF, remove the test probe and close the test port. Ensure the screws are seated firmly.

TestingthefluegasparameteratCGG-2

Flue gas can escape into the installation room, if the test port is left open. This results in a risk of asphyxiation.

Horizontal boiler flue connection

TestingthefluegasparameteratCGU-2- Insert the test probe into the flue pipe and find the core

flow.

- Record flue gas values.

- Take out the test probe and close test port.

Fig.: Flue gas test CGU-2(K)

Gas type Natural gas H LPG PCO2 - value in % 8.0 9.3

The CO2 value may deviate by a maximum of ± 1%.

Distributor with measuring opening

413062347_0309

Limiting the maximum outputThe output setting can be modified with Wolf control accessories with eBUS capability via parameter HG 02, 03, 04.The heating output will be determined by the modulation current of the gas valve. By reducing the modulation current in accordance with the table, the maximum output will be matched at 80/60 °C to natural gas H and LPG.

Out

put [

kW]

Modulation current [%]

Output [kW] 10.9 12 15 18 21 24IMod [%] 0-27 33 46 60 75 100

Out

put [

kW]

Modulation current [%]

Output [kW] 8 10 12 14 16 18IMod [%] 0-27 39 52 65 77 100

Output adjustment 18 kW

Output adjustment 24 kW

42 3062347_0309

Selecting the pump stage / bypass

Fig.: Pump rate stages at the heating circuit pump

The appliance is equipped with an integrated pump.Depending on the appliance version a 3-stage pump (stage 2 in delivery condition) or a high-efficiency pump (HEP) is installed.

Bypass valve

The minimum circulation volume is ensured by a connection line between the flow and return. An automatic overflow valve and a manually adjustable bypass valve are integrated into the connection line.In the delivered condition, the bypass valve is fully opened to "MAX".Closing the valve can increase the residual head.(see "Selecting the pump stage / bypass").

Stage 1

Stage 2

Stage 3

Fig.: Bypass valve

0

100

200

300

400

500

600

0 200 400 600 800 1000 1200 1400

min

max

Troubleshooting Problem SolutionIndividual radiators do not get properly warm.

Carry out a hydraulic adjustment, i.e. throttle the warmer radiators. Increase pump speed (HG16)

The desired room temperature is not achieved during the transition period.

Increase the room temperature with the controller, e.g. with a set value setting of ±-4

The desired room temperature is not achieved when outside temperatures are very low.

Set a steeper heating curve on the con-troller, e.g. increase supply temperature at standard outside temperature.

High-efficiencypumpEEI<0.23(HEP)CGU-2(K)-18/24Bypass valve closed

Res

idua

l hea

d [m

bar]

Pump rate [l/h]

max.

min.

433062347_0309

Bypass valve CGU-2(K)-18 / CGG-2(K)-18 completely open (delivered condition)

Res

idua

l hea

d [m

bar]

Pump rate [l/h]

Pump stage

Bypass valve CGU-2(K)-18 / CGG-2(K)-18 closed

Res

idua

l hea

d [m

bar]

Pump rate [l/h]

Bypass valve CGU-2(K)-24 / CGG-2(K)-24 completely open (delivered condition)

Res

idua

l hea

d [m

bar]

Pump rate [l/h]

Bypass valve CGU-2(K)-24 / CGG-2(K)-24 closed

Res

idua

l hea

d [m

bar]

Pump rate [l/h]

Selecting the pump stage / bypass

Pump stage

Pump stage

Pump stage

44 3062347_0309

CheckingthefluegasmonitoringCGU-2(K)

The electronic flue gas monitoring switches off the gas boiler CGU-2(K) at the flue outlet on the draught hood. The boiler restarts automatically after approx. 15 mins.

A regular check must be carried out on the function of the flue gas monitoring. If something is wrong with the function of the flue gas monitoring, the gas boiler must not be operated, as flue gas can escape, causing a danger of poisoning.

Proceed as follows:

• Shut down the boiler.

• Raise flue pipe or boiler connection bend and cover flue gas connection to the draught hood with a plate.

• Start the boiler.

• Enable emissions test mode. The signal ring flashes yellow.

If functioning perfectly, the flue gas monitoring switches off after 2 mins at the latest.

• Remove cover plate. Re-install flue pipe or flue bend.

• The boiler restarts automatically after approx. 15 mins.

Reassemble all components and test for functional reliability.Observe all maintenance safety instructions.

Flue gas connection Coverplate

Fig.: Uncover flue gas connection

CheckingthefluegasmonitoringCGU-2(K)

453062347_0309

Engineeringinformation–balancedfluesystemThe maximum lengths identified in the table under"Adjustingthefluepipelengths"mustnotbe exceeded, otherwise incomplete combustion can occur, resulting in damage to the boiler and in particular moisture related damage to the system.

If the CO content in the flue gas is higher than300ppm(freeofair),removethecause;otherwise do not continue to operate the gasfiredboiler, as therewould be a risk offluegasescaping, resulting in thedangerofpoisoning.

WolfboilersarecertifiedasoneunitwiththeoriginalWolfbalancedfluesystem.Useonlyoriginal Wolf balanced flue systems. Using alternative accessories can lead to incorrect functions. Material losses and injuries cannot then be prevented.

General information:From a length of 2.5 m upwards, we recommend the installation of a condensate trap.

Calculatingthefluelength60/100mm

Calculated flue length = length of straight pipes + 1.0 m per 90° bend / tee + 0.5 m per 45° bend

Type C12x

Outside wall connection (balanced flue)concentric horizontal system 60/100 mmcalculated pipe length min / max = 0.3 / 5.0 m

Type C32x

Roof outlet (balanced flue)concentric vertical system 60/100 mmcalculated pipe length min / max = 0.3 / 5.0 m

Type C42x

Connection to a room sealed balanced flue(balanced flue)concentric system 60/100 mm

A+B<2m

Connection to a chimney;ventilation air directly via the boiler or through a horizontal concentric supply line (open flue)concentric system 60/100 mm

Type B32

A+B<2m

46 3062347_0309

Vertical balanced flue system LAF CGG-2(K) The following applies to gas fired combi 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 fires spreading, if these requirements are ignored.

If fire resistance is not required for the ceiling, route the lines for the combustion air supply and the flue gas from the top edge of the ceiling to 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 fires spreading, if these requirements are ignored.

If the balanced flue crosses different floors, route the pipes outside the boiler room inside a duct with a fire resistance of at least 90 min., and in living spaces of low height with a resistance of at least 30 min. Plastic flues are not permissible. Fire may spread if these instructions are not observed.

The rated boiler output must be reduced to below 11 kW, if the gas fired combi boiler is installed on an external wall (balanced flue via an external wall).

A clearance between the balanced flue and combustible materials or components is not required, as temperatures are limited to 85 °C at the rated boiler output.

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

Vertical balanced flue system (LAF) horizontal CGG-2(K)through an external wall

If a condensate trap is installed horizontally or vertically in the balanced flue, the tightness of the plugs needs to be regularly checked to guard against flue gas escaping. If the plug is not working properly the boiler must not be operated, as flue gas may escape, causing a danger of poisoning.

7

2

5

2b

121117

12

11

17

4

9

9

125-170 mm

Engineeringinformation–balancedfluesystem

3b

If the balanced flue routing is longer than 2.5 m and the heating demands are very low, a condensate trap is recommended, to avoid moisture damage to the gas boiler (see Wolf accessories).

3b

11

5

125-170 mm

Note

Note

473062347_0309

1 Gas fired boiler2 Boiler connection (straight)2b Boiler connection bend 90°, for connection to the gas fired boiler3 Sliding coupling3b Condensate trap horizontal or vertical4 Balanced flue incl. inspection aperture 250 mm5 Lengths of straight balanced flue: 500 mm, 1 000 mm6 Bend 45°, for connecting two balanced flues7 Bend 90°, for connecting two balanced flues8 Balanced flue routing vertical, (three-layered roof outlet) for flat or pitched roof9 Balanced flue routing horizontal, incl. cowl10 Connection to a flue gas chimney B32 length 65 mm with air apertures11 Rosette for internal walls12 Rosette for external walls13 Flat roof collar14 Universal tile or roof plate or "Klöber" adaptor for pitched roof part 115 Universal tile or roof plate or "Klöber" adaptor for pitched roof part 216 Mounting bracket for roof outlet17 Spacer clip19 Balanced flue for connection to an existing room sealed balanced flue, length: 300 mm20 Connector for balanced flue chimney length 962 mm

Vertical balanced flue system (LAF) vertical CGG-2(K)

3

5

6

8

1

4

7

2 2b

11

13

8 8

6

4

5

5

4

16

15

17

14

2


48 3062347_0309

Connector for flue gas chimney B32

The flue gas chimney connection (17) must be installed directly to the flue gas chimney in accordance with the figure shown (no extension piece between flue gas chimney and flue outlet).

The air vents to the boiler room must be free from obstruction.

The relevant local flue inspector must check the suitability of the flue chimney before installation.

Connection to room sealed balanced flue and flue gas chimney

Installation information:

e.g. System Plewa e.g. System Schiedel

19/20 19/20

Install with a 1-3% outwards slope.Install the centring appliances near the end of the pipe.

If an inspection aperture is required for the balanced flue, insert a balanced flue with inspection aperture (4).

12

9

11

Air apertures

102b 4

17

1

Flat roof: Ceiling outlet approx. 120 mm Ø aff ix 13 into roof

cover.Pitched roof: At 15 observe the

installation instructions on the cowl, regarding roof pitches.

Insert the roof outlet 8 from above through the roof and secure vertically with 16 to a rafter or brickwork.Install the roof outlet only in its original condition.Modifications are not permissible.

If an inspection aperture is required for the balanced flue, insert a balanced flue with inspection aperture (4). When the LAF length is greater than 2 m, when installing the boiler in a cold area and/or the required heating output lies below 15 kW, we recommend the installation of a three-layered- roof outlet (insulated).

13

8

16

17

15

14


493062347_0309

Notes:Use the screws supplied to connect the boiler.


Flue gas damper for CGU-2(K)The installation of motorised flue gas dampers is recommended. These dampers must have a CE approval and are connected at the terminal box of the control unit.In order to prevent overtemperatures in the flue gas collection box, the flue gas flap is closed with a delay of 30 seconds each time after the burner is switched off.

Straight balanced flues must not be more than 2 m long, when connecting the system to a balanced flue chimney. In addition to the boiler connection bend, a maximum of two 90° diverters may be installed. Nonobservance can lead to function errors.

Information about disposal:We are happy to accept the return of your old Wolf boiler free of charge at one of our delivery depots.

Determine distance A. Flue length (internal) = A-25 mm

Offset

Distance A

Distan

ce A

Bends Offset 90° min. 140 mm 45° min. 105 mm

6

4

67

17

17

7

6

6

4


Note


AC

BD

Typ C52 Typ C82

0

0

5

10

15

20

25

5 10 15 20 25

C + D

A+

B

Install with a 3% outwards slope.

50 3062347_0309

Commissioning CGU-2(K) / CGG-2(K) Actualvalueorconfirmation

1) Gas type Natural gas H

LPG

Wobbe Index_____________________kWh/m³ Net calorific value_________________kWh/m³

2) Calculated flue length _______________________________________ m

No.____________________ /_______________ mm

3) Gas supply pressure checked? ______________________________________ mbar

4) Nozzle pressures checked? (only complete when changing the gas type):

5) Gas leak test carried out?

6) Balanced flue system, tightness of condensate trap (optional), checked?

7) Water connections checked for leaks?

8) Boiler and system vented?

9) System pressure 1.5 - 2.5 bar?

10) Function test carried out?

11) Casing fitted?

12) System user trained, tech. docs. handed over?

13) Confirm commissioning?

Company / Name

Date / Signature

________________________________________

______________ / _________________________

Commissioning report

513062347_0309

Inspection and maintenance steps / Service report

Report about the inspection and service work

Advise the system user that an approved contractor should clean and check the heating system annually, to safeguard the reliable and economic function of his heating system and to avoid risks to individuals and prevent material losses.

Note

No. Step to be implementedalways if required Maintenance 1

1 Switch OFF the boiler, isolate it from the power supply and close the gas valve

x

2 Close the shut-off valves on the water and heating water side

x

3 Remove the gas burner and check for contamination x4 Clean the gas burner and gas nozzles x5 Check the heating water heat exchanger for

contaminationx

6 Clean the heating water heat exchanger x7 Reinstall the gas burner x8 Clean and refit the DHW heat exchanger x9 Clean and refit the strainer in the cold water inlet x10 Check the tightness of electrical plug-in connections x11 Check the condition of the ignition and ionisation

electrodesx

12 Replace the electrodes, if required x13 Re-open the shut-off valves on the water and heating

water sidex

14 Check the hydraulic component for possible leaks x15 Open the gas valve and start the boiler x16 Check the ignition and burner characteristics x17 Check the gas components for soundness x18 CheckingthefluegasmonitoringCGU-2(K) x19 Check condensate trap, plug (if provided) with

CGG-2(K) balanced fluex

20 Confirm the inspection or service steps

Supplied by ____________________________

Name _________________________________

Date __________________________________

Signature ______________________________

Stamp

We recommend users arrange a service contract.

52 3062347_0309

Inspection and maintenance steps / Service report to copy

Report about the inspection and service work

No. to be implementedalways if required

Maintenance 2

Maintenance 3

Maintenance 4

Maintenance 5

Maintenance 6

1 x

2 x3 x4 x5 x6 x7 x8 x

9 x

10 x11 x12 x13 x

14 x15 x16 x17 x18 x19 x20

We recommend users arrange a service contract

533062347_0309

MaintenanceCleaning the gas burner:- Switch OFF the boiler at the ON / OFF switch,

isolate it from the power supply and close the gas valve

- Remove the casing lid of the gas fired boiler. For this, pivot the control unit lid down, hook in the r.h. and l.h. turnbuckle, undo the lower casing lid and unhook at the top

- Push the retaining clip of the front cover up or down out of the way and remove the front cover (only with CGG-2(K)).

- Drain heating water, catch any water in a suitable container

- Detach cables from the ionisation electrode [1] and plug-in connection on the ignition electrode on the gas combi valve

- Burner - remove fixing screws [2]

- Slacken the union nut on the flow and return connection of the burner unit [3]

- Release the union nut of the gas supply pipe [4].

- The burner can be pulled out of the mounting bracket by applying light outward pressure

- In its disassembled state both the electrodes and the gas distributor pipe can be removed [5]

- Remove combustion residues with a brush (non-metallic)

- Clean the nozzles and injectors, if required, with a soft brush and compressed air

- Wash severely contaminated burners with a soapy solution and rinse with tap water

- The burner is reinstalled in reverse order, but only after cleaning the heating water heat exchanger

Fig.: Removed burner unit

Gas distributor pipe hexagon nuts [5]

Fig.: Cleaning the gas burner

Ionisation electrode [1] Ignition electrode [1]

Burner unit fixing screws [2]

Burner unit union nuts [3]

Gas supply line union nut [4]

Fig.: Cleaning the gas burner

Burner unit fixing screws [2]Please note: carry out in parallel with the other sideFig.: Cleaning the gas burner

54 3062347_0309

Maintenance

Cleaning the heating water heat exchanger:- Detach cable from ventilator (only CGG-2(K))

- Undothefanfixingscrew [6] and remove the fan (only CGG-2(K)).

- After undoing both fixingscrews, remove the front wall of the combustion chamber [7].

- Detachfluegastemperaturelimiter (only CGU-2(K)) [8]

- Remove flue pipe or bend and remove fluecollectorsor draught hood from front or above

(Please note: when assembling CGU-2(K) at the rear edge of the draught hood, push between the heating water heat exchanger and guide rails)

- Clean the heating water heat exchanger from the top and the bottom with a brush (non-metallic) and, if required, blow off residues with compressed air

During this step, take care not to bend the fins. If necessary straighten them with a pair of pliers [9]

Disassemble severely contaminated heating water heat exchangers

- Before disassembling the heating water heat exchanger depressurise and isolate the system on the water side, close gas valve, observe safety instructions

- Remove 2 x retaining clips from the flow-return heating water heat exchanger, placing them at the front [10]

- Disassemble heating water heat exchanger by lightly shaking it free from above the pipework (pay attention to O-ring thicknesses)

- Clean heating water heat exchanger with a soapy solution

- Reassemble the components in reverse order

Draught hoodHeating water heat exchanger

Fig.: Heating water heat exchanger removalRemove retaining clips [10]Fig.: Heating water heat exchanger [9]

Flue gastemperature limiter [8]

Fig.: CGU-2(K)

Flue gas collector

Fixing screws of ventilator [6]

Combustion chamber fixing screws [7]

Fig.: CGG-2(K)

553062347_0309

MaintenanceCleaning the DHW heat exchangerSubject to the water quality it may be advisable to regularly descale the DHW heat exchanger on the DHW side.For this the disassembly of the hydraulic group isrequired.

Take the hydraulic assembly apart as follows:

- Hydraulically depressurise the system, collecting water in a suitable container.

Switch OFF the mains electrical isolator. Close the gas valve, paying attention to safety

instructions.

- Pull out all 4 interlocking brackets (2) approx. 2 cm (see arrows - do not dismantle)

- Unlock both safety catches (3) by turning the screws to the left (see both views - SW 6)

- Pull out brackets (4) for sensors and thermomanometer to the right and remove them

- Open expansion vessel screw connection (5) and pull forward (SW 24)

- Open gas screw connection (6) and turn to the side (SW 24)

- Open piping safety valve (on-site) Remove alternative valve (7) by undoing the brackets

- Interlocking of flow and return (8) open by turning 90° to left, then press pipes to the side (pay attention to O-rings)

- Disconnect electric connector cables (9) from diverter valve, water sensor, pump, etc.

(Plugs are encoded to prevent confusion)

- Now pull complete hydraulic group upwards by shaking it lightly, then remove forwards

- Release the two fixing screws (10) on the disassembled hydraulic group with a 4 mm Imbus Allen key

10

56 3062347_0309

Fig.: View of dismantled heating water heat exchanger

- Remove the heat exchanger and treat with a commercially available descaler

Please note: When reinstalling make sure the four rubber

gaskets are in the right position and the mounting position is correct

When reinstalling pay attention to the inscription on the heating water heat exchanger. Look underneath (see photo)

- The reinstallation proceeds in reverse order, coat O-rings with silicon grease

- When filling the boiler, proceed in accordance with the corresponding chapter in these instructions. Only fill after having cleaned the strainer in cold water inlet

Please note when reinstalled:Look underneath the heating water heat exchanger for inscription.

Maintenance

Replacing the expansion vessel

- Procedure same as with cleaning the heating water heat exchanger and cleaning gas burner

- Undo fixing screws on expansion vessel, gas supply line and heating water heat exchanger [11]

- Detach cables from the ionisation electrode [1] and plug-in connection on the ignition electrode on the gas combi valve

- Loosen upper fixing brackets (do not dismantle) [12]

- Remove fixing screw [13]

- Pull thermal bracket completely up and forward [14]

- Replace expansion vessel

- Reassemble the components in reverse order

Fixing screw underneath [13]

Screw connection Expansion vesselGas supply line [11]

Fixing screw above [12]Mounting bracket [14]

Checking the expansion vessel

- The test connection on the expansion vessel is on the top, behind the draught hood

573062347_0309

Cleaning the strainer in the cold water inlet

- Close the cold water inlet on the system side.

- Remove the cold water inlet shut-off valve on the equipment side. Catch any escaping water in a suitable container.

- Pull out the strainer and blow through with compressed air or clean it under fresh running water.

- Reassemble in reverse order using new gaskets.

Note: As standard, a combined cold water strainer with throughput controller [16] is fitted at the cold water connection [15] of the boiler (see diagram).

[16]

[15]

Fig.: Throughput controller with cold water strainer

Maintenance

After a maintenance check proceed according to chapter "Commissioning procedure".

Dismantling the hydraulic pump

58 3062347_0309

Wiring diagram CGU-2(K)

An

sch

luß

kaste

n:

Netz

230V

AC

50H

z

A1

konfigurierb

are

rA

usgang

AK

Abgaskla

ppe

E1

konfigurierb

are

rE

ingang

eB

us

Busanschlu

ss

für

exte

rnes

Regelu

ngszubehör

AF

Auß

enfü

hle

r

+

-

>

bn

ws

wssw

bl

bngn

gr

gn bn

ws

ge

+

+GND

GND

+

+GND

GND

GND

GND

GND

GND

VCC

FS

TS

3

6

1

2

4

5

greenyellowredGND

LED

-+eBus

gr rs

rt bl

124 3

Y2

Y3

Y1

VT

VF

l

rt

bnorsw

sw

rtbnge

orgn

gegr

rsrt

bl

bn

bl

bn

sw

ws

rt

sw

bl

bn

>

ws

GND

GND

ws

sw

orbn

rtbn

gn

rs

ge

ws +GND

gr

21

rtbn

or

sw

bn

bl

ge

/gr

rt bn

or

Netz

A1

AK

oo

oo

oo

MT

3,1

5A

sw bl

bn

ge

/gr

bn

gn

gr

rs

ge

ws

B5

Ion

isa

tio

n

Y1

Ga

sko

mb

ive

ntil

E1

Zü

nd

ein

he

itP

um

pe

M1

S1

AS

W

(Ab

ga

sstr

öm

un

gs-

wä

ch

ter)

S2

VL

-TB

(Te

mp

era

turb

eg

ren

ze

r

Vo

rla

uf)

B1

VL

-1

(Vo

rla

uffü

hle

r1

)

B2

VL

-2

(Vo

rla

uffü

hle

r2

)

E2

PW

M

B4

Sp

eic

he

rfü

hle

r

B3

WW

-Du

rch

flu

ss-

se

nso

r

M2

3-W

eg

e-V

en

til-

Mo

tor

eB

us-S

tecke

r

L1

NN

L1

L1

NF

1

br

bl

ge/gn

rt

gr

sw

ws

E1

12

12

12

eB

us

AF

2

1

ws

NetzL

NetzN

ZubehörL´

RT/AK-Rück

ZubehörN´

Ausgang1L

AKL

GKV1/GKV2L

ZündungL

GKV½/ZündungN

SchichtladepumpeL

SchichtladepumpeN

AbgasventilatorL

AbgasventilatorN

GerätepumpeL

GerätepumpeN

PE

eBus

Außenfühler

Eingang1

Ionisation

Vorlauffühler1

Vorlauffühler2

DDW/ASW

HallsensorVCC

N

GND

+

+

+

+

Vorlauf-TB

Speicherfühler

PWMPumpe

Modulation

WW-Durchfluss-&

Temperatursensor

+

Schrittmotor

3-Wege-Ventil

GND

+0=CGU-2/1=CGG-2

sw

13

24

1:

sw

2:

rt

3:

bn

4:

ge

5:

or

6:

gn

32

1

65

4

Ste

cke

r3

-We

ge

-Ve

ntil-M

oto

r

(An

sic

ht:

Ka

be

lse

ite

)

Ste

cke

rW

W-D

urc

hflu

ssse

nso

r

(An

sic

ht:

Ka

be

lse

ite

)

1:

or

2:

bn

3:

sw

4:

rt

X1

X2

X3

X4

X5

X6

Term

inal

box

:P

ower

23

0VA

C 5

0Hz

A1

Pro

gram

mab

le o

utpu

tA

K

Flue

gas

dam

per

E1

Pro

gram

mab

le in

put

eBus

B

US

con

nect

ion

for e

xter

nal c

ontro

l acc

esso

ries

AF

Ext

erna

l sen

sor

Power LPower N

Accessories LRT / AK returnAccessories N

Output 1 LAK L

GKV 1 / GKV 2 L

Ignition LGKV ½ / ignition L

Stratification pump LStratification pump N

Flue gas fan LFlue gas fan N

Appliance pump LAppliance pump N

PE

eBusExternal sensor

Input 1

IonisationFlow temperature sensor 1Flow temperature sensor 2

DDW / ASW

Hall sensor

Flow TBCylinder sensor

PWM pump

ModulationDHW flow &

temperature sensor

Stepper motorThree-way valve

0 = CGU-2 / 1 = CGG-2

X 1

X 2

X 3

X 4

X 5

X 6

eBU

S p

lug

greenyellowredGND

1. b

k2.

rd3.

br

4. y

e5.

or

6. g

n

1. o

r2.

br

3. b

k4.

rd

Plug

DH

W fl

ow s

enso

r (v

iew

: Cab

le s

ide)

Plu

g th

ree-

way

val

ve m

otor

(v

iew

: Cab

le s

ide)

M2

Thre

e-w

ay v

alve

m

otor

B3

DH

W fl

ow s

enso

r

B1

VL-

1

(flow

sen

sor 1

)

B2

VL-

2

(flow

sen

sor 2

)

S1

AS

W

(flue

gas

flow

m

onito

r)

S2

VL-

TB

(flow

tem

pera

ture

lim

iter)

Pum

p M

1E

1 Ig

nitio

n un

it

B4

C

ylin

der s

enso

r

Y1

Gas

com

bi v

alve

B5

Ioni

satio

n

Pow

er

br

= bn

bl

= bl

ge

= ye

gn

= gn

ws

= w

hrt

= rd

gr

= gy

sw

= bk

rs

= рk

bn

= bn

or

= or

593062347_0309

Wiring diagram CGG-2(K)

An

sch

luß

kaste

n:

Netz

230V

AC

50H

z

ZZ

ubehöra

nschlu

ss

geschalten

230V

AC

50H

z

A1

konfigurierb

are

rA

usgang

E1

konfigurierb

are

rE

ingang

eB

us

Busanschlu

ss

für

exte

rnes

Regelu

ngszubehör

AF

Auß

enfü

hle

r

+

-

>

bn

ws

wssw

bl

bngn

gr

gn bn

ws

ge

+

+GND

GND

+

+GND

GND

GND

GND

GND

GND

VCC

FS

TS

3

6

1

2

4

5

greenyellowredGND

LED

-+eBus

gr rs

rt bl

124 3

Y2

Y3

Y1

VT

VF

l

rt

bnorsw

sw

rtbnge

orgn

gegr

rsrt

bl

bn

bl

bn

sw

ws

rt

sw

bl

bn

>

ws

GND

GND

ws

sw

orbn

rtbn

gn

rs

ge

ws +GND

21

rtbn

or

sw

rt bn

or

Ne

tzZ

A1

oo

oo

oo

MT

3,1

5A

sw bl

bn

ge

/gr

bn

gn

gr

rs

ge

ws

B5

Ion

isa

tio

n

Y1

Ga

sko

mb

ive

ntil

E1

Zü

nd

ein

he

itP

um

pe

M1

S1

DD

W

(Diffe

ren

zd

ruck-

se

nso

r)

S2

VL

-TB

(Te

mp

era

turb

eg

ren

ze

r

Vo

rla

uf)

B1

VL

-1

(Vo

rla

uffü

hle

r1

)

B2

VL

-2

(Vo

rla

uffü

hle

r2

)

E2

PW

M

B4

Sp

eic

he

rfü

hle

r

B3

WW

-Du

rch

flu

ss-

se

nso

r

M2

3-W

eg

e-V

en

til-

Mo

tor

Be

trie

bsa

nze

ige

un

dR

ese

tta

ste

r

eB

us-S

tecke

rS

ch

nitts

telle

zu

m

Be

die

nm

od

ul

L1

NN

L1

F1

br

bl

ge/gn

rt

sw

E1

12

12

12

eB

us

AF

2

1

ws

NetzL

NetzN

ZubehörL´

RT/AK-Rück

ZubehörN´

Ausgang1L

AKL

GKV1/GKV2L

ZündungL

GKV½/ZündungN

SchichtladepumpeL

SchichtladepumpeN

AbgasventilatorL

AbgasventilatorN

GerätepumpeL

GerätepumpeN

PE

eBus

Außenfühler

Eingang1

Ionisation

Vorlauffühler1

Vorlauffühler2

DDW/ASW

HallsensorVCC

N

GND

+

+

+

+

Vorlauf-TB

Speicherfühler

PWMPumpe

Modulation

WW-Durchfluss-&

Temperatursensor

+

Schrittmotor

3-Wege-Ventil

GND

+0=CGU-2/1=CGG-2

sw

13

24

1:

sw

2:

rt

3:

bn

4:

ge

5:

or

6:

gn

32

1

65

4

Ste

cke

r3

-We

ge

-Ve

ntil-M

oto

r

(An

sic

ht:

Ka

be

lse

ite

)

Ste

cke

rW

W-D

urc

hflu

ssse

nso

r

(An

sic

ht:

Ka

be

lse

ite

)

1:

or

2:

bn

3:

sw

4:

rt

ge/gn

bn

bl

bn bl ge/gr

Ve

ntila

tor

M3

bn

bl

P

sw

rt

bn

sw

rt

bn

1 2 3

Ste

cke

rH

allse

nso

r

(An

sic

ht:

Ka

be

lse

ite

)

1:

rt

2:

bn

3:

sw

X

Ha

llse

nso

r

B6

NL1

ws

X1

X2

X3

X4

X5

X6

Term

inal

box

:P

ower

23

0VA

C 5

0Hz

Z A

cces

sory

con

nect

ion

switc

hed

230V

AC

50H

zA

1 P

rogr

amm

able

out

put

E1

Pro

gram

mab

le in

put

eBus

B

US

con

nect

ion

for e

xter

nal c

ontro

l acc

esso

ries

AF

Ext

erna

l sen

sor

Power LPower N

Accessories LRT / AK returnAccessories N

Output 1 LAK L

GKV 1 / GKV 2 L

Ignition LGKV ½ / ignition L

Stratification pump LStratification pump N

Flue gas fan LFlue gas fan N

Appliance pump LAppliance pump N

PE

eBusExternal sensor

Input 1

IonisationFlow temperature sensor 1Flow temperature sensor 2

DDW / ASW

Hall sensor

Flow TBCylinder sensor

PWM pump

ModulationDHW flow &

temperature sensor

Stepper motorThree-way valve

0 = CGU-2 / 1 = CGG-2

X 1

X 2

X 3

X 4

X 5

X 6

Ope

ratin

g di

spla

y an

d re

set

butto

neB

US

plu

gIn

terfa

ce to

pro

gram

min

g m

odul

e

greenyellowredGND

1. b

k2.

rd3.

br

4. y

e5.

or

6. g

n

1. o

r2.

br

3. b

k4.

rd

1. ro

2. a

z3.

ne

Plu

g H

all s

enso

r(v

iew

: Cab

le s

ide)

Plug

DH

W fl

ow s

enso

r (v

iew

: Cab

le s

ide)

Plu

g th

ree-

way

val

ve m

otor

(v

iew

: Cab

le s

ide)

M2

Thre

e-w

ay v

alve

m

otor

B3

DH

W fl

ow s

enso

r

B1

VL-

1

(flow

sen

sor 1

)

B2

VL-

2

(flow

sen

sor 2

)

S1

DD

W

Diff

eren

tial

pres

sure

sen

sor

S2

VL-

TB

(flow

tem

pera

ture

lim

iter)

Pum

p M

1H

all s

enso

r B

6Fa

n M

3E

1 Ig

nitio

n un

it

B4

C

ylin

der s

enso

r

Y1

Gas

com

bi v

alve

B5

Ioni

satio

n

Pow

er

br

= bn

bl

= bl

ge

= ye

gn

= gn

ws

= w

hrt

= rd

gr

= gy

sw

= bk

rs

= рk

bn

= bn

or

= or

60 3062347_0309

SpecificationType CGU-2(K) 18 CGU-2(K) 24Rated output kW 18 24Rated thermal load kW 20.2 26.5Lowest output (modulating) kW 8.0 10.9Lowest thermal load (modulating) kW 8.8 12.0Standard efficiency at 75/60 °C (Hi/Hs) % 94/85 92/83Outside diameter, heating flow G ¾" ¾"Outside diameter, heating return G ¾" ¾"DHW connection (or cylinder connection) G ¾" ¾"Cold water connection (or cylinder connection) G ¾" ¾"Gas connection G ¾" ¾"Balanced flue connection mm 110 130Gas supply details: Natural gas H (Hi = 9.5 kWh/m³ = 34.2 MJ/m³) LPG P (Hi = 12.8 kWh/kg = 46.1 MJ/kg)

m3/hkg/h

2.11.5

2.82.1

Gas supply pressure: Natural gas LPG P

mbar mbar

20 50

20 50

Flow temperature (setting range) °C 40-90 40-90Heating water temperature range ( preselected ) °C 40-80 40-80Max. overall pressure, heating bar 3 3Heating water heat exchanger 2) water content l 0.5 0.5Residual pump head: Pump stage 1/2/3430 l/h supply volume (10 KW at ∆t = 20 K) mbar770 l/h supply volume (18 KW at ∆t = 20 K) mbar1 030 l/h supply volume (24 KW at ∆t = 20 K) mbar

mbar250/250/250180/250/250

- / - / -

250/250/250160/250/250- /210/250

Specific water throughput D at ∆t = 30 K l/min 8.7 11.7DHW throughput 2) (version IT, ES) l/min 2.7-6 (9) 2.7-8 (12)Minimum flow pressure / for 95% Qmax

2) bar 0.27 / 0,9 0.27 / 0,9Max. permissible overall pressure bar 10 10DHW temperature range * °C 40-60 (65) 40-60 (65)Expansion vessel Total capacity Inlet pressure

l

bar

10

0.75

10

0.75Flue gas mass flow rate 1) g/s 12.8 / 13.9 15.0 / 19.0Flue gas temperature 1) °C 80 /123 80 /125Required boiler draught Pa 1.5 1.5Flue gas group according to DVGW G 635 - -NOx class 5 5Flue gas monitoring delay min 15 15Electrical connection V~/Hz 230/50 230/50In-built safeguard, connection/circuit board A 3.15 mT / 2x2F 3.15 mT / 2x2FPower consumption / standby W 83 / 6 83 / 6Protection IPX 4D IPX 4DTotal weight (dry) kg 39 41CE ID CE-0085BS0516

1) QB_Min / QB_Rated at 80/60 °C at the boiler connection 2) Applies only to combi boiler versions CGU-2 K and CGG-2 K

* Only use temperatures above 60 °C under controlled conditions, as there is a risk of scalding.

613062347_0309

SpecificationType CGG-2(K) 18 CGG-2(K) 24Rated output kW 18 24Rated thermal load kW 19.7 26.5Lowest output (modulating) kW 8.0 10.9Lowest thermal load (modulating) kW 8.5 11.7Standard efficiency at 75/60 °C (Hi/Hs) % 94/85 92/83Outside diameter, heating flow G ¾" ¾"Outside diameter, heating return G ¾" ¾"DHW connection (or cylinder connection) G ¾" ¾"Cold water connection (or cylinder connection) G ¾" ¾"Gas connection G ¾" ¾"Balanced flue connection mm 60/100 60/100Gas supply details: Natural gas H (Hi = 9.5 kWh/m³ = 34.2 MJ/m³) LPG P (Hi = 12.8 kWh/kg = 46.1 MJ/kg)

m3/hkg/h

2.11.5

2.82.1

Gas supply pressure: Natural gas LPG P

mbar mbar

20 50

20 50

Flow temperature (setting range) °C 40-90 40-90Heating water temperature range ( preselected ) °C 40-80 40-80Max. overall pressure, heating bar 3.0 3.0Heating water heat exchanger 2) water content l 0.5 0.5Residual pump head: Pump stage 1/2/3430 l/h supply volume (10 KW at ∆t = 20 K) mbar770 l/h supply volume (18 KW at ∆t = 20 K) mbar1 030 l/h supply volume (24 KW at ∆t = 20 K) mbar

mbar250/250/250180/250/250

- / - / -

250/250/250160/250/250- /210/250

Specific throughput D at ∆t = 30 K l/min 8.7 11.7DHW throughput 2) (version IT, ES) l/min 2.7 - 6 (9) 2.7 - 8 (12)Minimum flow pressure / for 95% Qmax

2) bar 0.27 / 0.9 0.27 / 0.8Max. permissible overall pressure bar 10 10DHW temperature range * °C 65 65Expansion vessel Total capacity Inlet pressure

l

bar

10

0.75

10

0.75Flue gas mass flow rate 1) g/s 6.8 / 8.5 10 / 13.2Flue gas temperature 1) °C 100 / 160 100 / 170Required boiler draught Pa 0 0Flue gas group according to DVGW G 635 G01 G01Flue gas monitoring delay min - -Electrical connection V~/Hz 230/50 230/50In-built safeguard, connection/circuit board A 3.15 mT / 2x2F 3.15 mT / 2x2FPower consumption / standby W 120 / 6 120 / 6Protection IPX 4D IPX 4DTotal weight (dry) kg 42 43.5CE ID CE-0085BT0420

1) QB_Min / QB_Rated at 80/60 °C at the boiler connection 2) Applies only to combi boiler versions CGU-2 K and CGG-2 K

* Only use temperatures above 60 °C under controlled conditions, as there is a risk of scalding.

62 3062347_0309

TroubleshootingAny faults will be displayed as fault code by Wolf controllers with eBUS capability. To these faults, cause and remedy may be allocated 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 TBV excess temperature

The flow temperature has exceeded the limit forthe TBV shutdown temperature.

Heat exchanger severely contaminated.

Check the system pressure. Check the heating circuit pump. Check the HC pump step switch. Vent the heating system. Press reset button. Clean the heat exchanger.

4 No flame established No flame established during the burner start. Check the gas supply line and open the gas valve, if necessary. Check the ignition electrode and ignition cable. Press the reset button.

5 Flame failure during operation

Flame failure during flame stabilisation or soft start.

Check CO2 Values. Check ionisation electrode and cable.

6 TW excess temperature The flow/return temperature has exceeded the limit for the TW shut-down temperature.

Check the system pressure. Vent the system. Set the pump to stage 2 or 3.

7 TBA excess temperature

Maximum flue gas temperature exceeded or escape of flue gas at the draught safeguard

Check chimney draught; check supply of combustion air; clean the burner; check gas nozzle pressures.

8 Flue gas damper does not activate

Flue gas damper or its feedback faulty. Check lead.Replace flue gas damper.Check bridges in junction box.

10 Flow sensor 2 faulty Sensor 2 for the flow temperature orthe lead is faulty.

Check lead. Check/replace flow temperature 2.

11 Flame pretence A flame is recognised before theburner starts.

Check the ionisation.Press the reset button.

12 Flow sensor 1 faulty Sensor 1 for the flow temperature orthe lead is faulty.

Check lead. Check/replace flow temperature 1.

14 Cylinder sensor faulty DHW temperature sensor or lead faulty. Check lead.Check/replace cylinder sensor.

15 Outside temperaturesensor faulty

The sensor for the outside temperature orthe lead is faulty.

Check lead.Check/replace outside temperature sensor

17 Modulation current error

The modulation current was outside its nominal range by 20 mA for at least 10 seconds.

Press the reset button; Modulating valve and feed control; Check modulation current

22 Lack of air Differential pressure switch will not switch ON. Press the reset button; check the silicone hoses to the differential pressure switch. Check flue gas system and gas fan. Check the differential pressure switch.

23 Fault differentialpressure switch

Differential pressure switch does not switch OFF. Press reset button; replace the differential pressure switch, if required.

25 Gas fan fault The gas fan does not reach the set speed. Press the reset button, check the gas fan lead cable, check the flue gas fan and replace the gas fan.

26 Gas fan fault The gas fan does not stop. Press the reset button, check the gas fan lead cable, check the flue gas fan and replace the gas fan.

40 System pressure switch fault

The system pressure switch has responded. Check the system pressure switch.Check the system pressure.

41 Flow monitoring Flow temperature 1 > flow temperature 2 + 12 K , temperature change too great.

Vent the heating system, check the system pressure. Check heating circuit pump.

45 Fault sensorFlow rate

Lead or sensor faulty or not connected. Check the lead and replace the sensor, if required.

46 Fault DHW outlet temperature

Lead or sensor faulty or not connected. Check the lead and replace the sensor, if required.

52 Max. cylinder heating time exceeded

The cylinder heating time takes longer than is set. Check drawing rate, check DHW cylinder.

78 Manifold sensor faulty The manifold sensor is outside its permitted range. Check manifold sensor, replace.(The calculation of the set flow temperature changes according to the flow sensor).

633062347_0309

Sensor resistances

NTCSensor resistances

Boiler sensor, cylinder sensor, solar cylinder sensor, outside temperature sensor, return sensor, flow sensor, manifold sensor

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

64 3062347_0309

Product data sheet according to EU regulation no. 811/2013Product fiche according to Regulation (EU) no. 811/2013

Product group: CGU-2K

Supplier’s name or trade mark Wolf GmbH Wolf GmbHSupplier’s model identifier CGU-2K-18 CGU-2K-24

Load profile M M

Seasonal space heating energy efficiency class C C

Water heating energy efficiency class A A

Rated heat output Prated kW 18 24

Annual energy consumption for space heating QHE kWh 12348 16154

Annual fuel consumption for water heating AFC GJ 6 7

Seasonal space heating energy efficiency ηs % 78 79

Seasonal water heating energy efficiency ηwh % 67 65

Sound power level, indoors LWA dB 50 52

Any specific precautions that shall be taken when the space heater is assembled, installed or maintained

See installation instruction

See installation instruction

Wolf GmbH, Postfach 1380, D-84048 Mainburg, Tel. +49-8751/74-0, Fax +49-8751/741600, Internet: www.wolf-heiztechnik.deMaterial number: 3020409 03/2015

GB IE

653062347_0309

Technical parameters according to EU regulation no. 813/2013

Type CGU-2K-18 CGU-2K-24Condensing boiler [yes/no] no noLow temperature boiler (**) [yes/no] no noB11 boiler [yes/no] yes yesCogeneration space heater [yes/no] no noIf yes, equipped with a supplementary heater

[yes/no] - -

Combination heater [yes/no] yes yesItem Symbol UnitRated heat output Prated kW 18 24Useful heat output at rated heat output and high-temperature regime (*)

P4 kW 18,0 24,0

Useful heat output at 30% of rated heat output and low-temperature regime (**)

P1 kW 5,4 7,2

Auxiliary electricity consumption at full load

elmax kW 0,013 0,013

Auxiliary electricity consumption at part load

elmin kW 0,012 0,012

Auxiliary electricity consumption in standby mode

PSB kW 0,005 0,005

Seasonal space heating energy efficiency

ns % 78 79

Useful efficiency at rated heat output and high-temperature regime (*)

n4 % 81,0 81,2

Useful efficiency at 30% of rated heat output and low-temperature regime (**)

n1 % 82,4 83,2

Standby heat loss Pstby kW 0,144 0,190Ignition burner power consumption

Ping kW 0,000 0,000

Emissions of nitrogen oxides NOx mg/kWh 23 20Declared load profile (M, L,

XL, XXL)- M M

Daily electricity consumption Qelec kWh 0,164 0,159Water heating energy efficiency nwh % 67 65Daily fuel consumption Qfuel kWh 9,028 9,357Contact details Wolf GmbH, Industriestraße 1, D-84048 Mainburg

(*) High-temperature regime means 60°C return temperature at heater inlet and 80°C feed temperature at heater outlet.(**) Low temperature means for condensing boilers 30°C, for low-temperature boilers 37°C and for other heaters 50°C return temperature (at heater inlet).

66 3062347_0309

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Gas throughput table ........................................................ 37Guidelines for commissioning........................................... 19

HHeating water temperature selector ................................. 20

IIlluminated signal ring as status indicator ......................... 20Input E1 (24 V) connection ............................................... 17Installation dimensions ..................................................... 10Installation dimensions with cylinder .................................11Installation inside a cupboard ........................................... 13Installation instructions ..................................................... 10Installation on finished/unfinished walls............................ 12

LLAS and flue chimney e.g. Plewa, Schiedel ..................... 48Layout ................................................................................. 9Layout CGG-2(K) 18/24...................................................... 8Layout CGU-2(K) 18/24 ...................................................... 7Lower burner output HZ.................................................... 23

MMaintenance: Cleaning the DHW heat exchanger ........... 55Maintenance: Cleaning the gas burner............................. 53Maintenance: Cleaning the heating water heat exchanger 54Maintenance: Cleaning the strainer in the cold water inlet 57Matching the pipe length .................................................. 23Max. cylinder heating time ................................................ 29Maximum DHW temperature ............................................ 29Maximum limit, boiler circuit TV - max .............................. 25Minimum boiler water temperature TK-min. ..................... 29

NNotes ................................................................................ 64Nozzle pressures .............................................................. 36Nozzle replacement .......................................................... 34Nozzle size ....................................................................... 34Number of nozzles............................................................ 34

OOutput A1 (230VAC;200VA) ............................................. 15Outside temperature sensor connection........................... 17

PParameter overview / setting report.................................. 22Programmable input E1 .................................................... 27Programmable output A1 .................................................. 28Pump operating mode / boiler pump ................................ 24

AAdjusting the flue lengths CGG-2(K) ................................ 39Adjusting the gas type ...................................................... 35Anti-seizing pump protection ............................................ 21

BBalanced flue system (LAF) horizontal CGG-2(K)............ 46Balanced flue system (LAF) vertical CGG-2 (K) ............... 47Boiler certification ............................................................. 37Boiler circuit pump run-on time ......................................... 25Boiler overtemperature during DHW cylinder heating ...... 30Burner cycle block ............................................................ 26Burner switching differential ............................................. 23

CChanging a fuse ............................................................... 15Checking and adjusting the nozzle pressure .................... 36Checking the flue gas monitoring CGU-2(K) .................... 44CO2 value in % at CGG2 ................................................. 40Code scan ........................................................................ 23Cold water and DHW connection ..................................... 13Commissioning gas connection ........................................ 33Commissioning guidelines ................................................ 19Commissioning report....................................................... 50Connection of digital Wolf control accessories (e.g. BM, MM, SM1, SM2, KM) ......................................... 17Contractor level ................................................................ 23Conversion to other gas types .......................................... 34Cylinder hysteresis ........................................................... 29

DDHW connection versions ................................................ 31DHW cylinder sensor connection ..................................... 17DHW Quick Start .............................................................. 26DHW temperature selector ............................................... 20Diagram - bypass valve .................................................... 43Diagram - limiting the maximum output ............................ 41Dimensions ......................................................................... 6Disposal ............................................................................ 49

EElectrical connection CGG-2 (K) ...................................... 16Electrical connection CGU-2 (K)....................................... 15Emissions test mode ........................................................ 21Engineering information - balanced flue system............... 45Equipment codes ................................................................ 9External accessories CGG2 ............................................. 16

FFault history ...................................................................... 30Filling the system .............................................................. 18Filling / venting the system ............................................... 18Flue gas damper connection CGU2 ................................. 15Flue gas damper for CGU-2(K) ........................................ 49Flue gas test CGU-2(K) / CGG-2(K) ................................. 40Frost protection limit ......................................................... 23

GGas connection................................................................. 13

673062347_0309

Keyword index

RReadjust the gas valve ..................................................... 38Replacing expansion vessel ............................................. 56Reset .......................................................................... 20, 31

SSafety instructions .............................................................. 3Selecting the pump stage ................................................. 42Sensor resistances ........................................................... 63Service report ................................................................... 51Setting the eBUS address for cascade mode................... 32Sound insulation ............................................................... 10Specification CGG-2(K) 18/24 .......................................... 61Specification CGU-2(K) 18/24 .......................................... 60Standards and regulations.................................................. 5Summer mode .................................................................. 21

TTerminal box ..................................................................... 14Troubleshooting ................................................................ 62

UUpper burner output HZ.................................................... 24Upper burner output WW.................................................. 24

VVenting and filling the system ........................................... 18

WWinter mode ..................................................................... 21Wiring diagram CGG-2(K) ................................................ 59Wiring diagram CGU-2(K) ................................................ 58

EC declaration of conformity(according to DIN EN ISO/IEC 17050-1)

Number: 3062347

Issued by: Wolf GmbH

Adress: Industriestr. 1 D-84048 Mainburg

Product: Wall mounted gas fired boilers CGG-2-18/24, CGU-2-18/24, CGG-2K-18/24, CGU-2K-18/24

The product described above conforms to the requirements specified in the following documents

§ 6, 1.BlmSchV, 26.01.2010 DIN EN 297, 10/2005 DIN EN 298, 09/2006 DIN EN 483, 06/2000 DIN EN 625, 10/1995 DIN EN 60335-1, 02/2007 DIN EN 60335-2-102, 04/2007 DIN EN 55014-2, 06/2009

In accordance with the following Directives

90/396/EEC Gas user equipment 2004/108//EG (EMC Directive) 2006/95/EG (Low Voltage Directive) 2009/125/EG (ErP Directive) 2011/65/EU (RoHS Directive)

this product is identified as follows:

Mainburg, 15.07.2015

Gerdewan JacobsEngineering Director

i.V. Klaus GrabmaierTechnical Manager

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