Installation instructions and technical guideOil condensing boilerCOB Boiler for heatingCOB-CS Boilerwithstratificationcylinder
Document no.: 3062547_0311 Subject to modifications GB
Wolf GmbH · Postfach 1380 · D-84048 Mainburg · Tel. +49-8751/74-0 · Fax +49-8751/741600 · Internet: www.wolf-heiztechnik.de
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IndexIndex ..................................................................................................................Page
1. Safety instructions ...................................................................................................3
2. COB/COB-CS installation/standard delivery ...........................................................4
3. Specification .........................................................................................................5-7
4. Layout/description of components ...........................................................................8
5. System examples ....................................................................................................9
6. Standards and regulations..................................................................................... 10
7. Installation instructions ...........................................................................................11
Installation ............................................................................................................ 12-21
8. General notes ........................................................................................ 12-13
9. Installation accessories ...............................................................................14
10. Boiler/CS cylinder ......................................................................................15
11. Installation examples .................................................................................16
12. Oil connection in a single-line system .......................................................17
13. Siphon/neutralisation/condensate pump ...................................................18
14. Installation of a balanced flue system .......................................................19
15. Filling the heating system ..........................................................................20
16. Electrical connection .................................................................................21
Control unit .......................................................................................................... 22-31
17. Control unit .......................................................................................... 22-23
18. Displaying/modifying control parameters/Settings report ......................... 24
19. Contractor level parameters ................................................................ 25-31
Cascade operation ............................................................................................... 32-39
20. Control/specification/notes ........................................................................32
21. Flue system design ...................................................................................33
22. Flue gas header version ............................................................................34
23. Flue gas header version / notes ......................................................... 35-36
24. Flue gas damper installation ................................................................... 37
25. Flue gas damper installation / wiring diagram ......................................... 38
26. Flue gas damper tightness test ................................................................39
Commissioning .....................................................................................................40-44
27. Commissioning with Wolf control accessories (BM) ...........................40-41
28. Commissioning without Wolf control accessories (BM) ..................... 42-43
29. Commissioning report ...............................................................................44
30. Maintenance and design data .............................................................45-46
31. Design information - balanced flue system .........................................47-55
32. Wiring diagram .........................................................................................56
33. Reset ........................................................................................................57
34. Troubleshooting ................................................................................... 58-59
EC Declaration of Conformity ....................................................................................60
33062547_0311
1.SafetyinstructionsThefollowingsymbolsareusedinconjunctionwiththese important instructions concerning personal safety,aswellasoperationalreliability.
"Safety instructions" are instructionswith which you must comply exactly, toprevent risks and injuries to individuals andmaterial losses.
Danger through 'live' electrical components!NB: Switch OFF the ON/OFF switch before removing the casing.
Never touch electrical components or contacts when the ON/OFF switch is in the ON position! Thisresultsinariskofelectrocutionthatmayleadtoinjuryordeath.
The terminals are 'live' even when the ON/OFF switch is in the OFF position.
This indicates technical instructions which you must observe to prevent damage andmalfunctions.
NB
Diagram: Terminal box: Danger from electrical voltage
Diagram: Danger from electrical voltage and hot components
MaintenanceNB - only a heating contractor has thenecessaryknowledgeandexpertise!
- According to paragraph 10(3) EnEV the user is required to have the system serviced regularly to ensure the reliable and safe function of the oil condensing boiler.
- The boiler should be serviced annually.- Maintenance is explicitly detailed in the installation and
maintenance instructions.- Isolate the boiler from the power supply before any
maintenance work is carried out.- After a service and before the oil condensing boiler is
restarted, check that all components that were removed for maintenance have been refitted correctly.
- We recommend you arrange a maintenance contract with an approved heating contractor.
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2. COB/COB-CS installation/ standarddelivery
Oil condensing boilerConnection adaptor for flue gas with test nippleSiphon with hoseStainless steel cleaning brushMaintenance tool with setting gaugeProtective cap for maintenanceCOB/CS installation instructions COB/CS operating instructions COB/CS maintenance instructionsOil filter insert 40 μm
Oil condensing boilerStratification cylinderConnection adaptor for flue gas with test nippleSiphon with hoseStainless steel cleaning brushMaintenance tool with setting gaugeProtective cap for maintenanceCOB/CS installation instructionsCOB/CS operating instructions COB/CS maintenance instructionsOil filter insert 40 μm
COBstandarddelivery COB-CSstandarddelivery(notwithCOB-40)
The appliance is fully assembled with the casing fitted, and the control unit is fully wired.
COB-15/20/29/40 oil condensing boiler for heating with connection option for DHW cylinder e.g. SE-2, SEM-1, BSP
COB-15/20/29 oil condensing boiler with CS stratification cylinder, on the right, floorstanding
COB-15/20/29 oil condensing boiler with CS stratification cylinder, on the left, floorstanding
COB-15/20/29 oil condensing boiler with CS stratification cylinder, at the back, floorstanding
CO
B-1
5/20
/29:
129
0
5661210
CO
B-1
5/20
/29:
129
0
1132605
CO
B-1
5/20
/29:
129
0
6051132
CO
B-1
5/20
/29:
129
0C
OB
-40:
149
0
566605
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3.SpecificationBalanced flue connection
Opening the casing Closing the casing
Type plate
Return Optional fixing point for oil filter
Flow
Recesses for individual piping of the heating connections
Entries for oil hoses (optional)
Condensate drain level
1084
566
605
603
122
CO
B-1
5/20
/29:
129
0C
OB
-40:
149
0462
203
CO
B-4
0: 1
209
CO
B-1
5/20
: 919
194
516
26042
6
CO
B-2
9: 9
30
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3.SpecificationOil condensing boiler COB-15 COB-15/CS COB-20 COB-20/CSRated output at 80/60 °C, stage 1/2 kW 9.0 / 14.4 9.0 / 14.4 13.1 / 19.0 13.1 / 19.0Rated output at 50/30 °C, stage 1/2 kW 9.5 / 15.1 9.5 / 15.1 13.9 / 20.0 13.9 / 20.0Rated load, stage 1/2 kW 9.2 / 14.7 9.2 / 14.7 13.5 / 19.6 13.5 / 19.6Oil throughput, stage 1/2 kg/h 0.86 / 1.38 0.86 / 1.38 1.15 / 1.66 1.15 / 1.66Rated capacity CS (equivalent) Ltr - 160 (200) - 160 (240)Constant cylinder output CS kW/Ltr/h - 15 / 370 - 20 / 490Performance factor CS NL60 - 3,5 - 4.5DHW output CS l/10min - 250 - 280Standby input CS kWh/24h - 1.47 - 1.47Max. permissible cold water supply pressure CS bar - 10 - 10Minimum anode current, protective magnesium anode mA - > 0.3 - > 0.3External diameter, heating flow G 1½" 1½" 1½" 1½"External diameter, heating return G 1½" 1½" 1½" 1½"Condensate connection 1" 1" 1" 1"Oil connection, flow/return hoses G 3/8" 3/8" 3/8" 3/8"Cold water inlet G - 3/4" - 3/4"DHW connection G - 3/4" - 3/4"DHW circulation connection G - 3/4" - 3/4"Height mm 1290 1290 1290 1290Width mm 566 1132 566 1132Depth mm 605 605 605 605Boiler weight kg 92 92 92 92Cylinder weight kg - 76 - 76Balanced flue connection mm 80/125 80/125 80/125 80/125Balanced flue routing type B23, B33, C33(x), C43(x), C53(x), C63(x), C83(x), C93(x)Fuel oil Fuel oil EL, low sulphur, bio-oil B10 or fuel oil EL standardNozzle* Danfoss
0.30 / 80°S LESDanfoss
0.40 / 80°S LEFuel oil filter Siku max. 40 μmCO2 setting stage 1 and stage 2 % 13.5 ± 0.3 13.5 ± 0.3 13.5 ± 0.3 13.5 ± 0.3Pump pressure stage 1 bar 5.0 ± 0.5 5.0 ± 0.5 8.5 ± 1 8.5 ± 1Pump pressure stage 2 bar 12.0 ± 1.0 12.0 ± 1.0 16.8 ± 2.5 16.8 ± 2.5Maximum negative pressure in oil lines bar -0.3 -0.3 -0.3 -0.3Flow temperature, factory setting °C 80 80 80 80Max. flow temperature °C 85 85 85 85Heating water pressure drop at Δ T=20 K mbar 3.6 3.6 6 6Heating water pressure drop at Δ T=10 K mbar 12 12 21 21Max. permissible boiler pressure bar 3 3 3 3Heating surface, heating water heat exchanger m² 2.55 2.55 2.55 2.55Heat exchanger water content Ltr. 7.5 7.5 7.5 7.5Seasonal efficiency [to DIN] at 40/30 °C (Hi / Hs) % 105 / 99 105 / 99 105 / 99 105 / 99Seasonal efficiency [to DIN] at 75/60 °C (Hi / Hs) % 101 / 96 101 / 96 101 / 96 101 / 96Efficiency at rated load at 80/60 °C (Hi / Hs) % 97 / 92 97 / 92 97 / 92 97 / 92Efficiency at 30% partial load and TR=30 °C (Hi / Hs) % 103 / 97 103 / 97 103 / 97 103 / 97Boiler standby loss qB at 70 °C (EnEv) % 0.75 0.75 0.75 0.75Rated heat input (stage 2): Flue gas mass flow rate g/s 6.45 6.45 9.06 9.06 Flue gas temperature 50/30 - 80/60 °C °C 40 - 63 40 - 63 49 - 69 49 - 69 Available fan draught Pa 65 65 65 65Lowest heat input (stage 1): Flue gas mass flow rate g/s 4.04 4.04 6.28 6.28 Flue gas temperature 50/30 - 80/60 °C °C 35 - 55 35 - 55 40 - 61 40 - 61 Available fan draught Pa 32 32 45 45Electrical connection V~/Hz 230/50 230/50 230/50 230/50Integral fuse (medium slow) A 5 A 5 A 5 A 5 APower consumption, stage 1 / stage 2 W 86/128 86/128 99/139 99/139Protection IP20 IP20 IP20 IP20 Condensate volume at 40/30 °C Ltr./h 1.2 1.2 1.6 1.6Condensate pH value approx. 3 approx. 3 approx. 3 approx. 3CE ID CE-0085BS0326
* These nozzles comply with the emission requirements according to RAL-UZ 46 and ensure reliable operation. No other nozzles are permissible!
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* These nozzles comply with the emission requirements according to RAL-UZ 46 and ensure reliable operation. No other nozzles are permissible!
Oil condensing boiler COB-29 COB-29/CS COB-40Rated output at 80/60 °C, stage 1/2 kW 18.5 / 28.2 18.5 / 28.2 25.3 / 38.0Rated output at 50/30 °C, stage 1/2 kW 19.6 / 29.6 19.6 / 29.6 26.8 / 40.0Rated load, stage 1/2 kW 19.0 / 29.0 19.0 / 29.0 26.0 / 38.8Oil throughput, stage 1/2 kg/h 1.60 / 2.45 1.60 / 2.45 2.44 / 3.64Rated capacity CS (equivalent) Ltr - 160 (260) -Constant cylinder output CS kW/Ltr/h - 29 / 710 -Performance factor CS NL60 - 5.0 -DHW output CS l/10min - 300 -Standby input CS kWh/24h - 1.47 -Max. permissible cold water supply pressure CS bar - 10 -Minimum anode current, protective magnesium anode mA - > 0.3 -External diameter, heating flow G 1½" 1½" 1½"External diameter, heating return G 1½" 1½" 1½"Condensate connection 1" 1" 1"Oil connection, flow/return hoses G 3/8" 3/8" 3/8"Cold water inlet G - 3/4" -DHW connection G - 3/4" -DHW circulation connection G - 3/4" -Height mm 1290 1290 1490Width mm 566 1132 566Depth mm 605 605 605Boiler weight kg 99 99 122Cylinder weight kg - 76 -Balanced flue connection mm 80/125 80/125 110/160Balanced flue routing Type B23, B33, C33(x), C43(x), C53(x), C63(x), C83(x), C93(x)Fuel oil Fuel oil EL, low sulphur, bio-oil B10 or fuel oil EL standardNozzle* Danfoss
0.55 / 80° S LEDanfoss
0.65/ 80°S LEFuel oil filter Siku max. 40 μmCO2 setting stage 1 and stage 2 % 13.5 ± 0.3 13.5 ± 0.3 13.5 ± 0.3Pump pressure stage 1 bar 8.5 ± 1 8.5 ± 1 9.8 ± 1Pump pressure stage 2 bar 16.8 ± 2.5 16.8 ± 2.5 18.0 ± 2.5Maximum negative pressure in oil lines bar -0.3 -0.3 -0.3Flow temperature, factory setting °C 80 80 80Max. flow temperature °C 85 85 85Heating water pressure drop at Δ T=20 K mbar 17 17 54Heating water pressure drop at Δ T=10 K mbar 55 55 205Max. permissible boiler pressure bar 3 3 3Heating surface, heating water heat exchanger m² 3.05 3.05 3.85Heat exchanger water content Ltr. 9.0 9.0 11.5Seasonal efficiency [to DIN] at 40/30 °C (Hi / Hs) % 105 / 99 105 / 99 105 / 99Seasonal efficiency [to DIN] at 75/60 °C (Hi / Hs) % 101 / 96 101 / 96 102 / 97Efficiency at rated load at 80/60 °C (Hi / Hs) % 97 / 92 97 / 92 98 / 93Efficiency at 30% partial load and TR=30 °C (Hi / Hs) % 103 / 97 103 / 97 103 / 97Boiler standby loss qB at 70 °C (EnEV) % 0.55 0.55 0.45Rated heat input (stage 2): Flue gas mass flow rate g/s 13.33 13.33 17.51 Flue gas temperature 50/30 - 80/60 °C °C 55 - 76 55 - 76 56 - 83 Available fan draught Pa 105 105 150Lowest heat input (stage 1): Flue gas mass flow rate g/s 9.05 9.05 10.91 Flue gas temperature 50/30 - 80/60 °C °C 40 - 64 40 - 64 43 - 68 Available fan draught Pa 55 55 72Electrical connection V~/Hz 230/50 230/50 230/50Integral fuse (medium slow) A 5 A 5 A 5 APower consumption, stage 1 / stage 2 W 129 / 178 129 / 178 126 / 205Protection IP20 IP20 IP20Condensate volume at 40/30 °C Ltr./h 2.2 2.2 2.8Condensate pH value approx. 3 approx. 3 approx. 3CE ID CE-0085BS0326
3.Specification
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7
8
9
1011
2
3
6 5
4
1
COB-CS oil condensing boiler with stratification cylinder
Cold water
DHW
DHW circulation
Oil condensing boiler Stratificationcylinder
1 Cylinder heating from above with deflector and divider 2 DHW draw-off at the highest point 3 Cold water supply with control and distribution appliance 4 Cold water draw-off for cylinder heating 5 DHW circulation line 6 Protective magnesium anode 7 Sensor well for cylinder temperature sensor 8 Drain (in standard delivery) 9 Siphon 10 Neutralising system (accessory) 11 Condensate pump (accessory)
CSstratificationcylindercannotbeinstalledwithCOB-40NB
4.Layoutofcomponents
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5. Description of components
Automatic air vent
Regulated stratification pump
Blast tube connection
Plate-type heat exchanger
Oil pump motor
Immersion pipe, cylinder sensor
Two-stage oil pump
Stratification sensor
Boiler sensor
Cylinder primary pump
High limit safety cut-out
Heating return 1"
Ignition transformer
Flue gas temperature limiter
Expansion vessel 8 l (accessory)
Water pressure switch
Heating flow 1"
Drain valve
DHW circulation (accessory)
Drain
Protective anode (under cover)
Flame monitor
Fan
Cold water connection ¾" (optional accessory)
COB component description
CS component description
Hot water connection ¾"
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To save energy and protect against scalingif the total hardness is greater than 15 °dH (2.5mol/m³),theDHWtemperaturemaybesetto a maximum of 50 °C.
If the total hardness is greater than 20 °dH (3.58mol/m³),we recommendusing awatertreatmentfacilityinthecoldwatersupplylineforDHWheating,toprolongthemaintenanceinterval(descalingDHWheatexchanger).
COB / COB-CS oil condensing boiler
Two-stage oil condensing boiler with electronic ignition and electronic flue gas monitoring, for low temperature heating and DHW heating in heating systems with flow temperatures of up to 85 °C and a permissible operating pressure of 3 bar.
The COB complies with the following regulations:
EC Directives: - 92/42/EEC Efficiency Directive - 2004/108/EC EMC Directive - 2006/95/EC Low Voltage Directive
DIN / EN Standards: EN 230, EN 303, EN 304, EN 15034, EN 15035, EN 12828, EN 61000-3-2, EN 61000-3-3, EN 61000-4-3, EN 55014-1, EN 60335-1, EN 60335-2-102, EN 60529
Stratification cylinder type CS made of steel S235JR with connections to the on-site pipework.
Corrosion protection through enamel coating on the inside of the cylinder as per DIN 4753 and additional corrosion protection through a protective magnesium anode.
Openflueoilcondensingboilersmustonlybeinstalled in a room which complies with the appropriate ventilation requirements. Otherwise there is a riskof asphyxiationor poisoning.Read these installation and maintenance instructions before installing the boiler. Also take the technical guide into consideration.
Note: The DHW temperature should be limited to a maximum of 55 °C if the hardness of the hot water is more than 2.86 mmol/l. A reduced DHW temperature prevents excessive scaling. Thiscutsthelevelofmaintenanceandenergyinput.
6. Standards and regulations
ObtainthepermissionofyourlocalfluegasinspectorandthelowerwaterauthoritypriortotheinstallationofWolfoil condensing boilers.
Wolf oil condensing boilers must only be installed by a recognised heating contractor. This heating contractor will also be responsible for the proper installation and the commissioning of the heating system. The DVGW Code of Practice G676, boiler room guidelines or Building Regulations relating to the construction and installation of central boiler rooms and fuel storage facilities apply.
Thefollowingregulations,rulesandguidelinesmustbeobserved during installation:
- Energy Savings Act (EnEG) and related directives
- EnEV Energy Savings Order
- Technical regulations for oil installations IWO-TRÖL 2006 in the currently applicable version
Note: Pleasereadtheseinstructionscarefullybeforethe installation and keep them in a safe place. Please also note the technical information in the appendix.
Anydamageor loss resulting from technicalmodificationstothecontrolunitortothecontrolcomponentsareexcludedfromourliability.
- DIN 1988 Technical rules for DHW installations
- DIN EN 12831 Procedure for calculating the standard heating load
- EN 12828 Heating systems in buildings
Designing DHW heating systems
- DIN 4701 Rules for calculating the heat demand of buildings
- DIN 4751 Part 3 Safety equipment for heating systems with flow temperatures of up to 95 °C
- DIN 18160 Domestic chimneys
- DIN EN 1717 Protection of DHW against contamination in DHW installations
- ATV-A-251 Materials for drain pipes for condensate from condensing boilers
- VDI 2035 Avoiding damage in DHW heating systems Scaling in general water and DHW heating systems Local regulations from building and industry regulatory agencies (mainly covered by the local flue gas inspector)
- DIN VDE 0100 Regulations regarding the installation of high-voltage systems with rated voltages up to 1000 V
- VDE 0105 Operation of high-voltage systems, general considerations
- DIN EN 60529 Protection through casings
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7. Installation instructionsTransport Boiler/stratificationcylinder
- The boiler and the stratification cylinder are transported, fully packaged, on a pallet
- A sack truck is a suitable means of transportation
- Position the sack truck behind the boiler or stratification cylinder, secure with a strap and transport to the installation location
The COB and CS are installed adjacent to the wall, which means that a clearance of 70 cm only needs to be observed at the front. When installing the boiler, you should observe the recommended wall clearances in order to simplify assembly, maintenance and servicing.
Recommended minimum wall clearance
Installation information - Install the boiler or boiler plus DHW cylinder on a level surface which is substantial enough to carry its weight.
- Level the boiler and stratification cylinder horizontally using adjustable feet.
Adjustable feet
- Remove strap and packaging
- Remove the four fixing screws on the pallet
- Lift the boiler and/or stratification cylinder off the pallet
COB with CS behind
- The boiler must only be installed in a room that is protected from frost. Drain the boiler, stratification cylinder and heating system if there is a risk of frost when the system has been shut down.
- Boilers should not be installed in a room that is subject to aggressive vapours or in very dusty or highly humid conditions (workshops, washrooms, hobby rooms, etc.).
- The combustion air must be free from halogenated hydrocarbons.
NB
NB
NB
COB with CS rightor left
COB-40 minimum
room height
COB
70 cm 70 cm
70 c
m
70 c
m
70 c
m
190
cm
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8. Installation - general notesNote:Provide a fill and drain valve at the lowest point in the system.
SafetyequipmentThe COB has not been fitted with an expansion vessel at the factory. This must be fitted externally (available from the Wolf accessories range). The expansion vessel must be in accordance with DIN 4807.
There should not be a shut-off valve between the expansionvesselandtheoilcondensingboiler,because otherwise the pressure build-up would permanentlydamagetheboilerduringheating.Thereisariskofsystemcomponentsrupturing,giving rise to a risk of scalding.
Exceptions are cap valves upstream of the expansion vessel. The safety assembly from the Wolf accessories range includes an integral 3 bar safety valve. Route the blow-off line into a drain outlet. The minimum system pressure is 1.0 bar.The oil condensing boiler is permitted exclusively for sealed systems of up to 3 bar. The maximum flow temperature is factory-set to 80 °C and may be adjusted to 90 °C if required. Generally, the maximum flow temperature is 80 °C for DHW operation. There is no need for a minimum throughput at flow temperatures below 80 °C.
We recommend a heating water pH value of between pH 6.5 and pH 8.5. Wolf does not assume liability for any damage to the heat exchanger caused by oxygen diffusion in the heating water. In the event of oxygen penetrating the system, we recommend a system separation through the interconnection of a heat exchanger.
If the limit curve is exceeded, an appropriate portion of the system water must be treated.Example:Total hardness of the domestic hot water: 19°dHSystem volume: 1 m³This means at least 0.3 m³ = 300 l must be desalinated.Permissible methods:- Desalination using mixed-bed cartridges. These are multi-stage ion exchangers. We recommend, for example, using the "Megafill Alu" cartridges from Taconova for the first fill, and later as and when required.- Topping up with distilled water.
Tota
l har
dnes
s in
°dH
System volume in m3
Water treatment necessary
Water treatment not necessary
0.3 m3
Inhibitors (substances to prevent corrosionand limescale deposits) and antifreeze arenot permitted. There is a risk of damage to the boiler resulting from poor heat transfer or corrosion.
Heating waterThe return line to the appliance should have a dirt trap. Deposits in the heat exchanger may lead to boiling noise, a drop in performance or faults in the appliance. Domestic hot water may be used as fill water and top-up water. The addition of chemicals or de-scaling using single-stage ion exchangers is not permissible. In the case of high-volume systems or those where large top-up water volumes (e.g. due to water losses) are required, the following values must be observed.
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Wehighlyrecommendthatyouuselowsulphurfueloilto protect the environment.
Information on the use of bio-oil blends:
1. Permissible bio-oil percentages
The COB (from date of manufacture May 2010) can be operated with fuel oil with up to 10 % alternative constituents –B10- to DIN V 51603-6.
2.Bio-oilquality
The bio-oil must comply with EN 14213 when the customer tank is filled.
3. Oil storage tanks
The customer must obtain written confirmation from the manufacturer or supplier regarding the suitability of the tank for the use of bio-oils, giving the maximum permitted FAME percentage. It is important to ensure that the tank fittings and gaskets are suitable for bio-oil.
4. Cleaning the tank
FAME acts as a solvent, removing all deposits and residues in the tank and the oil lines. Wolf therefore always recommends cleaning the tank before filling it with bio-oil.
5. Storing bio-oils
Bio-oil is a natural product with a lower shelf life than fuel oil EL. Bio-oil must therefore be stored at low temperatures (ambient temperature between 5 °C and 20 °C) and protected from exposure to direct sunlight (in the case of plastic tanks in particular).Up-to-date information indicates that bio-oil should not be stored for longer than one year, but the mineral oil industry is currently searching for suitable additives to increase the shelf life.
6.Oilsupplytotheboiler
The oil line system mustbesetupasasinglelinesystem in order to avoid oxidising effects resulting from the introduction of air-borne oxygen into the oil tank.The oil lines must be made of plastics suitable for use with bio-oils, or stainless steel. Copper pipes and brass components, as well as galvanised pipes (damage to the bio-oil caused by zinc oxide coating), should also be avoided to prevent premature ageing of the oil.
Information from VDI 2035The method of commissioning in particular can affect scaling. Heat the system with burner stage 1 with an even and adequate throughput.Before commissioning, all hydraulic pipes must undergo a tightness test:Test pressure on heating water side max. 4 barPrior to testing, close the shut-off valves in the heating circuit for the appliance, because otherwise, the safety valve (accessory) opens at 3 bar. The appliance has already been tested at the factory for tightness at 4.5 bar.If the appliance is not watertight, there is a risk of leaks and resulting material losses.Themaximumflowratemustnotexceed6000l/h(100l/min).
8. Installation - general notes
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9. Installation - accessoriesWe recommend making the connection to the heating system with the following parts from the Wolf accessories range.
COBconnectionsetadjacenttothewallcomprising:2 cross pieces, each with one connection2 clips1 corrugated stainless steel pipe 1", length 1 300 mm1 corrugated stainless steel pipe 1", length 800 mm1 silicon grease tubeCOBconnectionsetwithCSadjacenttothewallcomprising:2 cross pieces, each with two connections4 clips3 corrugated stainless steel pipe 1", length 1 300 mm1 corrugated stainless steel pipe 1", length 800 mm2 corrugated stainless steel pipes ¾", length 800 mm1 silicon grease tube1 trimming set ¾"
COBconnectionsetadjacent to thewall fora freestandingcylinderuptoSEM-1-750andSE-2-750comprising:2 cross pieces, each with two connections3 corrugated stainless steel pipe 1", length 1 300 mm1 corrugated stainless steel pipe 1", length 800 mm4 clips 1 silicon grease tube 6 flat packings 1"1 pipe bend 2 flat packings 1½" EPDM1 pump 1 adaptor fitting G1½" (fem.)2 double nipples G 1" (male) - G 1" on G1" (male)1 elbow with air ventCSaccessorysetforcoldwatercomprising:1 expansion vessel 8 l1 cold water connection pipe to the expansion vessel2 double nipples ¾"1 trimming set ¾"
Pipeassemblycomprising:1 circulation pump2 thermometers in flow and return2 ball valves in flow and return- Incl. / excl. mixer- With manifold for 2 or 3 pipe assemblies
For further accessories, such as a safety assembly 1" or wallmounting bracket for pipe assembly, etc., see "Heatingsystems"pricelist
CSDHWcirculationpumpaccessorysetcomprising:1 analogue DHW circulation pump1 corrugated stainless steel pipe ¾"1 trimming set ¾"
Neutralisationbox,incl.plinthcomprising:1 granulate fill1 installation accessories set(for standard fuel oil EL (sulphur content > 50 ppm), neutralisation of the condensate is required).
Condensate lifting systemwith a zero-volt alarm outputcomprising:1 condensate lifting pump with a zero volt alarm output1 condensate tank with cover and wall mounting bracket1 PVC hose, 10 mm (6 m long)1 non-return valve1 condensate inlet adaptor
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10.Installation-boiler/CScylinderExample: COB-15/20/29 oil condensing boiler with CS stratification cylinder on the right,
floorstanding (when looking at front of boiler). The pipework for the heating flow and heating return, as well as the heating water flow and heating water return, are connected to the stratification cylinder with corrugated stainless steel pipes (accessories) (see chapter 9 "Installation - accessories").
Diagram: Cold water connection to DIN 1988
Non
-ret
urn
valv
e (in
divi
dual
ly te
sted
)
Dra
in
Shu
t-off
valv
e
Pres
sure
redu
cing
va
lve
Shu
t-off
valv
e
Col
d w
ater
inle
t
Pre
ssur
e ga
uge
port
DH
W fi
lter
Saf
ety
valv
e (in
divi
dual
ly te
sted
)
Dra
in
Above top edge of the cylinder
Boiler flow
Boiler return
Note: When selecting the installation material for the system, it is important to observe the technical rules and any possible electrochemical processes (mixed installation).
Cold water connection We recommend the installation of a maintenance valve into the cold water supply line. A tested and certified pressure reducer must be installed if the cold water supply pressure is above the maximum permissible operating pressure of 10 bar.Provide a centralised pressure reducer if mixer taps are used.Observe the regulations of DIN 1988 as well as those of your local water supply utility when connecting cold water and DHW. Your warranty rights may be lost if the installation does not comply with the illustration shown.
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11. Installation examples
Pipeassemblyfortwoheatingcircuitswithmanifoldforsafetyassemblyinstallation
Pipeassemblyforoneheatingcircuitforsafetyassemblyinstallation
Safety assembly for fixing to thecorrugated stainless steel pipes of heatingflowandreturn
The safety assembly and the required pipe assembly can be installed on the left, on the right or at the back of the boiler on a wall or attached to the side of the boiler casing.
Note: The pipe assembly for three heating circuits should always be wall mounted.
Pipeassemblyforthreeheatingcircuitswithmanifoldforsafetyassemblyinstallation
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12.Oilconnectioninasinglelinesystem
Assumptions:Kinematic viscosity 6 mm²/s at 20 °C, oil temperature = 10 °CAdditional pressure drops: 4 elbows 90°, 1 non-return valve, 1 shut-off valveIn view of possible outgassing of the oil, an inlet height of more than 4 m should be avoided.
Singlelinesystem
Secure the oil filter with the holder in the positions provided on the outside of the boiler casing. It can also be secured on the inside of the boiler. In this case, the oil hose can be up to 90 cm outside the casing when fed in from the top (to the back), and up to 50 cm when fed in from the bottom.
Oilfilter
Oil filter fitted inside the boiler
Oil filter fitted on the outside of the boiler
Oil lines that are too large may lead to operating faults caused by trapped air. The oil line must therefore have the smallest possible diameter.
Only materials that are suitable for oil lines should be used. In the case of copper pipes, only metallic compression fitting olives with support sleeves are permissible. They are a reliable means of preventing air intake.
The oil lines must be installed while the system is isolated from the electrical supply in order to avoid leaks.
With negative pressure controlled anti-lift valves, the negative pressure on the inlet side is increased considerably. It is often difficult to adhere to the maximum permissible negative pressure of 0.3 bar in the oil line. We therefore recommend using electromagnetically controlled anti-lift valves.The electrical anti-lift devices can be connected to the COB in two ways:1. The anti-lift valve is connected at output A1. For this, output A1 must be programmed to 9 (oil shut-off valve), see HG14.2. If output A1 is already being used (e.g. for a DHW circulation pump), an adaptor plug can be used. The plug (mat. no. 1718768761) is inserted between the motor of the oil pump.When connecting a feed pump in the supply line, the negative pressure must not exceed 0.5 bar.
Maximum line lengths insinglelinesystems
Single line system with pump higher than tank
Oil pump, burner
Floating air extraction
Single line system with pump lower than tank
Floating air extraction
Oil pump, burner
Anti-lift valve
Notes:
Only use filter inserts made of sintered plastic with 25 - 40 μm.
The temperature must not fall below +5 °C. External tanks must have supplementary heating facilities.
Contaminants can lead to system damage. The oil line must be flushed prior to commissioning.
The system must be connected as a single line system. A filter/air vent valve combination from the Wolf product range must be installed. Older two-line systemsmustbeconvertedtosinglelinesystems.Two-line systems lead to accelerated oil ageing and the penetration of air into the oil. They are no longer in line with the latest technology.In order to prevent damage to the oil pump, the fuel oil must be supplied to the filter using a suitable manual pump.
Output Throughput Internal line Ø Inlet height H (m)
kg/h mm 4 3 2 1 0 -1 -2 -3COB-15COB-20COB-29
to 2.54 77 68 58 49 40 31 22 13
6 100 100 100 100 100 100 87 64
COB-40 2.5 to 5.04 39 34 29 25 20 16 11 66 100 100 100 100 100 79 56 32
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13. Siphon/neutralisation/condensate pumpCondensate drain without neutralisation
If low sulphur fuel oil EL (sulphur content < 50 mg/kg) is used, it may be possible to forego neutralisation of the condensate after consultation with the lower water authority.
Connect the siphon supplied to the connectors on the combustion chamber pan.
Remove the sealing plug on the siphon plug before installing the siphon.
With a flexible siphon drain hose, form a connection to the on-site drain (condensate drain level from siphon 260 mm).When using a condensate pump, route the flexible siphon drain hose into the condensate pump and form a connection from there to the on-site drain.
Note: The siphon must be filled with water prior to commissioning.
If the appliance is operated with an empty siphon, there is a danger of poisoning caused by escaping flue gases. For this reason, the siphon must be filled with water prior to commissioning. Undo, remove and fill the siphon until water runs out of the side drain. Refit the siphon and make sure the gasket is perfectly seated.
If condensate is directly routed to the on-site drain, ventilation must be provided so that the drain pipe cannot affect the boiler.
NB
Condensate drain with neutralisation
For standard fuel oil EL (sulphur content > 50ppm),neutralisation of the condensate is required.
Note:Thesiphonandtheneutralisationboxmustbefilledwith water prior to commissioning.
Observe the neutralisation box installation instructions.
NB
SiphonDrain hose, siphon
SiphonCondensate pump
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14.Installationofabalancedfluesystem
Diagram: Example of a C93x balanced flue system
InstallationofthebalancedfluesystemForfluesandconcentricbalancedfluesystems,useonlyoriginalWolfcomponents.Please observe the technical information regarding balanced flue systems priorto installing the flue or the balanced flue connection.
As regulations in the individual Federal States [Germany] differ, we recommend consulting the relevant authorities and local flue gas inspector prior to installation.
Between the flue terminal and the roof surface, there must be a distance of at least 0.4 m.
Flue connections are created using couplings and gaskets. Always arrange couplings against the condensate flow direction.
The balanced flue should be installed with a slope of at least 3° (6cm/m) to the oilcondensing boiler. Spacer brackets should be fittedtosecuretheequipmentinposition.In theworst case scenario, a smaller slopeforthebalancedfluemayleadtocorrosionoroperating faults.
Generally bevel or deburr trimmed flues to ensure a gas tight installation of pipe joints. Ensure that gaskets are properly fitted. Remove all contamination prior to installation - never fit faulty parts.
The localfluegas inspectormusthaveclearaccesstothefluegastestnipples.
Route the balanced flue over the appliancein such away that the displacement devicecan be removed (minimum clearance via COB-15/-20/-29 is 30 cm; for COB-40 it is 40cm).
C93x
NB
NB
NB
NB
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The displacement device may have slipped during transport.To ensure perfect combustion, check the displacement device is correctly positioned before commissioning the appliance.
- Unplug the central connector.
- Loosen the three 6 mm Allen screws on the burner flange (do not unscrew them completely).
- Rotate the burner unit approx. 1 cm to the right (clockwise).
- Lift the burner unit upwards out of the combustion chamber lid and hang in place in the maintenance position, as shown in the figure.
- Undo the wing screws on the combustion chamber lid.
- Lift off the combustion chamber lid and place to one side.
- Measure the distance between the upper edge of the top displacement device and the upper end of the ridged profile, then compare with the table below.
Displacement device distance to ridged profile (mm)
COB-15 COB-20 COB-29 COB-40
98-103 98-103 123-128 123-125
- Assembly is carried out in reverse order.
Fill the system and vent it properly to ensure perfect boiler function.
Beforeconnectingtheboiler,flushtheheatingsystemtoremoveresiduessuchasweldingpearls,hemp,putty,etc.fromthepipework.
- Open the cap on the vent in the boiler by one revolution.- Open all radiator valves.- Fill the system via the return line at 2 bar (1.5 to 2.5 bar).- With the entire heating system and boiler in a cold
condition, fill slowly via the inspection/fill & drain valve at the return until 2 bar pressure is indicated.
- Check the entire system for water leaks.- Start the boiler, set the heating water temperature to
position "2" (pump running, illuminated signal ring as status indicator constantly green).
- Vent the pump; for this, briefly open and then retighten the air vent screw.
- Vent the heating circuit completely, switching the boiler ON for 5 seconds and OFF for 5 seconds at the ON/OFF switch, five times in succession.
- When the system pressure drops below 1.5 bar, top up the water.
Air vent valveFillingtheheatingsystem
15.Fillingtheheatingsystem
Diagram: Venting the COB
Checking the position of the displacement device
Diagram: View of COB displacement device
Displacement device distance
Achtung
Unplug the central connector
Burner in the maintenance position
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16. Electrical connectionGeneral notes
Thepowersupplyterminalsare'live'evenwhenthe ON/OFF switch has been switched OFF.
The installationmust be carried out by alicensed electrical contractor. Observe VDE regulationsaswellasall localregulationsbyyourpowersupplyutility.
Fuse M 5A
Power supply 230 V / 50 Hz
Two-wire eBUS connection
Replacement fuse
Outside temperature sensor
Cylinder sensor
Programmable input E1 (24 V), zero-voltRemove jumper a/b when making the connection
Heating circuit pump
Cylinder primary pump
Terminal box
Power plug, condensate pump
CS stratification pump Stratification sensor
Control signal, stratification pump
Alarm switch, condensate pump
Programmable output A1 (230 VAC; 200 VA)
Output A1 to DHW circulation
Stratification sensor
Control signal, stratification pump
Cylinder sensor
Stratification pump
Cylinder primary pump
Terminal boxThe terminal box is supplied fitted to the back panel of the boiler. If necessary, the terminal box can be mounted on the wall to the right, to the left or above the boiler.The control, regulating and safety equipment are fully wired and tested.
PowersupplyIn the case of a permanent connection, provide the power supply via a mains isolator (e.g. fuse, heating system emergency stop), which ensures at least 3 mm contact separation for all poles. Connecting cable, flexible, 3 x 1.0 mm² or rigid, max. 3 x 1.5 mm².The maximum current carrying capacity of the outputs is 2 A, but a total of 5 A must not be exceeded.
Installationinformation,electricalconnectionIsolate the system from the power supply before opening the casing.Unclip the terminal box from the holder.Open the terminal box.Insert the strain relief into the holes provided.Strip approx. 70 mm off the power cable insulation.Push the cable through the strain relief and secure the strain relief.Terminate the appropriate cores at the Rast-5 plug.Push the inserts back into the terminal box casing.Insert the Rast-5 plug.Fit the cover.
Isolate the boiler from the power supplybefore changing the fuse. The ON/OFF switch on the boiler does not provide separation from thepowersupply.Danger through 'live'electrical components. Never touch electrical components or contacts as long as the boiler hasnotbeenisolatedfromthepowersupply.Danger to life.
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0I
0 °C
20
40
60
80
100
120
ON/OFF switch DHW temperature
selector
Reset button Heating water temperature
selector
Illuminated signal ring
Thermometer
17. Control unit
ON/OFF switchThe condensing boiler is OFF in position 0.
Reset A fault is reset by pressing the reset button which will also restart the system. If the boiler is in a cycle block, this is reset by pressing the button (2 seconds)
Heating water temperature selectorSettings 2-8 correspond, when factory-set, to a heating water temperature of 20-80 °C. Combined with a BM programming module, the adjustment at the heating water temperature selector is disabled.
DHW temperature selectorWhen oil condensing boilers are combined with a DHW cylinder, setting 1-9 corresponds to a cylinder temperature of 15-65 °C. DHW temperatures of over 60 °C are not permissibleinconjunctionwithaCSstratificationcylinder. In combination with a BM programming module, adjustment at the DHW temperature selector is disabled. The temperature is set at the BM programming module.
Illuminated signal ring as status indicator
Display ExplanationFlashing green Stand by (ON/OFF switch ON, no heat demand,
pump OFF)Constant green light Heat demand: Pump running; burner OFFFlashing yellow Emissions test modeConstant yellow light Burner ON; flame steadyFlashing red Fault
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In summer mode, the circulation pump operates for approx. 30 seconds after a maximum idle period of 24 hours.
Anti-seizing pump protection
Summer modeWinter mode is disabled by rotating the heating water temperature selector into position. The boiler then operates in summer mode. Summer mode (heating OFF) means only DHW heating. Frost protection for the heating system and pump anti-seizing protection, however, remain enabled.
Setting Winter mode (settings 2 to 8)In winter mode, the boiler heats the flow temperature to the value set on the thermostat. According to the pump operating mode, the circulation pump operates constantly (factory setting) or only in parallel with the burner activation / run-on period.
Emissions test modeThe emissions test mode is activated by rotating the heating water temperature selector into position. The illuminated signal ring flashes yellow. After the emissions test mode has been activated, the boiler will heat with the selected maximum output. Any previous cycle block will be cancelled. The emissions test mode terminates after 15 minutes or when the maximum flow temperature has been exceeded. To reactivate, turn the heating water temperature selector anti-clockwise and then back into position .
0I
0 °C
20
40
60
80
100
120
ON/OFF switch Reset button BM programming module
Illuminated signal ring
Thermometer
Control unit with BM programming module
17. Control unit
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18. Displaying/modifyingcontrolparametersThecontrolparameterscanonlybemodifiedordisplayedviaWolfcontrolaccessorieswitheBUScapability.Forinstallationandprocedures,checktheoperatinginstructionsoftherelevantaccessories.
Pressing the r.h. rotary selector leads to control level 2, where you can select the menu levels shown in the overview by turning the rotary selector clockwise.Pressing the Info key takes you back to the standard display, irrespective of which submenu is currently displayed.The system automatically also returns to the standard display when no adjustment is made for more than one minute.All available set and actual temperatures, burner starts and hours run as well as other system values can be displayed. This scan is identical to that initiated via the Info key.
Parameter overview / settings report(settings and functions on the following pages)
Parameter Setting range Factorysetting Individual settingsA09 Frost protection limit -20 to +10 °C +2 °CA10 Parallel DHW operation 0 / 1 0A14 Maximum DHW temperature 60 to 80 °C 65 °C
HG00 Matching the pipe length 1 to 5 3HG01 Burner switching differential 1 to 20 K 10 KHG06 Pump operating mode 0 to 3 0HG07 Boiler circuit pump run-on time 0 to 30 min 3 minHG08 Maximum limit, boiler circuit TV-max. 40 to 90 °C 75 °CHG09 Burner cycle block 1 to 30 min 7 minHG13 Programmable input E1 1 to 11 1HG14 Programmable output A1 0 to 14 0HG15 Cylinder hysteresis 1 to 30 K 5 KHG16 N / AHG17 N / AHG19 Cylinder primary pump run-on time 0 to 10 min 5 minHG20 Maximum cylinder heating time 0 to 5 h 2 hHG21 Minimum boiler water temperature TK-min. 20 to 90 °C 20 °CHG22 Maximum boiler water temperature TK-max. 50 to 90 °C 80 °CHG25 Boiler overtemperature during DHW cylinder heating 0 to 40 K 10 KHG28 Burner operating mode 1 to 4 2HG31 Blocking time burner stage 2 0 to 40 min 4 min
A: - System parametersHG: - Boiler parameters
Topreventdamagetotheheatingsystem,cancelnight setback when outside temperatures fall below -12°C. If this rule isnotobserved, icemaybuildupontheflueoutletwhichmaycauseinjuryormateriallosses.
Modificationsmustonly thecarriedoutbyarecognisedheatingcontractororby theWolfcustomer service.
BM programming moduleL.h. rotary selector - program selection Display
R.h. rotary selector - temperature selection
Info key Single cylinder heating key
Setback keyHeating key
NB
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19. Contractor level parametersContractor level Press the r.h. rotary selector to change to control level 2. Turn the r.h. rotary selector
clockwise to select the contractor level and confirm the selection by pressing the r.h. rotary selector again.The display shows the code scan.
Heating contractor
The correct code is set by pressing (display indication flashes) and then turning the r.h. rotary selector from 0 to 1. After changing the code from 0 to 1, pressing the r.h. rotary selector again confirms the setting; you are then at the contractor level.
Code scan
code NO
- - - -
Factory setting: 1
Maximum DHW temperatureParameter A14
65
Factory setting: 65 °CSetting range: 60 to 80 °C
A14
The maximum DHW temperature is factory-set to 65 °C. If, for commercial reasons, a higher DHW temperature is required, a maximum temperature of up to 80 °C is enabled.If pasteurisation has been activated (BM), the DHW cylinder will be heated to the selected maximum DHW temperature during the first cylinder heating of the day.
Take adequate measures to prevent scalding.Parameter HG22 (maximum boiler water temperature) should be set at least 5 K higher than the selected maximum DHW temperature.DHWtemperaturesofover60°CarenotpermissibleinconjunctionwithaCSstratificationcylinder.
The boiler circuit pump operates constantly if the outside temperature stays below the selected value. The burner starts and heats the boiler to at least 20 °C if the boiler water temperature falls below +5 °C.
Note:Only change the factory setting if you can ensure that the heating system and its components will not freeze up at low outside temperatures.
Frost protection limitParameter A09
2.0
Factory setting: 2 °CSetting range: -20 to +10 °C
Incorrect operation can lead to system faults.Please note when adjusting parameter A09 (frost protection / outside temperature), that frost protection is no longer safeguarded if you set temperatures lower than 0 °C. This can lead to heating system damage.
A09
The heating circuit pump is switched OFF during cylinder heating with DHWpriority(0). The boiler energy will then be used exclusively for DHW heating. The cylinder primary pump will only start if the boiler water temperature is 5 °C higher than the current cylinder temperature. The burner shuts down and the heating circuit pump is started as soon as the cylinder has reached its set temperature. The cylinder primary pump runs on for, at most, the period selected under parameter HG19 (cylinder primary pump run-on time).The heating circuit pump continues to operate in parallelDHWmode(1). The cylinder primary pump starts if the boiler water temperature is 5 °C hotter than the cylinder temperature. Cylinder heating ends when the cylinder reaches the set water temperature. The cylinder primary pump runs on for, at most, the period selected under parameter HG19 (cylinder primary pump run-on time).
In parallel DHW mode (1), the heating circuit can temporarily be operated at a higher temperature.Parallel operation in conjunction with a stratification cylinder is not recommended.
Parallel DHW operationParameter A10
A10
Factory setting: 0Setting range: 0 / 1
0
NB
NB
NB
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19. Contractor level parameters
The burner switching differential regulates the burner temperature within a set range by switching the burner ON and OFF.The switching differential between burner stage 1 and burner stage 2 is always half the switching differential.See also parameter HG31 diagram.
Burner switching differentialParameter HG01
HG01
10
Factory setting: 10 KSetting range: 1 to 20 K
This parameter shifts the minimum and maximum fan speed parallel downwards or upwards.
This enables the CO2 value for burner stages 1 and 2 to be adjusted at the same time. See also chapter 22 "CO2 adjustment by matching the pipe lengths"
One unit = 120 r.p.mSetting 3 = set value, burner control unit
Matching the pipe lengthParameter HG00
HG00
3
Factory setting: 3Setting range: 1 to 5
Pump operating mode 0:Heatingcircuitpumpforheatingsystemswithoutcascadecontrolandwithoutlow loss headerThe heating circuit pump runs constantly when there is a heat demand. The heating circuit pump will be switched OFF during cylinder heating if DHW priority has been selected.
Pump operating mode 1:Feedpumpforheatingsystemswithcascadecontroland/orlowlossheaderHeating circuit pump becomes the feed pump.The header sensor affects the heating operation as well as cylinder heating. The feed pump runs only when there is a burner demand. Pump run-on in accordance with parameter HG07.
Hydraulic scheme:
Pump operating modeParameter HG06
HG06
0
Factory setting: 0Setting range: 0 / 1 / 2
ZUP = Feed pumpSPL = Cylinder primary pumpSF = Cylinder sensorSAF = Header sensorKF = Boiler sensorMKP = Mixer circuit pumpM = Mixer motorMM = Mixer module Oil condensing boiler
CylinderLow loss header or buffer
M
MM
SAF
ZUP
MKP
SPL
SF
KF
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Pump operating mode 2:BufferprimarypumpforBSPcylinderHeating circuit pump become the buffer primary pump.The manifold sensor (buffer) only affects the heating operation. In case of cylinder heating, the reference temperature is provided by the internal boiler sensor. In heating mode, the buffer primary pump runs only when there is a burner demand. Pump run-on in accordance with parameter HG07.
Subject to there being no heat demand from the heating circuit, the boiler circuit pump will run on in accordance with the set time, to prevent a boiler safety shutdown at high temperatures.
Boiler circuit pump run-on timeParameter HG07
HG07
3
Factory setting: 3 minSetting range: 0 to 30 min
Each time the burner is shut down in heating mode, it will be blocked for the duration of the burner cycle block.The burner cycle block is reset by switching the ON/OFF switch OFF and ON or by briefly pressing the reset button.
BurnercycleblockParameter HG09
HG09
7
Factory setting: 7 minSetting range: 1 to 30 min
19. Contractor level parameters
SPL = Cylinder primary pumpPLP = Buffer cylinder primary pumpSF = Cylinder sensorSAF = Header sensorKF = Boiler sensorMKP = Mixer circuit pumpM = Mixer motorMM = Mixer module
Wood boiler
Buffer cylinder
Oil condensing boiler
Solar thermal system integration
Hydraulic scheme:
M
J
SAF
SFPLP
KF
SPL
MKP
MM
This function limits the boiler water temperature upwards in heating mode, and the burner shuts down. This parameter has no function during cylinder heating, and the boiler water temperature may also be higher during this time. "Reheating effects" can result in the temperature being slightly exceeded.
Maximum limit boiler circuit TV-max.Parameter HG08
HG08
75
Factory setting: 75 °CSetting range: 40 to 90 °C
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The functions of input E1 can only be scanned and adjusted with Wolf control accessories with eBUS capability.The following functions can be allocated to input E1:
Programmable input E1Parameter HG13
HG13
1
Factory setting: 1Setting range: 1 to 10
Explanation
1
Room thermostat Closed contact is a prerequisite for enabling the burner in heating mode. No function for DHW mode. No function for emissions test mode and frost protection, no error message. Open contact blocks the enabling of the heating and the heating circuit pump (pump run-on).
2
Maximumthermostat/systempressureswitch Closed contact is a prerequisite for enabling the burner in heating and DHW mode. When the contact is opened, the burner switches off and the pump run-on begins - no error message. Applies to all pumps. When the mains power is on and the contact is open, there is only a pump kick, no run-on.
5
Flue gas/ventilation air damper Function monitoring of the flue gas/ventilation air damper with zero volt contact. Closed contact is a prerequisite for enabling the fan and burner in heating, DHW, cascade and emissions test mode. Output A1 must be programmed for flue gas/ventilation air damper function.If output A1 is controlled and does not close input E1 within two minutes, Fault Code 8 is issued.If output A1 is not controlled, input E1 must also open within two minutes. Otherwise FC8 is generated. With FC8, the fan is controlled with 65% of speed stage 1.
6DHW circulation pushbutton After the DHW circulation pushbutton is activated, output A1 is switched on for 5 minutes, if output A1 is programmed as DHW circulation pump (A1 = 13).
7 Header sensor A header sensor (5 K-NTC) is connected at E1; observe parameter HG 06.
8
Burner blocking Operation without burner. Closed contact, burner blocked. Heating circuit pump and cylinder primary pump run in standard mode. In emissions test mode and frost protection, the burner is enabled. Open contact enables the burner again.
10
External burner demand Closed contact, TKset is set to TKmax -5 K. Demand also functions in standby; cycle block active (control of output A1 when parameter output A1 = 14).
0,3,4,9,11arewithoutfunction.
19. Contractor level parameters
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The functions of output A1 can only be scanned and adjusted with Wolf control accessories with eBUS capability.
The following functions can be allocated to output A1:
Programmable output A1Parameter HG14
HG14
0
Factory setting: 0Setting range: 0 to 14
Explanation1 DHW circulation pump 100%
Output A1 is switched by control accessories (BM) if DHW circulation has been enabled. Output A1 is constantly enabled when no accessory controller is installed.
2 DHW circulation pump 50% Output A1 is switched by control accessories (BM) if DHW circulation has been enabled. 5 minutes ON and 5 minutes OFF. Output A1 constantly cycled in 5 minute cycles when no accessory controller is installed.
3 DHW circulation pump 20% Output A1 is switched by control accessories (BM) if DHW circulation has been enabled. 2 minutes ON and 8 minutes OFF. Output A1 cycles constantly when no accessory controller is installed.
4 Alarm output Output A1 is controlled after a fault and expiry of 4 minutes.
5 Flame detector Output A1 is controlled after a flame has been recognised.
7 Flue gas/ventilation air damper Output A1 is always controlled before the fan starts. The feedback is checked via input E1. If input E1 does not close, the fan and burner will not start, and after two minutes FC8 will be generated. The flue gas/ventilation air damper is controlled until the fan starts. If input E1 is interrupted during burner operation, the burner shuts down. In case of a fault, e.g. pressure switch, flame failure during operation etc., the flue gas damper is closed after the flushing time has expired. Input E1 must be programmed as flue gas/ventilation air damper. With FC8, the fan is controlled with 65% of speed stage 1.
8 External ventilation Output A1 is controlled inverted to the burner. Switching OFF external ventilation (e.g. extractor fan) during burner operation is only required, if the boiler is operated as open flue system.
9 Oil shut-off valve Output A1 switches simultaneously to the oil pump.
11 External pump Output A1 switches simultaneously with the heating circuit pump. Use with, for example, system separation.
12 Diverter valve Synchronous control with input E1 (E1 = 8, burner blocking).
13 DHW circulation pump DHW circulation pump ON for 5 mins if input E1 (E1 = 6) is programmed as DHW circulation pushbutton and input E1 Key is closed.
14 Pump with external burner demand Simultaneous control with input E1 (E1 = 10, ext. burner demand).0,6,10,15arewithoutfunction.
19. Contractor level parameters
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After completing cylinder heating (the cylinder has reached the set temperature), the cylinder primary pump will run on up to the maximum set run-on time. The cylinder primary pump will switch OFF prematurely if, during the run-on time, the boiler water temperature cools down to a differential between boiler and cylinder water temperature of 5 K, to prevent the boiler cooling down too severely.
Cylinderprimarypump run-on timeParameter HG19
HG19
5
Factory setting: 5 minSetting range: 0 to 10 min
Cylinder heating commences as soon as the cylinder temperature sensor demands heat. The heating circuit pumps would be constantly switched off if the boiler was undersized, the cylinder was scaled-up or if DHW was constantly drawn off during DHW priority mode. The accommodation cools down significantly. One option enables a max. cylinder heating time to be specified to limit this effect. If the set maximum cylinder heating time has expired, error message FC52 appears on the BM module. The control unit reverts to heating mode and cycles in the selected rhythm (HG20) between heating and cylinder heating mode, irrespective of whether the cylinder has reached its set temperature or not. This function remains enabled even in parallel mode (parameter A10 set to 1). It is only disabled if it is set to 0.Set this parameter to 0 in heating systems with a high DHW consumption, e.g. hotels, sports facilities, etc.
Max.cylinderheatingtimeParameter HG20
Factory setting: 2 hSetting range: 0 to 5 h
HG20
2
The control unit is equipped with an electronic boiler thermostat, with an adjustable minimum switch-ON temperature. The burner is switched on subject to the cycle block if this temperature is not achieved when heat is demanded. The minimum boiler water temperature TK-min. is also not necessarily achieved when there is no heat demand.
Minimum boiler water temperature TK-min.Parameter HG21
HG2120
Factory setting: 20 °CSetting range: 20 to 90 °C
19. Contractor level parametersThe cylinder hysteresis regulates the start point for cylinder heating. The higher the setting, the lower the start point for cylinder heating.
Example: Set cylinder temperature 60 °C Cylinder hysteresis 5 K
Cylinder heating commences at 55 °C and ends at 60 °C.
CylinderhysteresisParameter HG15
HG15
5
Factory setting: 5 KSetting range: 1 to 30 K
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Boiler overtemperature during cylinderheatingParameter HG25
The excess temperature differential between the cylinder temperature and the boiler water temperature during cylinder heating is selected with parameter HG25. The boiler water temperature continues to be limited by the maximum boiler water temperature (parameter HG22). This ensures that, even in spring and autumn, the boiler water temperature is higher than the cylinder temperature, thereby ensuring short heating times.
HG25
Factory setting: 10 KSetting range: 0 to 40 K
10
Burner operating modeParameter HG28
Factory setting: 2Setting range: 1 to 4
You can select any burner operating mode. Control unit is set at the factory for two-stage burner operation.
Setting "1": single stage burner operation, stage 1
Setting "2": two-stage burner operation, stages 1 + 2
Setting "3": single stage burner operation during cylinder heating two-stage burner operation in heating mode
Setting "4": N / A
HG28
2
19. Contractor level parametersMaximum boiler water temperature TK-max. Parameter HG22
Factory setting: 80 °CSetting range: 50 to 90 °C
The control unit is equipped with an electronic boiler thermostat which has an adjustable maximum shutdown temperature (maximum boiler water temperature). The burner is switched off if this temperature is exceeded. The burner will be started again when the boiler water temperature has fallen by as much as the burner switching differential.
If the boiler water temperature exceeds 95 °C (possible effect of reheating), the boiler circuit pump and cylinder primary pump (if installed) will also be started in "summer mode". These pumps are stopped again when the boiler water temperature falls below 92 °C. This prevents the boiler overheating.
HG22
80
Blocking time burner stage 2Parameter HG31
Factory setting: 4 minSetting range: 0 to 40 min
4
Burner stage 2 is started when there is stage 2 demand and after the blocking period has expired (factory setting 4 min). It is stopped once a temperature of approx. 5 °K above the set value has been reached. Once the stage 2 has been enabled, it will be started as soon as the set temperature has been reached or is no longer achieved. Enabling is removed when burner stage 1 is shut down.During cylinder heating and emissions test mode, this parameter is disabled.
TimeBlocking period, factory setting 4 min
Boi
ler
tem
pera
ture
°C Burner stage 1
Burner stage 1Burner OFF
Burner stage 1
Burner stage 2 Burner stage 2
Burner OFF
Set value
Demandstage 2
HG31
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SettingtheeBUSaddressforcascade mode(seeinstallationinstructionsforKMmodule)
The eBUS address is set by pressing the reset button for at least 5 seconds after the appliance has been switched on. After 5 seconds, the corresponding flashing code appears (in accordance with the table) at the illuminated signal ring. Select the corresponding eBUS address with the DHW temperature rotary selector. Your selection of the required eBUS address is saved by releasing the reset button. No address can be allocated more than once.
20. Cascade operation Control/specification/notes
Cascadetype 2 x COB-29
3 xCOB-29
4 xCOB-29
2 x COB-40
3 xCOB-40
4 xCOB-40
Rated output at 80/60 °C kW 56.4 84.6 112.8 76.0 114.0 152.0Rated output at 50/30 °C kW 59.2 88.8 118.4 80.0 120.0 160.0Rated heat input kW 58.0 87.0 116.0 77.6 116.4 155.2Lowest output at 80/60 °C Stage 1 kW 18.5 25.3Lowest output at 50/30 °C Stage 1 kW 19.6 26.8Lowest output kW 19.0 26.0
Specification
Heating circuit To ensure the heating water flow rate through every condensing boiler is as even as possible, the following connection types are recommended:
1. For precise hydraulic balancing, a line regulating valve can be fitted in the supply line to every appliance.
2. Design the flow and return lines with the same length for the flow and return according to the Tichelmann system, to ensure the pressure drop in every line is equally high.
These oil condensing boilers have control PCBs with functions that are optimally matched to the digital controller type KM for cascade control. Up to four COB-29 or COB-40 oil condensing boilers (with the same output) with an output range of 18.5 kW to 112.8 kW (cascade COB-29) or 25.3 kW to 152.0 kW (cascade COB-40) can be linked together to form a single cascade. Subject to load, this digital cascade controller KM can control the header flow, a mixer circuit and a DHW cylinder circuit. The digital controller type MM from the WOLF range of control accessories can be connected to regulate an additional mixer circuit and radiator circuit. Furthermore, a BM can be used in each case as a remote control.For a detailed description, see also the installation instructions for the individual modules.
General
Low loss header It must not be possible for the on-site heating circuit pumps or primary pumps to influence the function of the condensing boilers. A low loss header should therefore be installed upstream of the heating water circuit or DHW cylinder circuit. Furthermore, ensure that the heating water flow rate through the condensing boilers is set lower than that through the subsequent heating circuit. The flow rate should therefore be set upstream of the low loss header via a line regulating valve or butterfly valve.
Systemseparation Instead of the low loss header, a heat exchanger can be installed. If pipes are used which are not impermeable to oxygen, this is a requirement in any case.
DHWcylinder A DHW cylinder is generally connected downstream of the system separation (e.g. via a low loss header).Cylinder heating is controlled via the cascade controller type KM, to which a cylinder primary pump and the electronic cylinder sensor are connected.
*Factory setting (individual boiler without cascade mode)
Boiler in cascade operation
eBUSaddress
Rotaryselector,DHW temperature
selection
Illuminated signal ring indication
Boiler 1 1* 1* flashing red
Boiler 2 2 2 flashing yellow
Boiler 3 3 3 flashing yellow/red
Boiler 4 4 4 flashing yellow/green
333062547_0311
21. Cascade operation Fluesystemdesign
Balancedfluerouting Oil condensing boilers with a separate, concentric, balanced flue outlet (DN 80/125 or DN 110/160) above the roof, type C33x, may only be installed in attics, or in rooms where the ceiling also forms the roof, or where only the roof construction is located above the ceiling.
If the pipework for the combustion air supply and flue gas routing crosses different floors in the building, route the pipes outside the boiler room inside a duct with a fire resistance of at least 90 minutes, and in living spaces of low height with a resistance of at least 30 minutes.
Topreventfluegasbeingdrawnbackthroughadjacentroofoutletswhereseveralflueoutletsarearrangednexttoeachother,arrangetheoutletsatapproximatelythesameheightandwithatleast600mmbetweenthem.
The maximum permissible straight length for concentric balanced flue routing must not exceed 16 m with an internal diameter DN 80/125, or 21 m with DN 110/160. The calculated length of the balanced flue routing comprises the straight pipe length and the length of the pipe bends. In this calculation, an 87° bend is calculated as being 1.5 m and a 45° bend as being 1 m.
Cascade control with separate, vertical, concentric balanced flue routing, type C33x.
min. 600min. 600min. 600
KM module
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22. Cascade operation Flue gas header design
For open flue operation, there must be an aperture in the boiler room that opens to the outside and has a clear cross-section of at least 150 cm².Where necessary, adapt the installation examples to the relevant Building Regulations and requirements of your country/region. Discuss any questions relating to the installation, particularly of inspectioncoversandventilationapertures(ventilationgenerallyrequiredabove50kWoutput)with your local heating engineer.
Flue gas routing with header Oil condensing boilers with common flue routing - open flue operation in installation type B23.
Number 2 x COB-29
2 x COB-29
3 xCOB-29
4 xCOB-29
2 x COB-40
3 xCOB-40
4 xCOB-40
Installation Art B23Flue internal diameter DN110 DN160 DN160 DN160 DN160 DN160 DN160Total flue gas mass flow rate g/s 26.6 26.6 40.0 53.3 35.0 52.5 70.0Max. flue gas temperature °C 76 83Max. effective building height m 30
Cascade control with header
DWTK
min. 600
max. 1000
min. 605
max. 2000
min. 600
max. 1000
min. 600
max. 1000
KM module
Flue cascades are only suitable in balanced flue operation. They must be designed to EN 13984-1. To prevent flue gas escaping, a flue cascade is only permitted with a tested
flue gas damper.
Flue cascade
Cei
ling
heig
ht a
t lea
st 2
500
mm
The effective heights specified are only valid on the condition that the length of the flue between the individual appliances and downstream of the last appliance does not exceed 2 m. 325 m was assumed as the geodetic height. If the conditions at the installation site are different, an individual calculation is required.
353062547_0311
The maximum horizontal length of the flue gas header is 1.5 m between the appliances and 1.5 m downstream of the last appliance. In addition to the boiler connection bend, a maximum of two 87° diverters may be installed.
Pipe length calculation: The calculated length of the flue comprises the straight pipe length and the length of the pipe bends.
Minimum cross-section of the duct: With a round duct, the clear distance from the flue to the duct wall must be at least 3 cm and with an angular duct, at least 2 cm.
The flues must be installed in ducts and channels in such a way that it is possible to inspect and, if necessary, clean the ventilated cross-section. Close cleaning apertures in ducts with chimney cleaning covers which have been assigned a test mark.
The distance from the cleaning and inspection aperture in the duct/channel to the front edge of the flue can be twice the diameter of the flue, up to a maximum of 35 cm, as long as cleaning and inspection do not take place at the outlet.
Flues in ducts should be designed at the outlet in such a way that no precipitation can enter the space between the flue and duct, and the secondary ventilation can escape freely.
Removable covers must be able to be removed without tools and be secured to prevent them falling.
Retaining straps and spacers must be designed in such a way that it is possible to inspect and, if necessary, clean the free duct cross-section.
Provide sufficient cleaning and inspection apertures.
Installation in an existingchimney/duct
23. Cascade operation Flue gas header design / notes
Component Calculated length87° bend 1.5 m45° bend 1 m
87° tee with inspection aperture 2 mStraight pipe Subject to length
36 3062547_0311
In the vertical part of the flue, a cleaning and inspection aperture is required immediately above or below the flue diverter if the distance from the centre of the cleaning and inspection aperture in the horizontal part of the flue to the vertical axis of the flue is greater than 30 cm.
The distance can be up to 1 m if the inspection aperture in the horizontal part of the flue is arranged on the front and if there are no diverters in the flue from this cleaning and inspection aperture to the vertical part.
In the upper part of the flue arranged inside the building (< 5 m), a cleaning and inspection aperture is required if cleaning or inspection cannot be carried out from the roof.
Before commissioning the combustion system, have the safe usability of the flue system confirmed by the local flue gas inspector [in Germany; check local regulations].
Installingtheflue
23. Cascade operation Flue gas header design / notes
2616
23
24
25
26
27
33
3737373738
32
26
35
34
2
32
26
35
34
2
32
26
35
34
2
32
26
35
34
2
36
1 Oil condensing boiler
2 Connection adaptor with test nipple for air and flue gas (included in COB standard delivery)
16 Rose
23 Support rail
24 87° support bend
25 Spacer
26 PP pipe
27 Cowl
33 PP outlet
34 Electricalfluegasdamper
35 Extension(whererequired)
36 Siphon
37 PP header
38 End piece with inspection aperture and condensate drain
Secondary ventilation
Example of an open flue cascade design according to type B23
1 1 11
373062547_0311
24. Cascade operation Flue gas damper installation
- Push flue gas damper as far as it will go onto connection adaptor (with test nipple) on the boiler.
- Push the flue as far as it will go onto the flue gas damper.- Correctly route the limit switch cable and motor cable from
the flue gas damper to the terminal box and to the cable (programmable output A1).
In the delivered condition, the terminal box is fitted to the back panel of the boiler. If required, the terminal box can be mounted on the wall to the right or left of the boiler, or above it.The control, regulating and safety equipment are fully wired and tested.
Installation information regarding electrical connection of inputE1andoutputA1forthefluegasdamper
- Isolate the system from the power supply before opening.- Unclip the terminal box from the holder.- Open the terminal box.- Insert the strain relief into the holes provided.- Strip approx. 70 mm off the power cable from the limit
switch.- Push the cable through the strain relief and secure the strain
relief.- Connect the wires from the limit switch to input E1 (see chapter 25 "Wiring diagram cascade operation").- Connect motor cable from the flue gas damper via an on-
site junction box with programmable output A1 (see chapter 25 "Wiring diagram cascade operation").- Fit the cover.
Proceed with chapter 26 "Flue gas damper tightness test" and "Commissioning".
Terminal box
Flue gas damper installation
Flue gas damper
COB
Programmable output A1(230 VAC; 200 VA)
COB back view
Flue gas damper installation information
Electrical connection installation information
38 3062547_0311
25. Cascade operation Flue gas damper installation / wiring diagram
M
230 V ~
Netz KKP LP
N
N
NL1L1 L1
L1 L1L1 N NN
AF SFE1 eBUS
+ - 1 12 2a b
1 2 1 2 1 21 2
COB terminal box
Flue gas damper with servomotor
Limit switch
COB-15/20/29/40
Programmable output A1(230VAC; 200VA)
NB:Flue gas damper limit switch must be zero volt. Otherwise the COB control unit will be destroyed.
Note:Contractor parameter HG13 (input E1) must be set to 5 and HG14 (output A1) must be set to 7.
Power supply (230 VAC; 200 VA)
Flue gas damper wiring diagram
Junction box on site
393062547_0311
26. Cascade operation Flue gas damper tightness test
Testingadjacentappliances for tightness
1 2 3 4
1. ON OFF OFF OFF2. OFF ON OFF OFF
As part of the annual boiler test, the cascade damper in overpressure boiler systems must be tested for tightness to ensure no CO2 can escape into the boiler room; risk of poisoning or suffocation.The check must be carried out with the appliance closed.
We recommend proceeding as follows:
Testingadjacentappliancesfortightness
- Set the program selector (l.h. rotary selector) to “Standby” on the BM program-ming module.
- Then turn the first COB to position 1 “Emissions test” by means of the heating water temperature selector è COB starts.
- Operate the first COB for at least 5 minutes.
- On all other appliances, check the CO2 contents at the air connector:
- If the CO2 value exceeds 0.2% within 15 minutes, the leak must be found and remedied.
- Subsequently close all test apertures again. When doing so, ensure the caps are seated firmly.
TestingthefirstCOBfortightness
- Turn the temperature selector for heating water on the first COB to its centre posi-tion è COB shuts down.
- Turn the second COP to position 1 “Emissions test” by means of the heating water temperature selector è COB starts.
- Operate the second COB for at least 5 minutes.
- Carry out the CO2 test on the first COB.
- If the CO2 value exceeds 0.2% within 15 minutes, the leak must be found and remedied.
- Subsequently close all test apertures again. When doing so, ensure the caps are seated firmly.
40 3062547_0311
27. Commissioning with Wolfcontrolaccessories(BM)
0I
0 °C
20
40
60
80
100
120
ON/OFF switch Program selector switch
"Inlet air" test port
"Flue gas" test port
Ifnocontrolaccessoryisinstalled,seechapter28"CommissioningwithoutWolfcontrolaccessories(BM)".
Commissioning Only qualified personnelmust carry out the commissioning andoperationoftheboiler,aswellasinstructtheuser.
- Checktheboilerandsystemforleaks.Normaloperatingpressure whensystemiscold1.5-2.0bar.Preventwaterleaks.
- Check location and seating of the installation. (e.g. displacement deviceposition)
- Check the fuel level in the oil tank and water level in the siphon or neutralisation box.
- Checkallconnections,includingthosebetweencomponents,forleaks.
- If tightness cannot be ensured then there is a danger of water damage.
- Fit casing.
- Check that all flue gas accessories have been correctly installed.
- Open the shut-off valves on flow and return.
- Open oil shut-off valves (tank, oil line, filter).
- Switch ON the heating system emergency stop switch.
- Switch ON the system ON/OFF switch on the control unit.
- Remove cap from r.h. test port (inlet air).
- Insert test probe 2 cm.
- Turn the program selector switch on BM module to "Emissions test" .
(Illuminated signal ring flashes yellow)
- After a pre-purge time of approx. 25 seconds, the pump starts up and opens the solenoid valve. The supplied fuel oil reaches the nozzle and a flame is established.
- The burner enters a fault state if, during commissioning, the oil pump does not supply sufficient oil during the pre-purge time. Repeat the burner start by pressing "Reset".
- Measure temperature and CO2 in the inlet air and enter the values in the commissioning report in chapter 29.
- The flue is not gas tight if the CO2 content > 0.2%; rectify the leak.
- Terminate the emissions test mode by turning the program selector switch on the programming module to the required operating mode.
- If emissions test mode is not reset manually, the appliance switches back to the original operating mode automatically after 15 minutes.
- Remove the test probe and close the test port. Ensure the cap is seated firmly.
413062547_0311
- Measure the flue gas, CO2 content, flue gas temperature and soot value and enter them in the commissioning report (chapter 29).
- Modifying the parameter HG00 has also adjusted the speed for stage 1. For checking purposes, the boiler must be set to stage 1.
- Switch HG28 burner operating mode from 2 (two-stage) to 1 (single stage).
- Measure the CO2 content and compare it against the values given in the stage 1 table adjacent.
- If the value is outside the set value, the CO2 value must be adjusted via the pump pressure (see chapter 28 "Commissioning without Wolf control accessories").
- Reset HG28 burner operating mode from 1 to 2.
- Terminate the emissions test mode by turning the program selector switch on the BM programming module to the required operating mode. If emissions test mode is not reset manually, the appliance switches back to the original operating mode automatically after 15 minutes.
- Remove the test probe and close the test port.
27. CO2check/adjustmentbymatchingthe pipe lengths
CO2adjustmentbymatching the pipe lengths
WithcontractorparameterHG00(seechapter19"Contractorlevelparameters"),theappliancescanbematchedtothefluegassystembychangingthespeedfor both stages.
- The casing must be closed for this setting.
- Remove the cap from the l.h. "flue gas" test port.
- Insert the test probe of the CO2 measuring instrument into the "flue gas" test port (approx. 70 mm).
- Turn the program selector switch on BM module to "Emissions test". (Illuminated signal ring as status indicator flashes yellow.)
- Measure the CO2 content and compare it against the values given in the Stage 2 table adjacent.
- If required, alter the CO2 content with parameter HG00.
Completingtheadjustments - Check the control parameters and match them to the system if necessary.
- Check the condensate drain.
- Instruct the customer in the operation of the boiler, with the aid of the operating instructions.
- Complete the commissioning report (chapter 29) and hand over the instructions to the customer.
- Instruct the customer about the need for annual servicing.
- Instruct the customer about energy saving options.
- Refer your customer to section "Information regarding energy efficient operation" in the operating instructions.
CO2 check in the lower load (stage1)
CO2setvalue,boilerclosedstage113.5 ± 0.3%
AdjustingtheCO2 value in the upperloadrange(stage2)(emissionstestmode)
CO2setvalue,boilerclosedstage2
13.5 ± 0.3%
HG 00 CO2 settings
Factory setting: 3
1 2 3 4 5
Lower CO2 valueHigher CO2 value
42 3062547_0311
28. Commissioning without Wolf control accessories(BM)
0I
0 °C
20
40
60
80
100
120
ON/OFF switch
Heating water temperature selector
DHW temperature selector
Commissioning Only qualified personnelmust carry out the commissioning andoperationoftheboiler,aswellasinstructtheuser.
- Remove front and top casing.
- Pivot the control unit downwards.
- Insert the oil pressure gauge into the pump's pressure gauge test port.
- Remove the cap from the l.h. "flue gas" test port.
- Insert the test probe of the CO2 measuring instrument into the "flue gas" test port.
(approx. 70 mm).
- Turn the heating water temperature selector to "Emissions test"
(illuminated signal ring as status indicator flashes yellow.)
- Measure the CO2 content and compare it against the values given in the stage 2 table adjacent.
- If required, set the CO2 content with the stage 2 pressure regulating screw using a 4 mm Allen key in accordance with the table.
Turn clockwise - higher CO2 value
Turn anti-clockwise - lower CO2 value
CO2 settings via pump pressure
IfnocontrolaccessoryisconnectedtotheapplianceortheCO2 set value is not achievedbymatchingthepipelengths,thesettingismadeviapumppressurecontrol:
"Inlet air" test port
"Flue gas" test port
- Checktheboilerandsystemforleaks.Normaloperatingpressure whensystemiscold1.5-2.0bar.Preventwaterleaks.
- Check location and seating of the installation.- Check the fuel level in the oil tank.- Check all connections and component links for leaks.- If tightness cannot be ensured then there is a danger of water damage.- Fit casing.- Check that all flue gas accessories have been correctly installed.- Open the shut-off valves on flow and return.- Open oil shut-off valves (tank, oil line, filter).- Switch ON the heating system emergency stop switch.- Switch ON the system ON/OFF switch on the control unit.- Remove cap from r.h. test port (inlet air).- Insert test probe 2 cm.- Turn DHW temperature selector to 1.- Turn heating water temperature selector to "Emissions test" (illuminated signal ring flashes yellow).- After a pre-purge time of approx. 25 seconds, the pump starts up and opens the
solenoid valve. The supplied fuel oil reaches the nozzle and a flame is established.- The burner enters a fault state if, during commissioning, the oil pump does not supply
sufficient oil during the pre-purge time. Repeat the burner start by pressing reset.- Measure temperature and CO2 in the inlet air and enter the values in the commissioning
report in chapter 24.- The flue is not gas tight if the CO2 content > 0.2%; rectify the leak.- Terminate the emissions test mode by turning the temperature selector back to its
original position.- If emissions test mode is not reset manually, the appliance switches back to the
original operating mode automatically after 15 minutes.- Remove the test probe and close the test port. Ensure the cap is seated firmly.
AdjustingtheCO2 value in the upperloadrange(stage2)(emissionstestmode)
Pressure regulating screw, stage 1
NB
Vacuum test connection
Vacuum test connection
Oil pressure test connection
Oil pressure test connection
Pressure regulating screw, stage 2
Pressure regulating screw, stage 2
Pump Danfoss
Pump Suntec
433062547_0311
Completingtheadjustments - Shut down the boiler and close the test ports again.- Check the control parameters and match them to the system if necessary.- Check the condensate drain.- Instruct the customer in the operation of the boiler, with the aid of the operating instructions.- Complete the commissioning report (chapter 29) and hand over the instructions to the customer.- Instruct the customer about the need for annual servicing.- Instruct the customer about energy saving options.- Refer your customer to section "Information regarding energy efficient operation" in
the operating instructions.
- Check whether the pump pressure is still within the tolerance range. If not, then check the nozzle and mixer head.
- Terminate the emissions test mode by turning the DHW temperature selector back to its original position.
- Press the reset button.- Set the heating water temperature selector to 8.- Approx. 60 seconds after the burner start, check the CO2 content with the CO2
measuring instrument.- If required, alter the CO2 content with the stage 1 pressure regulating screw using a
4 mm Allen key.
Testing must be carried out within 240 seconds of the burner start. If necessary, repeat the start phase for setting procedures by turning back the heating water temperature selector and pressing the reset button.
Turn clockwise - higher CO2 value Turn anti-clockwise - lower CO2 value
28. CO2check/adjustmentviapumppressure
- After completing the work, refit the casing lid and check the CO2 value with the boiler closed.
Observe the CO emissions whilst making CO2adjustments.TheCOvalue should be < 50 ppm if the CO2 value is correct.
- The condensing boiler is correctly adjusted when the CO2 values correspond to those in the adjacent table.- If the CO2 value increases too greatly, the balanced flue must be checked.- Enter the flue gas values of CO2, flue gas temperature and soot value in the
commissioning report in chapter 29.
Checking the CO2adjustment
AdjusttheCO2 value in the lowerload(stage1)
- Check whether the pump pressure is still within the tolerance range. If not, then check the nozzle and mixer head.
- Terminate boiler operation by turning the heating water temperature selector back to its original position.
- Remove the oil pressure gauge and close the aperture again.
Appliance open COB-15 COB-20 COB-29 COB-40Stage 2 CO2 set value 13.2 ± 0.3% 13.2 ± 0.3% 12.7 ± 0.3% 12.7 ± 0.3%Stage 1 CO2 set value 13.2 ± 0.3% 13.2 ± 0.3% 12.7 ± 0.3% 12.7 ± 0.3%
Appliance open COB-15 COB-20 COB-29 COB-40Stage 2 Pump pressure 12.0 ± 1.0 bar 16.8 ± 2.5 bar 16.8 ± 2.5 bar 18.0 ± 2.5 barStage 1 Pump pressure 5.0 ± 0.5 bar 8.5 ± 1.0 bar 8.5 ± 1.0 bar 9.8 ± 1.0 bar
Thepumppressureinstage2mustalwaysbegreaterthanthatinstage1
Appliance closed COB-15 COB-20 COB-29 COB-40Stage 2 CO2 set value 13.5 ± 0.3%Stage 1 CO2 set value 13.5 ± 0.3%
Pressure regulating screw, stage 1
Pressure regulating screw, stage 1
Pump Danfoss
Pump Suntec
44 3062547_0311
29. Commissioning report
Commissioning steps Testvalueorconfirmation
1.) Fuel oil Standard EL
Low sulphur EL
Bio-oil B10
2.) Oil leak test carried out?
3.) Balanced flue system checked?
4.) Water connections checked for leaks?
5.) Siphon filled?
6.) Boiler and system vented?
7.) Function test carried out?
8.) Function test carried out?
9.) Flue gas test:
Flue gas temperature gross
Inlet air temperature
Flue gas temperature net
Carbon dioxide content (CO2) or oxygen content (O2)
Carbon monoxide content (CO)
__________________ tA [°C] __________________ tL [°C] __________________ (tA - tL ) [°C] __________________ % __________________ ppm
10.) Casing fitted?
11.) Control parameters checked?
12.) System user trained, documentation handed over?
13.) Confirm commissioning? Date: ____________________________
Signature: ________________________
453062547_0311
30. Maintenance and design dataNTC sensor resistances
Boiler sensor, cylinder sensor, outside temperature sensor, header sensor, DHW heating sensor
Pressure drop on the heating water side COB-15
Watervolume(l/h)
Pressuredrop(m
bar)
Temp. °C Resist. Ω Temp. °C Resist. Ω Temp. °C Resist. Ω Temp. °C Resist. Ω-21 51393 14 8233 49 1870 84 552-20 48487 15 7857 50 1800 85 535-19 45762 16 7501 51 1733 86 519-18 43207 17 7162 52 1669 87 503-17 40810 18 6841 53 1608 88 487-16 38560 19 6536 54 1549 89 472-15 36447 20 6247 55 1493 90 458-14 34463 21 5972 56 1438 91 444-13 32599 22 5710 57 1387 92 431-12 30846 23 5461 58 1337 93 418-11 29198 24 5225 59 1289 94 406-10 27648 25 5000 60 1244 95 393-9 26189 26 4786 61 1200 96 382-8 24816 27 4582 62 1158 97 371-7 23523 28 4388 63 1117 98 360-6 22305 29 4204 64 1078 99 349-5 21157 30 4028 65 1041 100 339-4 20075 31 3860 66 1005 101 330-3 19054 32 3701 67 971 102 320-2 18091 33 3549 68 938 103 311-1 17183 34 3403 69 906 104 3020 16325 35 3265 70 876 105 2941 15515 36 3133 71 846 106 2852 14750 37 3007 72 818 107 2773 14027 38 2887 73 791 108 2704 13344 39 2772 74 765 109 2625 12697 40 2662 75 740 110 2556 12086 41 2558 76 716 111 2487 11508 42 2458 77 693 112 2418 10961 43 2362 78 670 113 2359 10442 44 2271 79 670 114 228
10 9952 45 2183 80 628 115 22211 9487 46 2100 81 608 116 21612 9046 47 2020 82 589 117 21113 8629 48 1944 83 570 118 205
200 400 600 800 1000 1200 1400 1600 1800 20000
0
5
10
15
20
25
30
COB-1520K-spread
COB-1510K-spread
46 3062547_0311
Pressure drop on the heating water side COB-20
Watervolume(l/h)
Pressuredrop(m
bar)
200 400 600 800 1000 1200 1400 1600 1800 20000
0
5
10
15
20
25
30
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000
0
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
0 400 800 1200 1600 2000 2400 2800 3200 3600 4000 4400 4800 5200 5600 6000
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160160
170
180
190
200
210
COB-2020K-spread
COB-2010K-spread
COB-2920K-spread
COB-2910K-spread
COB-4020K-spread
COB-4010K-spread
Watervolume(l/h)
Pressuredrop(m
bar)
Watervolume(l/h)
Pressuredrop(m
bar)
Pressure drop on the heating water side COB-29
Pressure drop on the heating water side COB-40
30. Maintenance and design data
473062547_0311
31. Design information
1) Marking "x" indicates that all components of the flue are surrounded by combustion air and meet increased requirements for gas tightness.2) For types B23 and B33, the combustion air is drawn from the installation room (open flue combustion equipment). For type C, the combustion air is drawn through a sealed system from the outside (balanced flue combustion equipment).
Connectiontypes
The following balanced flue or flues with CE-0036-CPD-9169003 certification may be used:
Flue DN 80Concentric balanced flue DN 80/125Flue DN 110Concentric balanced flue (on an external wall) DN 80/125Flue (flexible) DN83, DN110Concentric balanced flue (on an external wall) DN 110/160Flue DN 160 (for cascade)
The necessary type plates and certificates are included with the relevant Wolf accessories. Observe all additional installation instructions included with accessories.
Boiler type
Appliance type 1), 2)
Operating mode Can be connected toOpen flue Balanced
flueMoisture-resistant
chimneyBalanced flue
chimneyBalanced flue Certified
balanced flueMoisture-
resistant flueCOB-15/20/29/40
B23, B33, C53, C33x, C43x, C53x, C63x, C83x, C93x
Yes Yes B33, C53, C83x C43x C33x, C53x, C93x
C63x B23, C53x, C83x
I IIII IIIII IIIII IIII IIIII IIII IIIII IIIII IIII IIIII IIIII IIII IIIII IIII IIIII IIIII IIII IIIII IIIII IIII IIIII IIIII
I IIIII IIII IIIII IIIII III
IIIIIIIIIII
I
I
II
II
II
IIII
I
IIII
IIII
IIIIIIII
IIIIIIIIIC83x
C33x
C53x
B33C83x C93x
C33x
C93x C43xC53
B23
B33
C33x
48 3062547_0311
1) Available fan draught: COB-15: 32-65 Pa / COB-20: 45-65 Pa / COB-29: 55-105 Pa / COB-40: 70-150 Pa (the maximum length corresponds to the total length from the appliance to the flue terminal)
2) Vertical flue for installation in a duct, flexibleandrigidwith horizontal concentric connection line Calculation to DIN EN 13384 (balanced flue manufacturer)
Note: Systems C 33x and C 83x are also suitable for installation in garages.Where necessary, adapt the installation examples to the relevant Building Regulations and requirements of your country/region. Discuss any questions relating to the installation, particularly regarding the inspection components and ventilation apertures, prior to installation with your local flue gas inspector.Thelengthdimensionsrefertoconcentricbalancedflueandflues,andonlytooriginalWolfcomponents.
Balancedfluerouting
CalculatingthebalancedfluelengthThe calculated length of the balanced flue system or the flue is derived from the straight pipe length and the length of the pipe bends.Example:
Length of straight balanced flue 1.5 m
Inspection tee 87° = 2 m
2 x 45° bends = 2 x 1 m
L = 1.5 m + 1 x 2 m + 2 x 1 m
L = 5.5 m
31. Design information
Table: Pipe length calculation
Component Calculated length87° bend 1.5 m45° bend 1 m
Tee 87° with inspection aperture
2 m
Straight pipe Subject to length
Versions as condensing boilers Max. length, vertical 1)
COB-15 COB-20 COB-29 COB-40
B23 Flue in a duct and combustion air directly via the boiler (open flue) 30 30 30 30
B33 Flue in a duct with horizontal, concentric connection line (open flue) 30 30 30 30
B33 Connection to a moisture-resistant flue gas chimney with a horizontal concentric connection line (open flue)
Calculation to DIN EN 13384(balanced flue manufacturer)
C33x Vertical concentric roof outlet through a pitched or flat roof, vertical concentric balanced flue for installation in a duct, (balanced flue)
20 20 16 21
C43x Connection to a moisture-resistant balanced flue chimney, maximum pipe length from centre of boiler bend to connection 2 m (balanced flue)
Calculation to DIN EN 13384(balanced flue manufacturer)
C53 Connection to the flue in a duct and ventilation air line through an external wall (balanced flue)
30 30 30 30
C53x Connection to a flue on an external wall (balanced flue) 30 30 30 30
C83x Connection to the flue in a duct and ventilation air through an external wall (balanced flue)
30 30 30 14
C83x Concentric connection to a moisture-resistant flue gas chimney and combustion air through an external wall (balanced flue)
Calculation to DIN EN 13384(balanced flue manufacturer)
C93x Vertical flue for installation in a duct, flexibleandrigidwith horizontal concentric connection line
rigidflexible
2719
2719
22 16
202)
493062547_0311
Balancedfluerouting,rigidandflexibleinaduct
Minimum duct sizesRequiredsecondaryventilationtoDIN18160
C93x
Minimum duct sizes forbalancedflueoperationC93x
B23, B33 open flue in a DN80 duct
B23/B33 open flue in a DN80 duct
Assumptions: In the installation room, 2 x tee, 1 x 87° bend + 1.5 m horizontal with 87° support bend
C93x balanced flue
MinimumductsizesforopenflueoperationB23,B33and balancedflueoperationC53(x),C83(x)
31. Design information
C93x
Round Ø SquareDN 80 150 mm 130 mm DN 110 190 mm 170 mm
10
8110 120 130 140 150 160
12
14
16
18
20
22
24
26
28
30
32
COB-29
COB-15/-20
COB-40
Square duct a x a (mm)
Max
. ver
tical
leng
th (m
)
Flue DN80 (COB-15/20/29), DN110 (COB-40)
10
8
12
14
16
18
20
22
24
26
28
30
32
120 130 140 150 160 170 180
COB-40
COB-29
COB-15/-20
Round duct Ø (mm)
Max
. ver
tical
leng
th (m
)Flue DN80 (COB-15/20/29), DN110 (COB-40)
50 3062547_0311
2617
18
20
18
17
18
19
20
18
4 5 4 1610
4 16
23
24
25
26
1
2
16
23
11
4
4
33 33
27 27
510
1
2
16
8
4
5
S
S
16 16 4 55 2829 10
2
4 16
23
24
25
26
27
1
33
ConcentricbalancedflueC33x,C83x,C93xandflueonanexternalwallC53x(examples)DN80/125andDN110/160
1 Oil condensing boiler
2 Connection adaptor with test nipple for air and flue gas (included in COB standard delivery)
4 Balancedflue 500 mm 1000 mm 2000 mm
5 Spacer clip
7 Balancedflue,vertical (roof outlet for flat or pitched roofs)
8 Separator (slide coupling), if required
10 Inspection tee 87°
11 87° bend
16 Rose
17 External wall connection with smooth ends on both sides of the air pipe
18Airinlet,externalwall
19Balancedflue,externalwall
20Walloutlet,externalwall
21 Twin coupling
23 Support rail
24 Support bend 87°
25 Spacer
26PPflue 500 mm 1000 mm 2000 mm
27 Cowl
28 Air pipe
29 Air inlet pipe
33 PP outlet
Install the horizontal flue with approx. 3° fall (6 cm/m) towards the boiler. Route the horizontal air supply with a 3° fall towards the outside – install the air inlet with wind protection; permissible wind pressure at the air inlet 90 Pa. The burner will not operate with higher wind pressure. In a duct, after the support bend (24), a rigid or flexible flue in DN80 can be connected.
Flue on an external wall
C53x C33x, C93x
C83x
31. Design information
approx.1500 mm
513062547_0311
33
8
8
44
4
9
9
3
5
5
10 4 5 11
12
13
6
14
S
S
6 6 6
4
5
4
7 7 7
1
2
1
2
1
2
VerticalconcentricbalancedflueC33x(examples)systemDN80/125andDN110/160
1 Oil condensing boiler
2 Connection adaptor with test nipple for air and flue gas (included in COB standard delivery)
3 Balancedflueincl.inspectionaperture (250 mm long)
4 BalancedflueDN80/125 500 mm 1000 mm 2000 mm
5 Spacer clip
6 Mounting bracket for roof outlet
7 Balancedflue,vertical (roof outlet for flat or pitched roofs)
8 Separator (slide coupling), if required
9 45° bend
10 Inspectiontee,87°
11 87° bend
12 Universaltilefor pitched roof 25° - 45°
13 "Klöber" adaptor 20° - 50°
14 Flat roof collar
Please note: Install the horizontal flue with approx. 3° fall (6 cm/m) towards the boiler. During installation, slide the separator (8) fully into the coupling. Push the next balanced flue (4) 50 mm (dim. "S") into the coupling of the separator, and secure in this location, e.g. with pipe clips DN 125 (5) or a fixing screw on the air side.
Lubricate the pipe ends and gaskets for easier installation (use only grease without silicone).
Determine the required inspection piece (3) (10) with your local flue gas inspector prior to installation.
C33x C33xC33x
31. Design information
NB
52 3062547_0311
32 26 16
23
24
25
26
27
33
1
2
29
31 3230 26 161616
23
24
26
27
1
2
33
33
Balancedfluerouting,openflueB33andB23(examples)DN80/125andDN110/160
1 Oil condensing boiler
2 Connection adaptor with test nipple for air and flue gas (included in COB standard delivery)
4 Balancedflue 500 mm 1000 mm 2000 mm
5 Spacer clip (only if required)
10 Inspection tee 87°
16 Rose
22 Connection to fluegaschimneyB33 length 250 mm with air aperture
23 Support rail
24 87° support bend
25 Spacer
26 PPflue 500 mm 1000 mm 2000 mm
27 Cowl
29 Balancedfluedistributor 80/80 mm
30 Air inlet pipe
31 87° bend
32 Tee 87° with inspection aperture
33 PP outlet
Install the balanced flue distributor eccentrically (29) for separate balanced flue on the oil condensing boiler.Install the horizontal flue with approx. 3° fall (6 cm/m) towards the boiler. Route the horizontal air supply with a 3° fall towards the outside – install the air inlet with a cowl; permissible wind pressure at the air inlet 90 Pa. The burner will not operate with higher wind pressure.
Eccentricbalancedflue(examples)DN80andDN110
Secondary ventilation
C53
Secondary ventilation
B23
31. Design information
B33
Secondary ventilation
approx.1500 mm
1622
23
24
25
26
27
4 510
1
2
33
533062547_0311
SupplementaryinstallationinstructionsforbalancedflueDN80/125
During installation, slide the separator (8) fully into the coupling. Push the next balanced flue (4) 50 mm (dim. "S") into the coupling of the separator, and secure in this location, e.g. with pipe clips DN 125 (5) or a fixing screw on the air side.
Flat roof: Affix the ceiling outlet approx. Ø 130 mm (14) in the roof cover.Pitched roof: At (12), observe the installation instructions on the
cowl regarding roof pitches.
If an inspection aperture is required for the balanced flue, insert a balanced flue with inspection aperture (3) (250 mm long).
Insert the roof outlet (7) from above through the roof and secure vertically with (6) to a rafter or brickwork.Installtheroofoutletonlyinitsoriginalcondition.Modificationsare not permissible.
31. Design information
Wet or lubricate all air/flue gas joints prior to installation, e.g. using a grease without silicone.NB
Fit connection adaptor with test nipple (2) to the oil condensing boiler connection.
Separate the flue via a slide coupling (8)
For inspection purposes, undo and move the inspection piece clamp. Undo and remove the inspection pipe cover.
Inspection piece (3)
Determine distance A. Length of balanced flue (4) always approx. 100 mm longer than distance A. Always trim the flue on the smooth side, never on the coupling side.Chamfertheflueaftertrimming.
Distan
ce A
Offset
11
10
11
11
4
4
Distance A
Distance A
Slide coupling (isolating appliance) (8)
Connection adaptor with test nipple (2)
Bends Offset87° min. 204 mm45° min. 93 mm
7
650
550-1
050
1250
1750-2
300
8
4
5
S
S
4
54 3062547_0311
General notes
Particularly for safety reasons, useonlyoriginalWolfcomponents for flues and concentric balanced flue systems.
Where necessary, adapt the installation examples to the relevant Building Regulations and requirements of your country/region. Discuss any questions relating to the installation of inspection covers and ventilation apertures with your local flue gas inspector.
The electronic flue gas temperature limiter switches the oil condensing boiler off when the flue gas temperature exceeds 120 °C.
The boiler restarts when the reset button is pressed.
Flue gas temperature limiter
The clear cross-section of flues must be able to be inspected. Therefore, install an inspection and/or test aperture inside the boiler room; agree suitable arrangements with your local flue gas inspector.
31. Design information
At low outside temperatures, the water vapour contained in the flue gas may condense and freeze on the balanced flue. This ice may fall from the roof causing injuries or material losses. Prevent ice from falling through on-site measures, e.g. the installation of a snow catcher grille.
Secure the balanced flue or flue outside ducts with spacer brackets with a minimum clearance of 50 cm from the flue outlet or upstream/downstream of diverters to prevent the pipe joints being pulled apart. If this is not observed, there is a danger of poisoning caused by escaping flue gas. Furthermore, equipment damage may result.
A clearance between the concentric balanced flue and combustible materials or components is not required, as temperatures are limited to 85 °C at the rated boiler output.If only a flue is installed, maintain the clearances specified by DVGW/TRGI 86/96 [or local regulations].
Balanced flues without ducts must not be routed through other installation rooms, as there is a risk of fire spreading, and mechanical protection is not ensured.
The combustion air must not be drawn from chimneys that used to carry flue gases from oil or solid fuel boilers.
If the balanced flue crosses different floors, route the pipes outside the installation room inside a duct with a fire resistance of at least 90 min, and in low residential buildings with a resistance of at least 30 min. Fire may spread if these instructions are not observed.
The following applies to boilers with a balanced flue above the roof, where only the roof structure lies above the ceiling:
If fire resistance is required for the ceiling, the pipes for combustion air supply and flue gas exhaustion running between the top edge of the ceiling and the roof skin must be run inside a liner that provides the same fire resistance and is constructed from non-combustible materials. There is a risk of fire spreading if these requirements are ignored.
If fire resistance is not required, route the pipes for combustion air supply and flue gas exhaustion between the top edge of the ceiling and the roof skin inside a duct made from non-combustible, rigid materials or inside a protective metal pipe (mechanical protection). There is a risk of fire spreading if these requirements are ignored.
Condensing boilers with a balanced flue outlet above the roof may only be installed in attics, or in rooms where the ceiling also forms the roof, or where only the roof construction is located above the ceiling.
Connectiontothebalancedflue
Ducts which were previously connected to an oil or solid fuel boiler must be thoroughly cleaned by the flue gas inspector. There must be no dust, sulphur or soot residues left on the inner surface of the chimney. If this is not possible, use a separate ventilation supply. If the combustion air is drawn in via the cleaned duct, the prior use can cause odours in the boiler room.
Flue cascade
Flue cascades are only suitable in balanced flue operation. They must be designed to EN 13984-1.
To prevent flue gas escaping, a flue cascade is only permitted with a tested flue gas damper.
NB
NB
553062547_0311
Connectiontoamoisture-resistantbalancedfluechimneytypeC43x
Straight balanced flues must be no longer than 3 m when connecting the system to a balanced flue chimney. In addition to the boiler connection tee, up to two 90° diverters may be installed.The balanced flue chimney must be CE-designated.
Connectiontoamoisture-resistantfluetypeB23foropenflueoperation
The straight, horizontal flue must be no longer than 3 m. In addition to the boiler connection tee, up to two 90° diverters may be installed in the horizontal flue.The flue gas chimney must be CE-designated.
The straight, horizontal flue must be no longer than 3 m. For horizontal air supply pipes, a maximum length of 3 m is recommended. Observe special requirements for flues that are not surrounded by combustion air in accordance with locally applicable combustion regulations.
Connectiontoamoisture-resistantfluetypeC53,C83xforbalancedflueoperation
Connection to a combustion air andflue system typeC63x that is not tested together with the oil combustion equipment
Original Wolf components are designed for long-term use and are matched for use with Wolf oil condensing boilers. When using CE-designated third party equipment, the installer is responsible for the correct sizing and perfect function of such systems. Faults, material losses and injuries resulting from incorrect pipe lengths, excessive pressure drop, premature wear with escaping flue gas and condensate or incorrect function, e.g. through components working themselves loose, are excluded from our warranty if non-approved third party equipment is used.
Straight balanced flues must be no longer than 3 m, when connectingthesystemtoacombustionairsupplyandaseparateflue.In addition to the boiler connection tee, up to two 90° diverters may be installed. The chimney must be free from contamination if the combustion air is drawn from the chimney.
Connectiontoamoisture-resistantfluegaschimneyorafluesystemtypeB33foropenflueoperation
Straight balanced flues must be no longer than 3 m when connecting the system to a flue gas chimney. In addition to the boiler connection tee, up to two 90° diverters may be installed.The flue gas chimney must be CE-designated.If necessary, the flue outlet should be obtained from the chimney manufacturer.The air apertures to the boiler room must be completely free from obstruction.
31. Design information
56 3062547_0311
32. Wiring diagram
SF
12
gn
/ge
br
bl
32
1
LN
NL
NN
NL
LN
LN
LL
NN
+-
~+
+-
-+
-~
~~
~~
+-
++-
++
+-
--
~~
++
-
eBUS
eB
US
gn
ge
rt
GND
GND
R6
80
12V
+
+
-
-
GND0,5..4,5V
GND5V
>
X1
X2
X3
X6
X4
X7
X5
X8
br
wsgn
br
gnrt
gews
br
gnbr
br
gn
gews
gn
sw
bl
br
rt
rt
bl
br
sw
br
br
bl
bl
br
br
vio
br
sw
or
gn
bl
rt
ge
ws
ge
gn br
A2
A1
AF
E1
eB
US
+-
12
ab
L1
oo
oo
oo
oo
oo
12
12
12
12
rt
gn
sw
bl
or
vio
br
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L1
rt
sw
>
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gn
br
S4
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5 4 3
3
2
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1
1
br rt gn
345 2 1
P
gra
u
Ne
tzK
KP
LP
N
N
NL
1L
1M
T
5A
F1
br
bl
gn/ge
sw
ws
L1
NL1
NN
L1
NN
XXX
12
34
56
bl
br
gn
/ge
12
3
PE
PE
PE
PE
NN
NL
LL
br
bl
gn
/ge
PW
M
N-Klemme
Term
inal
box
:M
ains
23
0 VA
C 5
0 Hz
LP
Externalprim
arypu
mp
23
0 VA
CE1
Pr
ogra
mm
able
inpu
teB
US
BUSconn
ectio
nfore
xternal
co
ntro
l acc
esso
ries
KK
P H
eatin
g ci
rcui
t pum
pA
F O
utsi
de te
mpe
ratu
re s
enso
rSF
Cylinders
ensor
Mains
Accessories
Primary pumpOutput A1
Heating circuit pump
Stratification pump
Oil pumpN terminal
Ignition
Oil preheater
L valves
Valve 1Valve 2
Input E1Outside temperature sensor
PWM stratification pump
Stratification sensor
Flow sensor
Speed
TW flowTW flue gas
External boiler monitoring
Cylinder sensor
Fan
X10
(ear
th
cond
ucto
r te
rmin
al)
X9
boile
r cod
ing
card
eBU
S p
lug
PW
M s
tratifi
catio
n pu
mp
Faul
t mes
sage
, co
nden
sate
pum
p
B1
(flow
sen
sor)
E1
(igni
tion
trans
form
er)
Y2
(val
ve 2
)Y
1 (v
alve
1)
Out
put A
1
M3
(oil
pum
p)
Bur
ner
M4
(fan)
S4
(wat
er p
ress
ure
switc
h)
S2
(TW
flue
gas
)
S1
(TW
flow
)
Stra
tifica
tion
sens
or
Jum
per
M1
(stra
tifica
tion
pum
p)
B3
(IRD
)
eBUS
grey
GND5 V
0.5..4.5 VGND
Mai
ns
bn
bu
gn/ye
wh
bk
rd
yebkog
vt
bngn
rd
bu
gn ye rd GND
bn
bl
bn
bl
rd
bn
bk
bn
rd
bl
bn
rd
rd
bn
bl
bk
og
vt
bkyebn
gn
blrd
gn
bngnbngn
bnwhye
rd
gnbn
whgn
wh
gn
bn
ye
ye bn gn wh
bn rd gn
bngn
/ye
bl
bn bl
gn/y
e
bn bl
gn/y
e
wh
ye gn bn
wh
ye gn bn
573062547_0311
33. ResetReset Observe the following steps to implement a reset:
- The ON/OFF switch must be set to O (OFF).- Press and hold down the reset button on the standard control unit whilst setting the ON/OFF switch to I (ON).- Hold down the reset button again for at least 2 seconds after switching on the system.
All parameters (individual settings) are returned to their factory settings by a reset.
0I
0 °C
20
40
60
80
100
120
ON/OFF switchReset button
58 3062547_0311
34. TroubleshootingAny faults will be displayed as fault code by Wolf control accessories with eBUS capability. The cause and remedy for a fault can be established using the following table. This table is designed to allow your local heating contractor to trace the fault more easily.
Fault code
Fault Cause Remedy
1 Excess temperature (high limit safety cut-out)
The flow temperature has exceeded 110 °C Test heating circuit pump, vent system, press reset, clean heat exchanger
4 No flame established
No flame at burner startInspection window for flame monitor/mixer head contaminated Faulty flame monitor Air in oil line Negative pressure at oil pump too high, max. 0.3 bar Overpressure at oil pump too high, max. 0.5 bar
Check oil line, if necessary check fuel level, check ignition electrode and ignition transformer, press reset Check inspection window for flame monitor/mixer head Check flame monitor and leadSiphon backpressure
5 Flame failure during operation
Flame failure during safety time Negative pressure at oil pump too high, max. 0.3 bar, flue gas recirculation (flue gas in the ventilation air)
Check CO2 values, check flame monitor and lead, press reset, check flue system for leaks
6 TW excess temperature The flow has exceeded the limit of the temperature limiter (100 °C)
Vent the system, check the heating circuit pump
7 Flue gas sensor excess temperature
The flue gas temperature has exceeded 120 °C Clean heat exchanger, check whether all displacement devices are installedCheck the flow through the boilerCheck boiler flow / boiler returnpress reset
8 Flue gas/ventilation air damper does not move
Flue gas/ventilation air damper contact (E1) fails to close or open when there is a demand
Check flue gas/ventilation air damper and wiring
11 Flame pretence A flame is recognised before the burner starts Press the resetCheck solenoid valve for oil pump
12 Faulty boiler sensor Faulty boiler sensor or lead Check sensor and lead14 Faulty cylinder sensor
SFFaulty cylinder sensor or lead Check sensor and lead
15 Faulty outside temperature sensor
Faulty outside temperature sensor or lead Check sensor and lead
25 Fan fault The fan does not reach the set speed Check power cable to fan and check fan;Check that the condensate can drain off freely from the balanced flue systempress reset
26 Fan fault The fan does not stop Check power cable to fan and check fan; press reset
27 Faulty stratification sensor
Faulty stratification cylinder sensor or lead Check sensor and lead
40 Insufficient water pressure
The pressure switch does not switch on, water pressure is too low (< 0.8 bar)
Check system pressure >1.5 bar Check water pressure switch, check lead, press reset
593062547_0311
34. Troubleshooting
Fault code
Fault Cause Remedy
42 Condensate pump is not pumping anything out
Faulty condensate pump, drain line blocked, no power supply to pump
Check pump, check drain line, check mains plug and fuse
52 Max. cylinder heating time exceeded
Set cylinder temperature is not being reached, insufficient flow
Vent cylinder, increase cylinder heating time (HG20), check cylinder sensor assembly
78 Header sensor fault Faulty header sensor or lead Check sensor and leadInsufficient heating system heating, frequent cycling
Air in the heating or cylinder system Vent radiators, vent cylinder primary circuit, vent heating circuit pumps, vent boiler
No DHW heating Sensor is not detected by the boiler Switch boiler off and on; sensor will be detected on restarting
Gerdewan JacobsTechnical Management
Mainburg, 21 April 2010
DECLARATION OF CONFORMITY(to DIN EN ISO/IEC 17050-1)
Number: 3062547
Issued by: Wolf GmbH
Adress: Industriestraße 1, D-84048 Mainburg
Product: Oil condensing boiler COB/COB-CS
Theproductdescribedaboveconformstotherequirementsspecifiedinthefollowingdocuments:
DIN EN 230, 10/2005DIN EN 303, 12/2003DIN EN 304, 01/2004DIN EN 15034, 01/2007DIN EN 15035, 05/2007DIN EN 12828, 06/2003DIN EN 61000-3-2, 03/2010DIN EN 61000-3-3, 06/2009DIN EN 61000-4-3, 06/2008DIN EN 55014-1, 02/2010DIN EN 60335-1, 02/2007DIN EN 60335-2-102, 04/2007DIN EN 60529, 09/2000
In accordance with the following Directives
92/42/EWG (Efficiency Directive)2004/108/EG (EMC Directive)2006/95/EG (Low Voltage Directive)
thisproductisidentifiedasfollows:
Klaus GrabmaierProduct approval
0085
Wolf GmbH · Postfach 1380 · D-84048 Mainburg · Tel. +49-8751/74-0 · Fax +49-8751/741600 · Internet: www.wolf-heiztechnik.de