Wolf CGG-1K-24 User manual

Installation and
operating instructions
Gas red wall mounted boiler
CGG-1K-24/28
Part no. 30 62 087 Subject to modications
Wolf GmbH · Postfach 1380 · D-84048 Mainburg · Tel. [phone] · Fax [phone] · Internet: www.wolf-heiztechnik.de
11/08 GB

23062087_1108
Index
General information
Safety instructions / Standards and regulations............................................ 3-4
Operation
Control / Function / Operation...........................................................................5
Installation
Dimensions / Installation dimensions................................................................6
Layout CGG-1K-24/28 .................................................................................. 7-8
Positioning information / Installation..................................................................9
Installation
On nished walls.............................................................................................10
On unnished walls.........................................................................................11
Flue gas buttery orice plate / Routing ventilation air / ue gas.............. 12-13
Power connection............................................................................................14
Commissioning
Filling the system ............................................................................................15
Commissioning / Checking the gas supply pressure ......................................16
Boiler settings and matching
Displaying / modifying control parameters ......................................................17
Limiting the maximum output ..........................................................................18
Selecting the pump stage.......................................................................... 19-20
Commissioning report .....................................................................................21
Inspection and maintenance
Inspection and maintenance / Service report..................................................22
Service report..................................................................................................23
Service ...................................................................................................... 24-25
Additional information
Conversion to other gas types .................................................................. 26-31
Flue gas test....................................................................................................32
Wiring diagram................................................................................................33
Specication....................................................................................................34
Fault / Cause / Remedy ..................................................................................35
EC Declaration of Conformity..........................................................................36

3
3062087_1108
The following symbols are used in conjunction with these
important instructions concerning personal safety as well
as operational reliability.
Safety instructions
This indicates technical instructions that you
must observe to prevent material losses and
boiler malfunctions.
NB
Danger through 'live' electrical components.
NB Switch OFF the ON / OFF switch before
removing the casing.
Never touch electrical components or contacts
when the ON / OFF switch is in the ON position.
This results in a risk of electrocution that may
lead to injury or death.
The main supply terminals are 'live' even when
the ON / OFF switch is in the OFF position.
"Safety instructions" are instructions with
which you must comply exactly, to prevent
injury and material losses.
Fig.: Terminal box: Danger from electric current
Fig.: Gas connection: Escaping gas may cause poisoning or the risk
of explosion
Fig.: Ignition transformer, high voltage ignition electrode, combustion
chamber
Risk of electrocution, risk of burning through hot components
Fig.: Gas combination valve
Danger from electric current
Escaping gas may cause poisoning or the risk of explosion

43062087_1108
Safety instructions / Standards and regulations
Please follow these safety instructions closely to prevent accidents and material losses.
Commissioning - Commissioning must only be carried out by the system installer or a commissioning
engineer designated by him. All actual values must be recorded in a commissioning/
service report that should be kept with these instructions.
Safety regulations - Observe all national safety regulations and installation requirements.
- Installation, commissioning, inspection, maintenance and repairs must only be carried
out by a competent person (heating engineer / installation contractor).
- Before working on the equipment / heating system, switch OFF the power supply
(e.g. by removing a separate mains fuse or by means of a main electrical isolator)
and safeguard against unauthorised reconnection.
- Disconnect the system by means of a device that isolates all non-earthed conductors
simultaneously with at least 3 mm contact separation.
- It is not permitted to carry out repairs on parts that full a safety function.
- Use only original WOLF replacement parts or those that are equivalent and that have
been approved by the manufacturer.
Instructing the system user - The system installer must hand the operating instructions to the system user and
instruct him/her in the operation of the system.
Standards and regulations Category: II2H3B/P, <PL> II2ELw3B/P, II2H3P
NOx class: 3
Efciency:  (3 stars acc. to 92/42/EEC)
Flue types: C12x, C32x, C42x, C52, B32
Operating mode: Open ue / balanced ue
To be connected to: Chimney / balanced ue chimney / balanced ue
Standards Directives
EN 297 90/396/EEC
EN 483 2004/108/EC
EN 60 335-1 73/23/EEC
EN 50 165 92/42/EEC
EN 55 014
EN 61 000-3-2/-3
- Obtain the permission of your mains gas supplier and all relevant authorities prior to
the installation of Wolf gas red combi boilers.
- Open ue gas red boilers must only be installed in a room that complies with the
appropriate ventilation requirements.

5
3062087_1108
Control / Function / Operation
ON / OFF switch DHW temperatu-
re selector
Pressure
gauge
Reset
button
Heating water tempe-
rature selector
Illuminated
signal ring
Thermometer
In conjunction with the accessory controllers BM / AWT / ART, the settings at the boiler
relating to DHW and heating water are disabled.
Note:
Signal ring as
status display
9
1
28
3
7
4
6
5
DHW temperature selector
The settings 1-9 correspond to a DHW temperature of 40 to 60 °C. Combined with a
control thermostat for wall mounted gas red boilers, the adjustment at the DHW tem-
perature selector is disabled; instead the temperature is selected at the boiler control
thermostat.
28
3
7
4
6
5
Heating water temperature selector
The setting range 2-8 corresponds to a heating water temperature of 40 to 80 °C. Com-
bined with a control thermostat for wall mounted gas red boilers, the adjustment at the
heating water temperature selector is disabled; instead the temperature is selected at
the boiler control thermostat.
Emissions test mode
Turning the switch to position lets the boiler operate at maximum output. The illu-
minated signal ring ashes yellow for 15 minutes or until the maximum ow temperature
has been exceeded.
Summer mode
Switch set to circulation pump OFF (heating OFF); only DHW heating, frost pro-
tection, pump anti-seizing protection enabled, i.e. the circulation pump runs for approx.
30 s every 24 hours.
°C
0 120
bar
04
2
13
Thermometer/pressure gauge
The heating water temperature is displayed in the upper half, the heating system
water pressure in the lower half.
Setting Winter mode (position 2 to 8)
The circulation pump operates in heating mode.
Display Explanation
Flashing green Standby (power supply ON, burner OFF)
Constant green light Heat demand: pump running, burner OFF
Flashing yellow Emissions test mode
Constant yellow light Burner ON, ame steady
Flashing red Fault

63062087_1108
Dimensions / Installation dimensions
1 Heating ow
2 DHW
3 Cold water
4 Heating return
5 Gas connection
Minimum clearances
Min.200Min.200
Min.40
190
393
855
73
134
5
2
3
1
4
176
440
170
694 257,5
39 49
344
512 3 4
120

7
3062087_1108
Layout
CGG-1K-24/28
Flue gas fan
Combustion chamber
Internal lling facility
(optional)
Gas combination
valve
Expansion vessel
Three-way diverter
valve
Flow sensor 2
Limit thermostat
LAF connection ue gas
buttery orice plate
Monitoring elec-
trode Ignition electrode
Heating water heat
exchanger
Differential pres-
sure switch
Safety valve
Drain valve
DHW ow &
temperature sensor
Flow sensor 1
Flue gas collec-
tor box
Gas burner
Heating circuit
strainer
Cold water strainer with
throughput limiter
Heating circuit pump
Air vent valve
Bypass

83062087_1108
Layout
Heating water heat
exchanger
Gas burner
Gas combination
valve
Expansion vessel
Air vent
Heating circuit
pump
DHW heat ex-
changer
Safety valve
Drain valve
Heating circuit
strainer
Cold water strainer with
throughput limiter
Limit thermostat
Flow sensor 2
Flow sensor 1
Three-way diverter valve
DHW ow
& temperature sensor
Bypass valve
Hydraulic as-
sembly
Overow valve

9
3062087_1108
Positioning information / Installation
- Determine the installation location for the gas red boiler;
maintain the specied minimum clearances (see the r.h.
diagram).
- Fit the installation template (paper poster) supplied to the
wall.
- Transfer the xing hole and connection positions marked
on the installation template to the wall (e.g. with a power
drill).
- Remove the installation template.
- Drill Ø 12 mm holes for the mounting bracket and secure the
bracket using the rawl plugs and screws supplied. (Before
securing the bracket, check that the rawl plugs are suitable
for the wall construction.)
- Remove the casing lid of the gas red boiler. For this, pivot
the control unit lid down, hook in the r.h. and l.h. turn buckle,
undo the bottom of the casing lid and unhook at the top.
- Hang the gas red boiler with the hook-in brace on the back
of the boiler into the mounting bracket.
General
The gas red boiler may only be installed in rooms that are
protected from frost.
During the boiler installation ensure that all xings
are sufciently strong to carry its weight. Also con-
sider the wall consistency, otherwise gas or water
may escape which could lead to explosions and
ooding.
During the boiler installation, ensure that no
contaminants (e.g. drilling swarf) enter the gas
red boiler otherwise faults may develop.
The combustion air supplied to the boiler must
be free from chemicals, e.g. uoride, chlorine or
sulphur. Such materials are contained in sprays,
solvents and cleaning agents. Under the most un-
favourable conditions, these may lead to corrosion,
even in the ue gas system.
Balanced ue gas red boilers must only be
installed in a room that complies with the appro-
priate ventilation requirements. Otherwise there
is a risk of asphyxiation or poisoning. Read
these installation and operating instructions
before installing the gas red boiler. Also take
the technical guide into consideration.
Fig.: Installation template
200
40
For installation of the gas red boiler inside a cupboard note
the following:
Never install the gas red boiler on the back wall of
the cupboard, as this component may not be sub-
stantial enough to carry the boiler weight. This would
create the risk of water and gas leaks which in turn
would result in a risk of explosion and ooding.
- Remove the back wall of the cupboard
Minimum clearance between the gas red boiler and the cup-
board sides 25 mm.
Installation inside a cupboard
l.h. turnbuckle r.h. turnbuckle
Fig.: Opening the turnbuckle
NB

10 3062087_1108
Installation
Gas connection
Laying the gas pipe as well as making the gas
connections must only be carried out by a licensed
gas tter. Close the gas ball valve on the gas red
combi boiler to pressure test the gas pipe.
Remove all residues from the heating pipework and
the gas pipe prior to connecting the gas red boiler,
particularly in older systems.
Prior to commissioning, test all pipe and gas con-
nections for leaks.
Inappropriate installation or using unsuitable com-
ponents or assemblies may lead to gas escaping,
which results in a risk of poisoning and explosion.
The gas valve can be subjected to a maximum
pressure of 150 mbar. Higher pressure may
damage the gas valve, resulting in a risk of ex-
plosion, asphyxiation or poisoning. Close the
gas ball valve on the gas red boiler to pressure
test the gas pipe.
Install a tested and certied pressure reducer,
if the cold water supply pressure is above the
maximum permissible operating pressure of 10
bar. Otherwise water could escape resulting in
a risk of ooding.
Fig.: Cold water connection in accordance with DIN 1988
Drain Drain Shut-off valve Pressure reducing valve Shut-off valve Cold water inlet Pressure gauge port Drinking water lter
Safety valve
Cold water and DHW connection
For the cold water and DHW connection, we recommend the
installation in accordance with DIN 1988.
- Wolf connection sets (accessories) are available for installa-
tion on nished and unnished walls. The connection pipes
are Cu 18x1.
Hydraulic connections
Note: As standard, a combined cold water strainer with
throughput controller  is tted at the cold water
connection  of the boiler. (see Fig.)


Fig.: Throughput controller with cold water strainer
Installation on nished walls
Fig.: Front view, connection set for installation on nished walls
(part no. 86 12 188)
 Heating ow
 DHW
 Cold water
 Heating return
 Gas connection

11
3062087_1108
Installation
Installation on unnished walls
Fig.: Front view, connection set for installation on unnished
walls (part no. 86 12 189)
Fig.: View from below, connection set for installation on nished
walls (part no. 86 12 188)
Fig.: View from below, connection set for installation on un-
nished walls (part no. 86 12 188)

12 3062087_1108
Flue gas buttery orice plate / Routing
ventilation air / ue gas
Flue gas
buttery orice
plate
- Prior to installing the ue gas system, check using the appro-
priate tables, which of the ue gas buttery orice plates
supplied should be used. This is subject to the length of the
balanced ue pipe.
Selection of the ue gas buttery orice plate
Never exceed the maximum lengths specied
in the tables, otherwise incomplete combustion
may result.
If the CO content in the ue gas is higher than
300 ppm (free of air), remove the cause; other-
wise do not continue to operate the gas red
boiler, as there would be a risk of ue gas esca-
ping, resulting in the danger of poisoning.
Wolf boilers are certied as one unit with the
original Wolf balanced ue system. Use only
original Wolf balanced flue systems. Using
alternative accessories can lead to incorrect
functions. Material losses and injuries cannot
then be prevented.
General information:
From a length of 3 m upwards, we recommend the installati-
on of a condensate trap.
Calculating the ue length 60/100 mm
Calculated ue length = length of straight pipes + 1.0 m per 90° bend / tee + 0.5 m per 45° bend
Type C32x Roof outlet (balanced ue)
concentric vertical system 60/100 mm
calculated pipe length min. / max. = 0.3 / 5.0 m
Type C12x Outside wall connection (balanced ue)
concentric horizontal system 60/100 mm
calculated pipe length min. / max. = 0.3 / 5.0 m
Boiler CGG-1K Calculated
length
Flue gas buttery
orice plate no. Ø
24 ≤3 m 1 (38,0 mm)
>3 m 2 (39,8 mm)
≤5 m
28 ≤2 m 2 (39,8 mm)
>2 m 3 (42,5 mm)
≤5 m
Boiler CGG-1K Calculated
length
Abgasdrossel-
blende Nr. Ø
24 ≤3 m 1 (38,0 mm)
>3 m 2 (39,8 mm)
≤5 m
28 ≤2 m 2 (39,8 mm)
>2 m 3 (42,5 mm)
≤5 m

13
3062087_1108
Balanced ue system
Connection to the ue in a duct and ventilation air through an
external wall (balanced ue) system 80/80 mm
Type C82
Room sealed balanced ue / duct sizing through calculation
according to EN 13384 or country-specic standard as at-
mospheric pressure system with an inlet pressure = 0 Pa
A
C
BD
Connection to the ue and ventilation air through an external
wall or roof (balanced ue) system 80/80 mm
Type C52
Connection to a chimney;
ventilation air directly via the boiler or through a horizontal
concentric supply line (open ue)
concentric system 60/100 mm
Type B32
Room sealed balanced ue / duct sizing through calculation
according to EN 13384 or country-specic standard as at-
mospheric pressure system with an inlet pressure = 0 Pa
Type C42x Connection to a room sealed balanced ue
concentric system 60/100 mm
Room sealed balanced ue / duct sizing through calculation
according to EN 13384 or country-specic standard as at-
mospheric pressure system with an inlet pressure = 0 Pa
0
0
5
10
15
20
25
510152025
C+D
A + B
admissible range
Boiler CGG-1K Calculated
length A+B
Flue gas buttery
orice plate no. Ø
24 ≤2 m 1 (38,0 mm)
28 ≤2 m 2 (39,8 mm)
Boiler CGG-1K Calculated
length A+B
Flue gas buttery
orice plate no. Ø
24 ≤3 m 1 (38,0 mm)
28 ≤2 m 2 (39,8 mm)
Boiler CGG-1K Calculated
length A+B+C+D
Flue gas buttery
orice plate no. Ø
24 ≤13 m 39,8 mm
28 ≤12 m 42,5 mm
Boiler CGG-1K Calculated
length A+B+C+D
Flue gas buttery
orice plate no. Ø
24 ≥2 m / ≤ 25 m 39,8 mm
28 ≥2 m / ≤ 25 m 42,5 mm

14 3062087_1108
Power connection
The mains terminals in the terminal box are
'live' even when the ON / OFF switch has been
switched OFF. Non-observance can result in a
risk of electrocution, which may be detrimental
to health or lead to death.
- Connection, outside temperature sensor
The outside temperature sensor for digital control accessory
(e.g. BM) may be connected to the terminal strip of the gas
red boiler or the terminal strip of the BM.
- Connection of digital Wolf control accessories (e.g. ART,
AWT, MM, BM)
Only connect control units from the Wolf accessory range.
Each accessory is supplied with its own connection diagram.
Use a 2-core cable (cross-section > 0.5mm²) as the connec-
ting cable between the control unit accessory and the gas
red boiler.
- Connection, room thermostat 230 V
Connect the room thermostat cable at the terminals in ac-
cordance with the wiring diagram; rst remove the jumper
between the respective terminals.
Connec-
tion, outside
temperature
sensor
Connection, di-
gital Wolf control
accessories
Connection,
room thermo-
stat
Connection,
power supply
230 VAC/50Hz
Installation information
Power connection
- Isolate the system from the power supply before opening.
- Pivot the control unit to the side.
- Open the terminal box.
- Insert the strain relief into the holes provided.
- Strip approx. 70 mm off the power supply cable insulation.
- Push the cable through the strain relief and secure the strain
relief.
- Push the inserts back into the terminal box casing.
- Terminate the appropriate cores inside the terminal box.
Terminal box
Only qualied electricians must carry out the
electrical installation; that installer will be
responsible for compliance with all current
standards and directives.

15
3062087_1108
Filling the system
Filling the system Fill the system and vent it thoroughly to safeguard the perfect function
of the gas red boiler.
The heating water must not be mixed with inhibitors or antifreeze;
otherwise leaks and ooding could result.
- Before connecting the gas red boiler to the heating system, ush the entire system
to remove residues such as welding pearls, hemp, putty, etc. from the pipework.
- Fill the DHW system of the boiler until water ows out of a DHW draw-off point.
- Open the cap of the automatic air-vent valve on the heating circuit pump by one
revolution, but do not remove the cap.
- Open all radiator valves and the shut-off valves on the heating water side of the
boiler.
Procedure for boilers with internal
lling facility
- Fill the entire heating system and boiler via the lling facility or an on-site ll & drain
valve up to approx. 1.5 bar, whilst simultaneously venting the heating system.
- Close the shut-off valves on the heating water side of the boiler (ow and return).
- Push the drain hose onto the drain valve of the hydraulic assembly.
- Flush all air out of the heat exchanger by simultaneously opening the internal lling
facility and the drain valve on the hydraulic assembly.
Procedure for boilers without inter-
nal lling facility
- Fill the entire heating system and boiler via an on-site ll & drain valve up to approx.
1.5 bar, whilst simultaneously venting the heating system.
- Close the return shut-off valve on the heating water side of the boiler.
- Push the drain hose onto the drain valve of the hydraulic assembly.
- Flush all air out of the heat exchanger by simultaneously opening the on-site ll &
drain valve and the drain valve on the hydraulic assembly.
- Remove the drain hose and open the boiler shut-off valves on the heating water
side again.
- Open the gas ball valve.
- Start the boiler, set the heating water temperature selector to position "2" (pump
running, illuminated signal ring (status display) constantly green).
- Vent the pump; for this, briey open and then retighten the air vent screw.
Top up with water when the system pressure falls severely.
- Open the gas shut-off valve. Press the reset button.
- In constant operation, the heating circuit will be automatically vented via the hea-
ting circuit pump.
Internal lling
facility
(option)
Drain valve

16 3062087_1108
Commissioning /
Checking the gas supply pressure
Prior to installation, ensure that the boiler corresponds to the
gas type available.
Only qualied personnel must carry out the
commissioning and boiler operation as well
as the user instruction to prevent dangers and
injuries as well as material losses.

- Open the gas connections.
- The boiler and system must be fully vented and must be
absolutely tight.
- Check that all ue gas accessories have been correctly
installed.
- Remove the casing cover.
- Release the plug at test nipple  and vent the gas supply
pipe.
- Retighten the plug.
- Start the boiler.
- Check the ignition and the regular ame structure of the
burner.
- If the system water pressure falls below 1.5 bar, top up with
water up to 1.5 to max. 2.5 bar.
Check test nipple  for soundness, otherwise
gas may escape, resulting in a risk of explosion,
asphyxiation or poisoning.
Remove the test equipment:
- Shut down the boiler. Close the gas shut-off valve.
- Pull the hose off and tighten the test nipple again. Open the
gas shut-off valve.
Check the test nipple for soundness, otherwise
gas may escape, resulting in a risk of explosion,
asphyxiation or poisoning.
Connect the test equipment
- The gas red boiler must be switched OFF. Open the gas
shut-off valve.
- Remove the casing lid.
- Release the plug at test nipple .
- Connect the hose to the pressure test device at test nipple
 and check against atmosphere.
- Start the boiler and read off the indicated value.
- Enter the value in the commissioning report.
Never take the boiler into use if the actual value falls outside
the specied limits.
→ Notify your gas supply company.
Gas type Nom. supply
pressure
Permissible
range
Natural gas H 20 mbar 18*-25 mbar
LPG B/P 50 mbar 43-57 mbar
LPG B/P 29 mbar 25-35 mbar
* 13 mbar in Russia; this may result in a reduction in boiler output
by up to 2 kW.
Gas type Wobbeindex Ws
kWh/m³ MJ/m³
Natural gas H 12,7 -15,2 45,7 - 54,7
LPG 20,3 - 24,3 72,9 - 87,3

17
3062087_1108
Displaying / modifying control parameters
If parameter A 09 (frost protection limit) is set lower than the factory setting, frost protection is no longer ensu-
red. This can lead to heating system damage.
The settings in column 1 apply to control accessories ART, AWT.
The settings in column 2 apply to Wolf control systems with programming module BM.
Modications must only the carried out by a
recognised heating contractor or by the Wolf
customer service to prevent a risk of injury,
equipment damage and incorrect functions.
NB
1 2 Parameters Unit Factory
set..
Min Max
GB 01 HG 01 Burner switching differential K 8 5 25
HG 02 Min. modulation current HTG / DHW
Min. modulation current of the gas valve for HTG / DHW
% 1 1 100
HG 03 Max. modulation current DHW
Max. modulation current of the gas valve for DHW
% 100 1 100
GB 04 HG 04 Max. modulation current HTG
Max. modulation current of the gas valve for HTG
% 100 1 100
GB 06 HG 06 Pump operating mode
0 > Pump ON in winter mode
1 > Pump ON during burner operation
- 0 0 1
GB 07 HG 07 Pump run-on time HTG
Heating circuit pump run-on time in minutes in htg. mode
min 1 0 30
GB 08 HG 08 Max. ow temperature
Applicable to heating operation
°C 80 40 90
GB 09 HG 09 Cycle block
Applicable to heating operation
min 7 1 30
HG 11 DHW quick start temperature
Temp. of the plate-type heat exchanger in summer mode
°C 10 10 60
HG 12 Gas type
1 > NG (natural gas)
0 > LPG (LPG)
- 1 0 1
GB 05 A 09 Frost protection limit
with connected outside temperature sensor and
insufcient temperature > pump ON
°C 2 -20 10
HG 21 Min. ow temperature for heating operation °C 40 20 60

18 3062087_1108
Limiting the maximum output
The output setting can be modied with Wolf control accessories with eBUS capability via parameter HG 04.
The heating output will be determined by the modulation current of the the gas valve. By reducing the modulation current in accor-
dance with the table, the maximum output will be matched at 80/60 °C to natural gas H and LPG.
Output [kW]
Modulation current [%]
Output change CGG-1K-24 G31 / G30 / G20
Output [kW]
Modulation current [%]
Output change CGG-1K-28 G31 / G30 / G20
0
2
4
6
8
10
12
14
16
18
20
22
24
26
0510 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
0510 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Output [kW] 9,4 12 15 18 21 24
IMod [%] 1 22 39 54 69 100
Output [kW] 10,9 14 18 22 26 28
IMod [%] 1 22 38 56 73 100

19
3062087_1108
Selecting the pump stage
The boiler is equipped with a three-stage pump that is set to
stage 2 in the delivered condition.
The minimum circulation volume is ensured by a connection
line between the ow and return. An automatic overow valve
and a manually adjustable bypass valve are integrated into
the connection line.
In the delivered condition, the bypass valve is fully opened
to "MAX". Closing the valve can increase the residual head
(see diagram).
Fig.: Pump rate stages at the heating circuit pump
Bypass valve
Stage 1
Stage 2
Stage 3

20 3062087_1108
Selecting the pump stage
Bypass valve fully opened (delivered condition)
Residual head [mbar]
Pump rate [l/h]
Bypass valve closed
Residual head [mbar]
Pump rate [l/h]
0
50
100
150
200
250
300
350
400
450
500
550
600
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0
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