Wolf CGS-2-14/120L User manual

GB
IE
WOLF GMBH / POSTFACH 1380 / D-84048 MAINBURG / TEL. [phone] / FAX [phone] / www.WOLF.eu
Art.-Nr.: 3064816_201804 Subjecttotechnicalmodications
Installationinstructionsforcontractors
Gas condensing centre
CGS-2 gas condensing centre
CGS-2-14/120L
CGS-2-20/160L
CGS-2-24/200L
CGS-2-14/150R
CGS-2-20/150R
CGS-2-24/150R

23064816_201804
Tableofcontents
1. Information on documentation/standard delivery...............................3
2. Safety instructions .............................................................................5
3. Dimensions/installation dimensions...................................................8
4. Specification ....................................................................................10
5. CGS-2L layout .................................................................................12
6. Electronic gas/air mixture ................................................................14
7. Casing .............................................................................................15
8. Standards and regulations...............................................................16
Installation
9. Siting................................................................................................19
10. Installation/separation......................................................................20
11. Installation .......................................................................................22
12. Gas connection................................................................................24
13. Fitting the trap..................................................................................25
14. Balanced flue...................................................................................26
Control unit
15. Electrical connection........................................................................27
16. Flue gas/ventilation air damper electrical connection......................33
17. Display module/programming unit/installation.................................34
18. Display module/programming unit/dismantling................................35
19. AM display module/description........................................................36
20. AM display module menu structure .................................................37
21. Heating appliance operating mode/burner status............................38
22. BM-2 programming unit...................................................................39
23. HG control parameters ....................................................................40
24. Parameter description .....................................................................41
Commissioning
25. Filling the heating system/trap.........................................................52
26. Filling of optional appliance versions...............................................56
27. Draining the heating system............................................................57
28. Determining/changing the gas type.................................................58
29. Commissioning................................................................................60
30. Checking the gas supply pressure ..................................................61
31. Adjusting the maximum heating output ...........................................62
32. Testing the combustion parameters.................................................63
33. Heating circuit pump function description........................................65
34. Commissioning report......................................................................67
Specication
35. Safety devices .................................................................................69
36. Technical information, balanced flue ...............................................70
37. Technical information, underfloor heating system/DHW circulation.85
38. Reset ...............................................................................................86
39 Technical maintenance and design data .........................................87
40. Troubleshooting...............................................................................88
41. Troubleshooting warning messages................................................96
42. HCM-2 wiring diagram.....................................................................98
43. Product datasheet to regulation (EU) no. 811/2013 ......................100
44. Technical parameters according to EU regulation no. 813/2013...101
EU DECLARATION OF CONFORMITY................................................103

3064816_201804 3
1. Informationondocumentation/
standarddelivery
1.1 Otherapplicabledocuments
- Operating instructions for the user
- Maintenance instructions
- System and operating log
The instructions for all accessory modules and other accessories also apply where
relevant.
1.2 Safekeepingofthesedocuments
The system user or operator should ensure the safekeeping of all instruction manuals
and documents.
► Handovertheseinstallationinstructionsaswellasallotherapplicablemanuals
to the system user or operator.
1.3 Instructingthesystemuser
- Instruct the system user to take out an inspection and maintenance contract with
an approved contractor.
- Inform the system use that the annual inspection and maintenance may only be
performed by an approved contractor.
- Inform the system use that repair work may only be performed by an approved
contractor.
- Inform the system user that only original spare parts may be used.
- Inform the system user that no technical changes may be made to the boiler or
control unit.
- Inform the system user that they are responsible for the safety, environmental com-
patibility and energy quality of the heating system (German Immission Control Act/
Energy Saving Ordinance) [Germany].
- Inform the system user that these instructions and the other applicable documents
must be kept in a safe place.
- Instruct the system user how to operate the heating system.
1.4 Applicabilityoftheseinstructions
These installation instructions apply to the CGS-2 gas condensing boilers.
1.5 Acceptance
Within 4 weeks of commissioning the combustion system, the operator must notify
the local flue gas inspector accordingly [check local regulations].
According to the Bundes-KÜO (German Federal Sweeping and Inspection Act), tests
and inspections are only required every 3 years.
1.6 Recyclinganddisposal
- Old equipment may only be disconnected from the gas and electricity supply by a
qualiedcontractor.
- Always dispose of materials according to environmental, recycling and waste man-
agement standards.
- Old equipment, worn parts, defective components and liquids and oils which are a
hazard to the environment must be disposed of or recycled according to the appli-
cable waste disposal regulations in an environmentally compatible manner.
They must not be disposed of as household waste.
- Disposeofpackagingmadeofcardboard,recyclableplasticsandsyntheticller
materials in an environmentally compatible manner through appropriate recycling
systems or a recycling centre.
- Please observe the applicable national and local regulations.

43064816_201804
1. Informationondocumentation/
standarddelivery
1x Gascondensingboilerwithintegralstraticationcylinder(CGS-2L)
or cylinder with internal indirect coil (CGS-2R), fully wired, in casing
1 x Suspension bracket for wall mounting
1 x Installation instructions for contractors
1 x Operating instructions for users
1 x Maintenance instructions
1 x Commissioning checklist
1 x Label "G31/G30" (for conversion to LPG)
1x Installationset(trapwithhose,cleaningbrush,connectionpiecesforheatingow/
returnwithboilerdrain&llvalve,R½"bracketforgasconnection,gasconnection
line,exible,hoseforsafetyvalve)
Standarddelivery
Accessories The following accessories are required for installing the gas condensing boilers:
- Balancedueaccessories(seetechnicalinformation)
- Control unit for room temperature-dependent or weather-compensated control
(AM/BM-2)
- Condensate drain outlet with hose retainer
- Maintenancevalvesforheatingowandreturn
- Gasballvalvewithreprotection
- Safety assembly for DHW
Other accessories as per pricelist

3064816_201804 5
2. Safetyinstructions
Danger:ifyousmellgas
- Close the gas tap.
- Open the windows.
- Do not operate any electrical switches.
- Extinguish naked flames.
- Phone the gas supply utility company and an ap-
proved contractor from an external location.
Danger:ifyousmelluegas
- Switch OFF the appliance.
- Open windows and doors
- Notify an approved contractor.
Authorisedpersonnelshouldreadtheseinstructionsbe-
foreanyinstallation,commissioningormaintenancework.
Adheretothespecicationsinthisdocument.Failureto
observe these installation instructions voids any WOLF
warranty.
Insomecountries,therelevantgassupplycompanymust
benotiedoftheinstallationofagasboilerandmustgive
theirapproval.
Pleasenotethatregionalpermitsmayberequiredforthe
uegassystemandconnectingthecondensatedrainto
thepublicsewer.
Beforeinstallationworkbegins,thelocaluegasinspector
andwastewaterauthoritymustbeinformed[checklocal
regulations].
The gas condensing boiler must be installed, commis-
sioned and serviced by qualied and trained personnel
only.InaccordancewithVDE0105Part1,workonelectrical
components(e.g.controlunit)mustonlybecarriedoutby
qualiedelectricians.
VDE/ÖVE regulations [Germany/Austria] and those of
yourlocalpowersupplyutilityareapplicabletoelectrical
installationwork.
Onlyoperatethegascondensingboilerwithinitsoutput
range, which is stated in the technical documentation
supplied by WOLF. Intended use of the boiler includes
exclusiveuseforhotwaterheatingsystemsinaccordance
with EN 12828.
Neverremove,bypassorotherwisedisableanysafetyor
monitoringequipment.Onlyoperatetheapplianceifitis
intechnicallysoundcondition.
Anyfaultsordamagewhichimpactormightimpactupon
safetymustberemediedimmediatelybyaqualiedcon-
tractor. Replace faulty components and equipment only
withoriginalWOLFspareparts.
Dangerfrom„live“electricalcomponents
Nevertouchelectricalcomponentsorcontacts
whentheON/OFFswitchisintheONposition.
Thereisadangerofelectrocution,resultingin
arisktohealthordeath.Themainterminalsare
‚live‘,evenwhentheON/OFFswitchisintheOFF
position.
Riskofscalding
Boilersmaycontainhotwater.
Hotwatercancauseseverescalding.
Beforeworkingonpartswhichareincontact
withwater,allowtheappliancetocooltobelow
40°C,shutoffallvalvesand,ifnecessary,drain
the appliance.
Riskofburns
Boilercomponentsmaybeextremelyhot.
Hotcomponentscancauseburns.
Beforeworkingontheopenedupappliance,al-
lowittocoolbelow40°Corwearsuitablegloves.
Symbols
The following warning symbols are used in these instructions.
These relate to personal safety and operational reliability.
Instructions that must be followed precisely in order
to prevent risk and injury to persons.
Instructions that must be followed precisely in order
to prevent risk and injury to persons from live electri-
cal components.
Indicates technical instructions that must be
observed to prevent damage to the boiler and
malfunctions.
Please
note

63064816_201804
2. Safetyinstructions
Dangerfrompressurisedwater
Boilersaresubjecttohighwaterpressure.
Waterpressurecancausesevereinjuries.
Beforeworkingonpartswhichareincontact
withwater,allowtheappliancetocooltobelow
40°C,shutoffallvalvesand,ifnecessary,drain
the appliance.
Note:
Sensorscanbeincontactwithwaterandthere-
foreexposedtopressure.
Workingonthesystem
- Close the gas shut-off valve and secure it against uninten-
tional reopening.
- Isolate the system from the power supply (e.g. by remov-
ing the separate mains fuse or by means of a main switch
or a heating emergency stop switch) and check to ensure
there is no voltage.
- Safeguard the system against reconnection.
Inspectionandservice
- Ensure the correct operation of the gas boiler by having a
contractor carry out inspections at least once a year and
maintenance/repair when required.
- (DVGW - TRGI 2008 - G600).
We recommend arranging a suitable maintenance con-
tract.
- The operator is responsible for the safety, environmental
compatibility and energy quality of the heating system
(German Immission Control Act/Energy Saving Ordi-
nance) [Germany].
- Only use genuine WOLF spare parts.

3064816_201804 7
2. Safetyinstructions
Gaskombiventil
Fig.: Ignition transformer, high voltage ignition electrode, combustion
chamber
Danger through live electrical components, risk of burning from hot
components
Fig.: Gas combination valve
Danger through live electrical components
Escaping gas may cause poisoning or an explosion
Fig.: Terminal box: Danger through live electrical components Fig.: Gas connection: Risk of poisoning or explosion in the event of
gas escaping

83064816_201804
8614177_01
02 01.12.16 A10 1
1
.0,000
MA 3063612_Maßblatt_CGS-
2L
Catia V5 R19
16.07.13 Trm
1:5
41.5 41.5
66
600
824
70
84
180
264
1462
262 190
65
635
22SW
109
563
646
726
85
691
617
672
684
300
151
204
272
282
452
156
200
300
400
454
204
272
3. Dimensions/installationdimensions
CGS-2L
Gascondensingcentrewithstraticationcylinder
Cold water
connection
G¾”
DHW circulation
connection
G¾” DHW connection
G¾”
Gas connection
R½”
Heatingow
G¾”
Heating return
G¾”
Control unit
cover hinged on
the left
Ø 60/100 Ø 60/100
Ø 80/125 Ø 80/125

3064816_201804 9
8614437_01
1
1
.0,000
10500051
MA 3063612_Maßblatt_CGS-
2R
Catia V5 R19
14.07.14 Trm
1:10
1152
1792
66
41.5
41.5
600
22SW
180 264
70
84
262
85
109
563
635
65
190
1054
974
946
1000
1014
946
156
300
400
454
204
272
151
204
272
282
452
300
200
3. Dimensions/installationdimensions
CGS-2R
Gascondensingcentrewithcylinderwithinternalindirectcoil
Control unit
cover hinged on
the left
Cold water
connection
G¾”
DHW circulation
connection
G¾”
DHW connection
G¾”
Gas connection
R½”
Heatingow
G¾”
Heating return
G¾”
Ø 60/100 Ø 60/100
Ø 80/125 Ø 80/125

10 3064816_201804
4. Specication
Type CGS-2-14/120L CGS-2-20/160L CGS-2-24/200L
Rated heating output at 80/60 °C kW 13.5 18.9/22.2 1)
23.8/27.1 1) (23.8 3))
Rated heating output at 50/30 °C kW 15.2 20.4 25.8
Rated heat input kW 14.0 19.6/23.0 1)
24.6/28.0 1) (24.6 3))
Lowest heating output (modulating) at 80/60 °C kW 1.8/4.6 2) 3.8/6.8 2) 4.8/6.8 2)
Lowest heating output (modulating) at 50/30 °C kW 2.1/5.4 2) 4.4/7.4 2) 5.6/7.4 2)
Lowest heat input (modulating) kW 1.9/4.9 2) 3.9/6.9 2) 4.9/6.9 2)
Heatingowconnection G ¾" (DN 20) ¾" (DN 20) ¾" (DN 20)
Heating return connection G ¾" (DN 20) ¾" (DN 20) ¾" (DN 20)
DHW connection G ¾" ¾" ¾"
Cold water connection/DHW circulation G ¾" ¾" ¾"
Gas connection R ½" ½" ½"
Balancedueconnection mm 60/100 60/100 60/100
Dimensions Depth mm 635 635 635
Width mm 600 600 600
Height mm 1462 1462 1462
Balancedue Type B23P, B33P, C13(x), C33(x), C43(x), C53(x),
C63(x), C83(x), C93(x)
Gas supply details
Natural gas E/H (Hi = 9.5 kWh/m³ = 34.2 MJ/m³) m³/h 1.44 2.06/2.42 2.52/2.95
Natural gas LL (Hi = 8.6 kWh/m³ = 31.0 MJ/m³) m³/h 1.59 2.28/2.67 2.79/3.25
LPG P (Hi= 12.8 kWh/m³ = 46.1 MJ/m³) kg/h 1.07 1.53/1.80 1.87/2.19
Standardseasonalefciency[toDIN]at40/30°C(Hi/Hs) % 110/99 110/99 110/99
Standardseasonalefciency[toDIN]at75/60°C(Hi/Hs) % 107/96 107/96 107/96
Efciencyatratedloadat80/60°C(Hi/Hs) % 98/88 98/88 98/88
Efciencyat30%partialloadandTR=30°C(Hi/Hs) % 109/98 109/98 109/98
Flow temperature, factory setting °C 75 75 75
Flow temperature up to approx. °C 90 90 90
Max. overall pressure, heating circuit bar 3 3 3
Residual head for heating circuit: HE pump (EEI <0.23)
 600l/hpumprate(14kWat∆t=20K) mbar 550 550 550
 860l/hpumprate(20kWat∆t=20K) mbar - 430 430
 1030l/hpumprate(24kWat∆t=20K) mbar - - 280
Max. permissible overall pressure, DHW bar 10 10 10
DHW temperature range (adjustable) °C 15-65 15-65 15-65
Water content, heating water heat exchanger l 1.3 1.3 1.3
Nominalcapacityofthestraticationcylinder/equivalent
nominal capacity
l 90/120 90/160 90/200
Spec.waterthroughput"D"atΔT=30K l/min 18.7 23.2 25.2
Continuous DHW output to DIN 4708 l/h (kW) 366 (14.6) 560 (23.1) 684 (27.8)
Output factor to DIN 4708 NL1.3 2.1 2.5
DHW output l/10 min 161 199 215
Standby heat loss to EN 12897 kWh/24 h 1.0 1.0 1.0
Corrosion protection, DHW heat exchanger/cylinder Stainless steel/two-layer enamel coating to DIN 4153
Expansion vessel, total capacity l 10 10 10
Expansion vessel, pre-charge pressure bar 0.75-0.95 0.75-0.95 0.75-0.95
Flue gas temperature 80/60-50/30 at Qmax °C 62-45 70-50 76-50
Flue gas temperature 80/60-50/30 at Qmin °C 30-25 30-25 33-27
FluemassowrateatQmax g/s 6.2 8.8/10.7 1) 10.9/13.0 1)
FluemassowrateatQmin g/s 0.9 1.8 2.3
Available gas fan draught at Qmax Pa 125 135 180
Available gas fan draught at Qmin Pa 10 14 17
Flue gas category G52 G52 G52
NOx class 6 6 6
Amount of condensate at 50/30 °C l/h approx. 1.4 approx. 2.0 approx. 2.4
pH value of condensate approx. 4.0 approx. 4.0 approx. 4.0
Power consumption on standby W 3 3 3
Maximum power consumption W 17-59/93 1) 17-51/110 1) 17-62/135 1)
IP rating IP IPX4D IPX4D IPX4D
Power supply/fuse protection 230 V/50 Hz/16 A/B
Total weight kg 84 (35+49) 84 (35+49) 84 (35+49)
CE designation CE-0085CO0098
ÖVG quality symbol [Austria] G 2,991
SVGW no. [Switzerland] 14-027-4
1) Heating mode/DHW mode
2) Natural gas/LPG (G31)
3) Applies only to Switzerland
Meets the requirements of proKlima and KfW.