Wolf CGU-2-18 User manual

Part no. 30 62 347 Subject to modications 03/09 GB
Wolf GmbH · Postfach 1380 · D-84048 mainburg · Tel. [phone] · Fax [phone] · Internet: www.wolf-heiztechnik.de
Installation and
maintenance instructions
Wall mounted gas red combi boilers
and wall mounted gas red boilers
with integral cylinder connection
CGU-2-18/24
CGG-2-18/24
CGU-2 K-18/24
CGG-2 K-18/24
Illustration:
Wall mounted gas red boiler with auxiliary equipment BM

23062347_0309
General information
Safety instructions / Standards and regulations............. 3-5
Installation and commissioning
Dimensions .......................................................................6
Layout / Equipment code ............................................... 7-9
Positioning information / Installation dimensions ........10-11
Installation on nished walls /
Installation on unnished walls ........................................12
General boiler installation ................................................13
Electrical connection ................................................. 14-17
Fill / Vent the system........................................................18
Guidelines for commissioning ..........................................19
Control / Function / Commissioning ........................... 20-21
Setting and adjusting the boiler
Displaying / Modifying control parameters ................ 22-30
DHW connection versions / Resetting control unit...........31
Setting the eBUS address for cascade mode ..................32
Commissioning gas connection .......................................33
Conversion to other gas types / Nozzle change ..............34
Setting the control unit after converting the gas type.......35
Checking nozzle pressure.......................................... 36-37
Resetting gas valve / Setting nozzle pressure .................38
Adjusting the ue lengths CGG-2(K)................................39
Flue gas test CGU-2(K) CGG-2(K) .................................40
Limiting the maximum output ...........................................41
Selecting the pump stage / Bypass............................ 42-43
Checking the ue gas monitoring CGU-2(K)....................44
Notes on planning ventilation /
Flue gas system CGU-2(K)........................................ 45-49
Commissioning report ......................................................50
Maintenance and additional information
Inspection and maintenance steps ..................................51
Service report...................................................................52
Maintenance .............................................................. 53-57
Wiring diagram CGU-2(K)................................................58
Wiring diagram CGG-2(K)................................................59
Specication............................................................... 60-61
Fault / Cause / Remedy ...................................................62
Resistance table ..............................................................63
Notes................................................................................64
Keyword index ........................................................... 65-67
EC declaration of conformity............................................68
Contents

3
3062347_0309
"Safety instructions" are instructions
with which you must comply exactly, to
prevent risks and injuries to individuals
and material losses.
The following symbols and reference symbols
are used in this description. These important
instructions concern personal safety, as well as
operational reliability.
"Note" indicates technical instructions
that you must observe to prevent material
losses and boiler malfunctions.
Note
Danger through 'live' electrical
components.
Please note: Switch OFF the ON / OFF
switch before removing the casing.
Never touch electrical components or
contacts when the ON / OFF switch is in
the ON position. This results in a risk of
electrocution that poses a danger of injury
or death.
The main supply terminals are 'live' even
when the ON / OFF switch is in the OFF
position.
Fig.: Terminal box: Danger from electric current
Fig.: Gas connection: Escaping gas may cause poisoning
or the risk of explosion
Fig.: Ignition transformer, high voltage ignition electrode,
combustion chamber
Risk through 'live' electrical components, risk of burning
through hot components
Fig.: Gas combination valve:
Danger from electric current
Escaping gas may cause poisoning or the risk of
explosion
Balanced flue operated gas boilers
must only be installed in a room that
complies with the appropriate ventilation
requirements. Otherwise there is a risk
of asphyxiation or poisoning. Read these
installation and maintenance instructions
before installing the boiler. Also take the
technical guide into consideration.
Safety instructions / Standards and regulations

43062347_0309
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 an appliance that isolates all non-earthed
conductors simultaneously with at least 3 mm contact separation.
- It is not permitted to carry out repairs on parts that 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 them in the operation of the system.
Only use propane compliant with local regulations, otherwise
faults may arise with the starting characteristics and operation
of the wall mounted gas red boiler; this in turn, may lead to
boiler damage and risk of injury.
Poorly vented LPG tanks can lead to ignition problems. In such
cases, contact your local LPG supplier.
Note: Please read these instructions carefully before the installation
and keep them in a safe place. Please also note the technical
information in the appendix.
Any damage or loss resulting from technical modications to
the control unit or to the control components are excluded from
our liability.
Incorrect use can lead to a risk to life and limb or to a risk of
material losses.
Obtain the permission of your gas supply utility, the ue gas inspector
and the lower water authority [where appropriate] prior to the installation
of Wolf gas red boilers.

5
3062347_0309
Safety instructions / Standards and regulations
Standards and regulations
Category: II2ELL3P<DE> and
II2H3P<AT>
NOx class: 5
Efciency: *** star rating according
to 92/42/CEE) for
balanced ue operation
Flue types: CGG-2:
C12x, C32x, C42x, C52, B32
CGU-2:
B11BS
Operating mode: open / balanced ue
To be connected to: chimney, ue chimney /
balanced ue system
- 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.
The gas red boiler meets with the following regulations
EC Directives
- 2006/95/EC Low Voltage Directive
- 2004/108/EC EMC Directive
- 90/396/EEC Gas user equipment
- 92/42/EEC Efciency directive
DIN / EN Standards
- EN 297; EN298; EN 483; EN 625;
EN 55014-2; EN 60335-1; EN 60335-2-102;
EN 60529; EN 61000-3-2; EN 61000-4-3
The following regulations, rules and guidelines must
be observed during installation:
- Boiler room guidelines or Building Regulations
relating to the construction and installation of
central boiler rooms and fuel storage facilities
- Technical regulations for gas and DHW installations
DVGW-TRGI 1996 and TRF 1996
(in the currently applicable form)
DIN / EN Standards
- EN 437 Test gases; test pressures;
appliance categories
- DIN EN 1283 Procedure for calculating the
standard heating load
- DIN EN 12828 Heating systems in buildings
- DIN EN 1717 Protection of DHW against
contaminations in DHW
installations
- DIN EN 50156-1 (VDE 0116 part 1)
Electrical equipment for
combustion systems
- On site regulations from building and industry
regulatory agencies (mainly covered by the emission
test switch)
- On site regulations from the gas supply utility

63062347_0309
440
Dimensions
Gas red combi
boilers
Gas red boilers
1 Heating ow Heating ow
2DHW DHW ow
3Cold water DHW return
4Heating return Heating return
5 Gas connection Gas connection
Installation inside a cupboard
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 it may not be substantial
enough to take the boiler's weight. This would
create the risk of water and gas leaks which in
turn would result in a risk of explosion
and ooding.
- Removing the rear wall of the cupboard
Minimum lateral clearance between the gas red boiler
and the cupboard sides 25 mm.
A cutout of 410 x 550 mm is required in the
cupboard top. Otherwise there is a risk of
suffocation and poisoning
With open ue gas red boilers the
ventilation grill in the cupboard door must
be installed with a free minimum diameter
of 600 cm2
Otherwise there is a risk of suffocation
and poisoning
3
1
2
4
5
3
1245
Min.400
Min.400
>25
694 366 CGU-2(K) 18
380 CGU-2(K) 24
258 CGG-2(K) 18/24
344
120
176
170
39
49
855
393
190
226
(CGG-2)
(CGU-2)
73
134

7
3062347_0309
Layout CGU-2(K) 18/24
Combustion
chamber
Internal lling
equipment (optional)
not <DE><AT>
Gas combination
valve
Expansion vessel
Three-way
diverter valve
Flow sensor 2
Limit thermostat
Monitoring
electrode
Ignition electrode
Heating water heat
exchanger
Safety valve
Drain valve
DHW
Flow & temperature
sensor
Flow sensor 1
Draught hood
Gas burner
Heating circuit
strainer
Cold water strainer
with throughput
limiter
Heating circuit
pump
Air vent
Bypass
Flue gas
temperature limiter
HZ - VL HZ - RL

83062347_0309
Layout CGG-2(K) 18/24
Flue gas fan
with speed
regulation
Combustion
chamber
Internal lling
equipment (optional)
not <DE><AT>
Gas combination
valve
Expansion vessel
Three-way
diverter valve
Flow sensor 2
Limit thermostat
LAF connection
Monitoring
electrode
Ignition
electrode
Heating water heat
exchanger
Differential
pressure switch
Safety valve
Drain valve
DHW
Flow & temperature
sensor
Flow sensor 1
Flue gas
collector
box
Gas burner
Heating circuit
strainer
Cold water strainer
with throughput
limiter
Heating circuit
pump
Air vent
Bypass HZ - VL HZ - RL

9
3062347_0309
Layout / Equipment code
Heating water heat
exchanger
Gas burner
Gas
combination
valve
Expansion vessel
Air vent
Heating circuit
pump
DHW heat
exchanger
Safety valve
Drain valve
Heating circuit strainer
Cold water strainer with
throughput limiter
Limit thermostat
ow
Flow sensor 2
Flow sensor 1
Three-way
diverter valve
DHW ow
& temperature sensor
(only combi boilers)
Bypass valve
Hydro Tec system
(integrated
components)
Overow valve
Flue gas
temperature limiter
Wolf Low NOx unit with hydro tec system (plug-in technology for quick installation)
compactly designed for low emissions, high energy efciency.
DHW heat exchanger and DHW ow temperature sensor
only with combi boilers
CGU-2 - 18/24 Open ue gas red boiler with integrated cylinder connection
CGU-2 K - 18/24 Open ue gas red combi boiler
CGG-2 - 18/24 Balanced ue gas red boiler with integrated cylinder connection
CGG-2 K - 18/24 Balanced ue gas red combi boiler
Equipment codes

10 3062347_0309
Balanced ue gas red boilers must only
be installed in a room that complies with
the appropriate ventilation requirements.
Otherwise there is a risk of asphyxiation
or poisoning. Read these installation and
operating instructions before installing
the gas red boiler. Also take the technical
guide into consideration.
Sound insulation:
Under certain critical installation conditions
(e.g. installation on a drywall) additional
measures may be necessary to soundproof
the boiler. In this case use soundproof
plugs and, if necessary, rubber buffers or
insulation strips.
Positioning information /
Installation dimensions
l.h. turnbuckle r.h. turnbuckle
Fig.: Opening the turnbuckle
- Determine the installation location for the gas red
boiler; maintain the specied minimum clearances
(see dimensions).
- Fit the supplied installation template (paper poster) 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. turnbuckle, 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 onto 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 consider the wall consistency, otherwise
gas or water may escape which could lead to
explosions and ooding. It can also lead to
noise developing.
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 unfavourable conditions, these
may lead to corrosion, even in the ue gas
system.
Note
500
25 25
(CGU-2-18) Ø110 (CGU-2-24) Ø130
(CGU-2) min.400
(CGG-2) min.200
(CGG-2-18)
Ø100
1212
344
min.200
1478