Wolf ComfortLine CHK User manual

Installation and
maintenance instructions
ComfortLine
FunctionLine
Cast iron boilers up to 60 kW
GBPart.-No. 3060918_1203 Subject to modications
Wolf GmbH · Postfach 1380 · 84048 Mainburg · Tel. [phone] · Fax [phone] · Internet: www.wolf-heiztechnik.de

23060918_1203
Index
Index .......................................................................................................Page
Safety instructions / Reference symbols ......................................................3
Standards / Regulations ............................................................................. 4-5
ComfortLine cast iron boilers..........................................................................6
FunctionLine cast iron boilers.........................................................................7
Installation ................................................................................................. 8-9
Boiler installation on a plinth.........................................................................10
Boiler installation on a horizontal DHW cylinder...........................................11
Boiler assembly ...................................................................................... 12-15
ComfortLine decorative panel installation............................................... 16-17
FunctionLine decorative panel installation....................................................18
Flue pipe installation.....................................................................................19
Central heating to boiler connections ...........................................................20
DHW cylinder to boiler pipework ..................................................................21
Filling the heating system....................................................................... 22-23
Draining the heating system.........................................................................24
Pressure jet oil burner installation / Electrical supply ...................................25
Initial start-up.......................................................................................... 26-27
Maintenance........................................................................................... 28-29
Maintenance log ..................................................................................... 30-31
Specication ........................................................................................... 32-33
Dimensions............................................................................................. 34-35
Troubleshooting............................................................................................36

33060918_1203
Reference symbols / Safety instructions
The following symbols are used in
conjunction with these important in-
structions concerning personal safety
and technical reliability.
“Safety instructions“ are
instructions with which you
must comply exactly, to
prevent injury and material
losses.
Danger through “live“ elec-
trical components.
Please note: Switch OFF the
ON/OFF switch before remo-
ving the casing.
Never touch electrical com-
ponents or contacts when the
switch is in the ON position.
This creates a risk of elec-
trocution, which may cause
injury or death.
The mainsupply terminals are
“live“ even when the ON/OFF
switch is in the OFF position.
This indicates technical in-
structions which you must
observe to prevent material
losses and boiler malfunc-
tions.
In addition to the installation instructions,
operating instructions and adhesive labels
are included or tted to the boiler. These
must also be observed.
Note
General
Authorised personnel should read these
instructions before any installation, com-
missioning or maintenance work.
Adhere to the instructions given in this
document.
Non-observance of these installation
instructions voids any guarantee offered
WOLF.
Safety instructions
• Only use qualied and trained personnel
for the installation, commissioning and
maintenance of the boiler.
• In accordance with DIN EN 50110-1,
work on electrical components (e.g.
control units) may only be carried out
by qualied electricians.
• The regulations of VDE/ÖVE and those
of your local electricity supplier as well
as all other local regulations are appli-
cable to electrical installation work.
• Only operate the boiler within its output
range which is stated in the specication
supplied by WOLF.
• Appropriate use of the boiler refers to
the exclusive use for hot water heating
systems in accordance with DIN 4751.
• Never remove, bypass or otherwise
disable any safety or monitoring equip-
ment.
• The boiler may only be operated in per-
fect technical condition. Any faults and
damage which may impact on safety
which might limit the safe use of the
equipment must be remedied immedi-
ately by a qualied contractor.
• Only replace faulty components or
equipment with original WOLF spare
parts.

43060918_1203
Standards / Regulations
Standards and regulations
Observe all current Building Regulati-
ons and other local requirements.
Only recognised heating contractors may
install WOLF boilers.This heating contrac-
tor will also be responsible for the proper
installation and the commissioning of the
heating system.
The boilers described in these installation
instructions are low temperature boilers
according to HeizAnlV and 92/42/EEC
(Efciency of Hot Water Boilers).
Locate the enclosed operating instructions
in a clearly visible position in the boiler
room.
Boilers may only be installed and ope-
rated in boiler rooms which are suitable
according to the Landes-FeuVo [or local
regulations].
The following regulations, rules and guide-
lines must be observed during installation:
• Boiler room guidelines or Building Regu-
lations relating to the construction and
installation of central boiler rooms and
fuel storage facilities.
• Energy Savings Act (EnEG) and related
directives (Heating Systems Order).
Note: Please read these instructions
carefully before the installation
and keep them in a secure place.
• DIN standards
DIN 1988 Technical rules for DHW
installations
DIN 4701 Rules for
calculating the heat
demand of buildings
DIN 4751 Part 3 - Safety Equipment
for heating systems with ow
temperatures up to 95 °C.
DIN 18160 Domestic chimneys
• VDE requirements:
VDE 0100 General information
regarding the installation of
HV systems with rated
voltages up to 1000V.
VDE 0105 Operation of HV
systems, general
considerations.
VDE 0722 Electrical equipment of
non-electrically heated
heat generators.
VDE 0470/ Protection through
housings
EN 60529
EN 60335-1 Safety of electrical
equipment for domestic
use and similar purposes.

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Standards / Regulations
Cast iron boilers
acc. to DIN EN 303 as well as in accordance with EC Directive 90/396/EEC (gas
consuming equipment),
73/23/EEC (Low Voltage Directive), 89/336/EEC (EMC Directive), 92/42/EEC (Ef-
ciency of Hot Water Boilers) and 93/68/EEC (Identication Directive) for heating
systems with heating circuit pumps and ow temperatures up to 110 °C and 3 bar
permissible operating pressure in accordance with DIN 4751 and DHW cylinder pres-
sure (max. 10 bar) in accordance with DIN 4753.
For the operation with pressure jet gas burners, the following gas device categories apply:
The NOx limits required by the 1st BImSchV para. 7(2) are maintained.
Country abbreviation Country Gas device category
DE Germany II2ELL3B/P
AT Austria II2H3B/P
LU Luxembourg I2E or I3+

63060918_1203
ComfortLine cast iron boilers
Oil and gas-red cast iron boilers, type
CHK
(boiler plinth, accessory)
Oil and gas-red cast iron boilers, type
CHK-CB
incl. DHW cylinder
Oil-red cast iron Unit boiler, type CHU
incl. pressure jet oil burner
(boiler plinth, accessory)
Oil-red cast iron Unit boiler, type CHU-CB
incl. DHW cylinder
and pressure jet oil burner

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FunctionLine cast iron boilers
Oil and gas-red cast iron boilers, type FHK
(boiler plinth, accessory)
Oil and gas-red cast iron boilers, type
FNK-FB/FE incl. DHW cylinder
Oil-red cast iron Unit boiler, type FHU
incl. pressure jet oil burner
(boiler plinth, accessory)
Oil-red cast iron Unit boiler, type FHU-FB/FE
incl. DHW cylinder
and pressure jet oil burner

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Installation
The ventilation air supply must
be ensured and comply with
local regulations or those re-
lating to gas installations. We
recommend that you supply the
boiler with fresh air directly from
the outside. An insufcient fresh
air supply can lead to fuel gas
escaping, which represents
a risk to life (poisoning/suf-
focation).
Clearances towards walls and
combustible materials must
comply with local re regula-
tions, and should be at least
200mm, otherwise there is a
high risk of re.
General tips regarding location
• Install the boiler with or without the
DHW cylinder on a level surface which
is substantial enough to carry its weight.
• Position the boiler and DHW cylinder (if
installed) horizontally or slightly rising
towards the back to ensure adequate
venting of any trapped air (level with
adjustable feet).
Only install the boiler and DHW
cylinder (if installed) in a room
safe from the risk of frost.
Drain the boiler, the DHW
cylinder and the entire heating
system if there is a risk of frost,
when the system has been
shutdown, to prevent pipes
from bursting.
Boilers should not be installed
in areas subject to aggressive
vapours, very dusty or highly
humid conditions (workshops,
washrooms, hobby rooms etc.).
This prevents the optimum
burner function from being
achieved.
The combustion air supplied to
the pressure jet oil burner must
be free from halogenated hy-
drocarbons (e.g. as contained
in sprays, solvents, cleaning
uids, paints and adhesives).
Under the most unfavourable
conditions, these may lead to
pitting of the boiler and even
the ue gas system.
Never store or use combustible
material or liquids near the
boiler.
Note
Note

93060918_1203
Installation
Recommended minimum wall
clearance
Maintain a minimum clearance between
the boiler sides and walls of 400 mm to
enable the boiler door with tted burner
to be opened.
Ensure that sufcient space is available
for cleaning and maintenance.
1000
900
400
Recommended minimum wall clearance
Transportation into the boiler
room
To ease the transportation into the boiler
room, lifting slings with lifting hooks are
offered as accessories.
Only lift the boiler using all four
lifting slings.
Note
Lifting eyes for lifting slings
Boiler installation on adjustable feet
At the factory the boiler is equipped with
four adjustable bolts
• Level the boiler with adjustable feet
(accessory) horizontally or with a slight
incline to the rear.
Feet
(accessory)
Adjustable
bolt
Adjustable bolt/ feet

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9
Boiler installation on a plinth
Boiler
Boiler door
Thermal insulation, boiler
Thermal insulation, boiler back
Thermal insulation, boiler front
Side casing
Control unit bracket
Back wall casing
Control unit housing
Casing cover
Spring shackles
Front casing
Type plate
Wolf logo
Plinth (accessory)

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7
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9
Boiler installation on a horizontal
DHW cylinder
Boiler
Boiler door
Thermal insulation, boiler
Thermal insulation, boiler back
Thermal insulation, boiler front
Side casing
Control unit bracket
Back wall casing
Control unit housing
Casing cover
Spring shackles
Front casing
Type plate
Wolf logo
Horizontal DHW cylinder

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Boiler assembly
Boiler
• Install the plinth or the DHW
cylinder in accordance with the
enclosed installation instructions.
• Position the boiler with adjustab-
le bolts fully inserted using the
lifting slings on the fully assembled
plinth or DHW cylinder.
• To secure the boiler to the plinth
or DHW cylinder, tapped holes are
provided at the front sides of the
boiler. Additional xings are not
required.
• Check the horizontal level of the
boiler together with the plinth and
DHW cylinder and adjust, with a
slightinclinetotherear,ifnecessary.
Screws for securing the boiler
Screws for securing the boiler to the plinth
Screws for securing the boiler
Fixing screws on the DHW cylinder
Position the thermal boiler
insulation
around the boiler (overlapping) and
secure with spring clips.
Position the thermal boiler insula-
tion for the boiler back over the rear
connections and on the back wall of
the boiler.
Secure the boiler door
with the four M10x45 screws and
washers supplied.
Insert the door hinge pins into the
door bracket on the l.h. or r.h. side,
subject to door opening.
Boiler door installation
M10x45 screws

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Boiler assembly
Fixing plugs
Thermal insulation, boiler front
Thermal insulation, boiler front
Position the thermal insulation
loosely at the boiler front
and secure with xing plugs (4 no.).
Control unit bracket
Side casing
Hooks
Control unit bracket installation
Locate the control unit bracket
centrally and push parallel forward,
until both recesses in the side casing
click into the control unit bracket tabs.
and t the lower folded edge into
both notches of the boiler (view X).
Boiler notch
Lower folded edge of the side casing
View X
Side casing installation
Side casing
into the boiler front pushing the spring
clip behind the boiler bracket
Side casing installation
Spring shackle Bracket

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Boiler assembly
Locking tabs
Control unit bracket
Secure tightly
Control unit housing installation
Push the control unit housing
with locking tabs into the apertures
on the control unit bracket and pull
forward to its end stop. Secure the
control unit housing with the two
self-tapping screws supplied to the
control unit at the l.h. and r.h. rear,
working from top to bottom.
Route the boiler sensor to the front
and push into the sensor well in
any arrangement, then secure with
the circlip.
Rear wall installation
Back wall notches
Self-tapping screws
Locate the back wall casing
with tabs into the notches in the
side casing, and secure with the
self-tapping screws (4 no.) supplied.
Side casing xing screws
Self-tapping screws
Secure the control unit bracket and
side casing with the self-tapping
screws supplied (6 no.).

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Boiler assembly
Afx the type plate
in a clearly visible position.
Clip the Wolf logo
into the front casing
(only for FunctionLine).
Type plate / Wolf logo
Type plate
Wolf logo
Push the front casing
with open control unit lid with the
prole screws against the spring
shackles , until they click into
place.
Front casing installation
Position the casing cover
onto both side casings and push
towards the control unit bracket.
Cable clip
Cover cap
Burner cable holder
Guide the burner cable through the
aperture in the control unit bracket
(l.h. or r.h. subject to boiler door
opening).
Clip a cover cap into the control unit
bracket to protect the burner cable.
Secure the cable clip with the burner
cable at the l.h. or r.h. side (bottom)
of the boiler.

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In addition, all ComfortLine boilers require
the following work to be undertaken.
ComfortLine decorative
panel installation
Decorative panel
Position the decorative panel with the
document wallet on the holes and push
against the front casing, until the clips
click into place.
Decorative panel installation
Decorative panel installation, single boiler
Decorative frame
(CHK 22-60 single boiler)
Click the plastic clips (4 no., black) into
the front casing. Position the decorative
frame onto the clips and push down to
their end stop.

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ComfortLine decorative panel installation
Decorative frame
(CHU 22-29 Unit boiler)
With the dome at the top, push the silencer
hood into the decorative frame, then secure
the silencer hood with four self-tapping
screws from the inside to the decorative
frame.
Self-tapping
screws
Silencer hood
Decorative frame
Joining the decorative frame and the
silencer hood
Large silencer hood installation
Large silencer hood
(CNU 37-60 Unit boiler)
Click the plastic clips (4 no., orange)
into the front casing. Position the large
silencer hood onto the clips and push down
to their end stop.
Click both top plastic clips (black) from the
outside into the front casing. Click both
lower plastic clips (black) from the inside
into the front casing. Hook the decorative
frame with the silencer hood into the top
clips and secure in the lower plastic clips.
Decorative panel installation, Unit boiler

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FunctionLine decorative
panel installation
For models FHU-TH/22/29, the following
additional work should be undertaken.
Decorative panel
Click the plastic clips (4 no., grey) into
the front casing.
Decorative panel installation
Decorative panel

193060918_1203
Flue pipe installation
Flue pipe silencer (accessory)
Install the ue pipe silencer with ue pipe
extension in accordance with the gure
shown.
Flue pipe
extension
Flue pipe
silencer
Flue pipe extension/silencer
Flue pipe outlet
Clean-out covers
Clean-out covers
in ue pipe elbows
• The ue pipe cross-section must match
that of the boiler ue outlet.
• Reducing the ue pipe size is only
permitted, if the satisfactory function
has been veried (by calculation) in
accordance with DIN 4705.
Keep the ue pipe as short as
possible and inclined towards
the chimney stack.
• Thoroughly seal in the ue pipe.
• Use ue pipe elbows with clean-out
covers to facilitate the cleaning of the
ue pipe.

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Central heating boiler connections
Central heating boiler connections
Boiler return
Connection for venting
and safety ow
Filling / Draining
Boiler return
Connect the heating ow and return to the
respective boiler ttings. For connections,
see below.
Install a check valve downstream of the
boiler circuit pump(s) to prevent incorrect
circulation.
Install a safety assembly com-
prising a safety valve with a
response pressure of 3 bar and
an automatic air-vent valve.The
pipework between the boiler
and the safety valve must not
be able to be shut off. Severely
excessive boiler pressure due to
excessive boiler temperatures,
can burst the boiler body or the
boiler pipework, which would
lead to a sudden excape of hot
water (risk of scalding).
Connect any underoor heating
system via a three or four-way
mixer.
Return temperature raising facility
Heating systems with large
water volume (above 20 litres
per kW output) require a re-
turn temperature of 30 °C, as
otherwise the longer heat-up
time of such systems would
create condensate and run an
increased risk of boiler body
corrosion.
Note
Provide system separation by
means of a heat exchanger,
when using pipes which are not
impermeable to oxygen.
This boiler is only suitable for
heating systems with pumped
heating circuits. If no heating
circuit pump has been installed,
sufcient circulation through the
radiators cannot be ensured,
putting the room heating in
question.
Recommendation: Convert
open systems into sealed
systems.
Note