Wolf ComfortLine Series User manual

Installationand
maintenance instructions
ComfortLine
FunctionLine
Steel boilers up to 63 kW
Technology serving Mankind
WolfGmbH·Postfach1380·84048Mainburg·Tel.[phone]·Fax[phone] ·Internet: www.wolf-heiztechnik.de
12/03 TV GB
Part.-No. 30 60 917 Subject to modifications

2
Index
Index .............................................................................................................................. Page
Referencesymbols/Safetyinstructions ............................................................................................3
Standards/Regulations ..................................................................................................................... 4-5
ComfortLinesteelboilers ........................................................................................................................6
FunctionLinesteelboilers ......................................................................................................................7
Installation ............................................................................................................................................ 8-9
Boilerinstallationonaplinth .............................................................................................................10
BoilerinstallationonahorizontalDHWcylinder...........................................................................11
Boilerassembly ...............................................................................................................................12-15
ComfortLinedecorativepanelinstallation................................................................................16-17
FunctionLinedecorativepanelinstallation.....................................................................................18
Fluepipeinstallation ............................................................................................................................19
Centralheatingboilerconnections...................................................................................................20
DHWcylindertoboilerpipework .......................................................................................................21
Fillingtheheatingsystem............................................................................................................ 22-23
Drainingtheheatingsystem ..............................................................................................................24
Pressurejetoilburnerinstallation/electricalsupply ..................................................................25
Initialstart-up ........................................................................................................................................ 26
Commissioningreport ..........................................................................................................................27
Maintenance ...................................................................................................................................28-29
Maintenancelog.............................................................................................................................30-31
Specification.................................................................................................................................... 32-33
Dimensions ......................................................................................................................................34-35
Troubleshooting .....................................................................................................................................36

3
Reference symbols / Safety instructions
Thefollowingsymbolsareusedinconjunction
withtheseimportantinstructionsconcerning
personal safety and technical reliability.
"Safety instructions"are
instructions with which you
mustcomplyexactly,toprevent
injury and material losses.
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 switch is in the ON position.
This creates a risk of
electrocution, which may cause
injury or death.
The main supply terminals are
"live"even when the ON/OFF
switch is in the OFF position.
This indicates technical
instructions which you must
observetopreventmateriallosses
and boiler malfunctions.
In addition to the installation instructions,
operating instructions and adhesive labels
are included or fitted to the boiler. These
must also be observed.
Note
General
Authorised personnel should read these
instructions before any installation,
commissioning or maintenance work.
Adhere to the instructions given in this
document.
Non-observance of these installation
instructions voids any guarantee offered by
WOLF.
Safety instructions
• Only use qualified and trained personnel
for the installation, commissioning and
maintenance of the boiler.
• In accordance with DIN EN 50110-1, work
onelectricalcomponents (e.g. control units)
may only be carried out by qualified
electricians.
• The regulations of VDE/ÖVE and those of
your local electricity supplier as well as all
other local regulations are applicable to
electrical installation work.
• Only operate the boiler within its output
range which is stated in the specification
supplied by WOLF.
• Appropriate use of the boiler refers to the
exclusiveuseforhot water heatingsystems
in accordance with DIN 4751.
• Neverremove,bypassorotherwisedisableany
safety and monitoring equipment.
• The boiler may only be operated in perfect
technicalcondition.Anyfaults anddamage
which may impact on safety which might
limitthesafeuse oftheequipmentmustbe
remedied immediately by a qualified
contractor.
• Only replace faulty components or
equipment with original WOLF spare parts.

4
Standards / Regulations
Standards and regulations
ObserveallcurrentBuildingRegulationsand
other local requirements.
Onlyrecognisedheatingcontractorsmayinstall
WOLFboilers.Thisheatingcontractorwillalso
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
(Efficiency of Hot Water Boilers).
Locatetheenclosed operating instructionsina
clearly visible position in the boiler room.
Boilers may only be installed and operated in
boiler rooms which are suitable according to
the Landes-FeuVo [or local regulations].
Thefollowingregulations,rulesandguidelines
must be observed during installation:
• Boiler room guidelines or Building
Regulations relating to the construction
andinstallationofcentralboilerroomsand
fuel storage facilities.
• Energy Savings Act (EnEG) and related
directives(HeatingSystemsOrder).
• DIN standards
DIN 1988 Technical rules for DHW
installations
DIN 4701 Rulesforcalculatingtheheat
demand of buildings
DIN 4751 Part 3 - Safety Equipment
forheatingsystemswithflow
temperatures up to 95 °C
DIN 18160 Domesticchimneys
• VDE requirements:
VDE 0100 General information
regardingtheinstallationof
HVsystems withrated
voltages up to 1000V
VDE 0105 Operationof HVsystems,
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
equipmentfordomesticuse
and similar purposes
Note: Please read these instructions
carefullybeforetheinstallationand
keep them in a safe place.

5
Steel boilers
according to DIN EN 303 as well as in accordance with EC Directive 90/396/EEC (gas consuming
equipment),73/23/EEC(LowVoltageDirective),89/336/EEC(EMCDirective),92/42/EEC(Efficiencyof
Hot Water Boilers) and 93/68/EEC (Identification Directive) for heating systems with heating circuit
pumps and flow temperatures up to 110 °C and 3 bar permissible operating pressure in accordance
with DIN 4751 and DHW cylinder pressure (max. 10 bar) in accordance with DIN 4753.
For the operation with pressure jet gas burners, the following gas device categories apply:
Standards / Regulations
Countryabbreviation Country Gas device category
DE Germany II2ELL3B/P
AT Austria II2H3B/P
LU Luxembourg I2E or I3+
The NOxlimits required by the 1st BImSchV para. 7(2) are maintained.

6
ComfortLine steel boilers
Oil and gas-fired steel boiler, type CNK
(boilerplinth, accessory) Oil and gas-fired steel boiler, type CNK-CB incl. DHW cylinder
Oil and gas-fired steel boiler, type CNU
incl. pressure jet oil burner
(boilerplinth, accessory)
Oil-fired steel Unit boiler, type CNU-CB
incl. DHW cylinder
and pressure jet oil burner

7
Oil and gas-fired steel boilers, type FNK
(boilerplinth,accessory) Oil and gas-fired steel boiler, type FNK-FB/FE incl. DHW cylinder
Oil-fired steel Unit boiler, type FNU
incl. pressure jet oil burner
(boilerplinth,accessory)
Oil-fired steel Unit boiler, type FNU-FB/FE
incl. DHW cylinder
and pressure jet oil burner
FunctionLine steel boilers

8
Installation
Theventilationairsupplymustbe
ensured and comply with local
regulations or those relating to
gas installations. We recommend
that you supply the boiler with
freshairdirectlyfromtheoutside.
An insufficient fresh air supply
can lead to fuel gas escaping,
which represents a risk to life
(poisoning/suffocation).
Clearances towards walls and
combustiblematerialsmustcomply
with local fire regulations, and
should be at least 200mm,
otherwise there is a high risk of
fire.
General tips regarding location
• Install the boiler with or without the DHW
cylinderonalevelsurfacewhichissubstantial
enough to carry its weight.
• Position the boiler and DHW cylinder (if
installed) horizontally or slightly rising
towardsthebacktoensureadequateventing
of any trapped air (level with adjustable
feet).
Only install the boiler and DHW
cylinder(ifinstalled)inaroomsafe
from the risk of frost.
Draintheboiler,theDHWcylinder
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
areassubjecttoaggressivevapours,
very dusty or highly humid
conditions(workshops,washrooms,
hobbyroomsetc.).Thispreventsthe
optimum burner function from
being achieved.
Thecombustionairsuppliedtothe
pressurejetoilburnermustbefree
from halogenated hydrocarbons
(e.g. as contained in sprays,
solvents, cleaning fluids, paints
and adhesives). Under the most
unfavourable conditions, these
may lead to pitting of the boiler
and even the flue gas system.
Never store or use combustible
materialorliquidsneartheboiler.
Note
Note

9
1000
900
400
Installation
Transportation into the boiler room
To ease the transportation into the boiler
room,liftingslingswithliftinghooksareoffered
asaccessories.
Only lift the boiler using all four
lifting slings. Lifting eyes for lifting slings
Recommended minimum wall clearance
Note
Boiler installation on adjustable feet
At the factory the boiler is equipped with four
adjustable feet.
• Level the boiler with adjustable feet
(accessory) horizontally or with a slight
incline to the rear.
Adjustable
bolt Feet
(accessory)
Adjustable bolt/ feet
Recommended minimum wall clearance
Maintain a minimum clearance between the
boilersidesandwalls of 400mmtoenablethe
boiler door with fitted burner to be opened.
Ensure that sufficient space is available for
cleaning and maintenance.

10
Boiler
Thermal insulation, boiler
Thermal insulation, boiler back
Thermal insulation, boiler front
Side casing
Control unit bracket
Boiler door
Back wall casing
Boiler installation on a plinth
2
3
4
5
Control unit housing
Casing cover
Spring shackles
Front casing
Type plate
Wolf logo
Plinth(accessory)
6
8
9
10
11
12
13
1
7
14
15
26
9
1
5 5
3
14
15
13
13
7
10
11 11
12
4
8

11
26
9
1
5 5
3
14
15
13
13
7
10
11 11
12
4
8
Boiler installation on a horizontal DHW cylinder
Boiler
Thermal insulation, boiler
Thermal insulation, boiler back
Thermal insulation, boiler front
Side casing
Control unit bracket
Boiler door
Back wall casing
2
3
4
5
Control unit housing
Casing cover
Spring shackles
Front casing
Type plate
Wolf logo
Horizontal DHW cylinder
6
8
9
10
11
12
13
1
7
14
15

12
Boiler assembly
2
Positionthethermalinsulationforthe
boiler back
over the rear connections and on the
back wall of the boiler.
3
Positionthethermalinsulationforthe
boiler front
loosely on the boiler
4
Screws for securing the boiler
Screws for securing the boiler to the plinth
1Boiler
• InstalltheplinthortheDHWcylinder
in accordance with the enclosed
installation instructions.
• Position the boiler with adjustable
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 fixings are not
required.
• Check the horizontal level of the
boiler together with the plinth and
DHWcylinderandadjust,withaslight
incline to the rear, if necessary.
Screws for securing the boiler
Fixing screws on the DHW cylinder
Position the thermal boiler insulation
aroundtheboiler(overlapping)andsecure
with spring clips.

13
Boiler assembly
Locate the control unit bracket
centrally and push parallel forward,
until both recesses in the side casing
click into the control unit bracket tabs.
Securethecontrolunitbracketandside
casing with the self-tapping screws
supplied(6no.).
Control unit bracket
Side casing
Hooks
Control unit bracket installation
Self-tapping screws
Side casing fixing screws
6
Boiler notch
Lower folded edge
of the side casing View X
Side casing installation
and fit the lower folded edge into both
notches(viewX).
Insert the side casing
intothe boiler frontpushing thespring
shackles behindtheboilerbracket
5
Side casing installation
Spring shackle Bracket
11

14
Boiler assembly
Fit the boiler door
with the four M10x45 screws and
washerssupplied.
Insertthedoorhingepinsinto thedoor
bracketonthel.h.orr.h.side,subjectto
door opening.
7Door
hinge pin
Boiler door installation
M10x45screws
Back wall notches
Rear wall installation
Self-tapping screws
Hook the back wall casing
with tabs into the notches in the side
casing,andsecurewiththeself-tapping
screws(4no.)supplied.
8
Locking tabs
Control unit bracket
Secure tightly
Control unit housing installation
9Push the control unit housing
with locking tabs into the apertures in
thecontrolunitbracketandpullforward
to its end stop. Secure the control unit
housingwiththetwoself-tappingscrews
suppliedtothecontrolunitatthel.h.and
r.h. rear, working from top to bottom.
Route the boiler sensor to the rear and
push into the sensor well in any
arrangement,thensecurewiththecirclip.

15
Boiler assembly
Cable clip
Cover cap
Burner cable holder
13 Affix the type plate
in a clearly visible position.
Clip the Wolf logo
into the front casing
(only for FunctionLine).
14
Position the casing cover
ontoboth sidecasings and push towards
the control unit bracket.
10
Type plate / Wolf logo
Type plate
Wolf logo
12
11
Front casing installation
Guide the burner cable through the
aperture in the control unit bracket
(l.h.orr.h.subjecttoboilerdooropening).
Clip a cover cap into the control unit
bracket to protect the burner cable.
Securethecableclipwiththeburnercable
atthel.h.orr.h.side(bottom)oftheboiler.
9
Push the front casing
with open control unit lid with the
profile screws against the spring
shackles ,untiltheyclickintoplace.

16
ComfortLine decorative panel installation
Inaddition, all ComfortLine boilers requirethe
following work to be undertaken.
Decorative panel
Positionthedecorativepanelwiththedocument
wallet on the holes and push against the front
casing, until the clips click into place.
Decorative frame
(CNK 17-60 single boiler)
Clicktheplasticclips (4no.,black)intothe
front casing. Position the decorative frame
ontotheclipsandpushdowntotheirendstop.
Decorative panel installation, single boiler
Decorative panel installation

17
Large silencer hood installation
Large silencer hood
(CNU 40-63 Unit boiler)
Clicktheplasticclips (4no.,orange)into
the front casing. Position the large silencer
hoodontotheclipsandpushdowntotheirend
stop.
ComfortLine decorative panel installation
Decorative frame
(CNU 17-32 Unit boiler)
Withthedomeatthetop,pushthesilencerhood
into the decorative frame, then secure the
silencer hood with four self-tapping screws
from the inside to the decorative frame.
Self-tapping
screws
Joining the decorative frame and the
silencer hood
Silencer hood
Decorative frame
Decorative panel installation, Unit boiler
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.

18
FunctionLine decorative panel installation
For models FNU-TH/17/20/25, the following
additional work should be undertaken.
Decorative panel
Clicktheplasticclips (4no.,grey)intothe
front casing.
Decorative panel installation
Decorative panel

19
Flue pipe installation
Flue pipe outlet
Clean-outcovers
Clean-outcovers
in flue pipe elbows
• Thefluepipecross-sectionmustmatchthat
of the boiler flue outlet.
• Reducingthefluepipesizeisonlypermitted,
if the satisfactory function has been
verified(bycalculation)inaccordancewith
DIN 4705.
Keep the flue pipe as short as
possible and inclined towards
thechimneystack.
• Thoroughly seal in the flue pipe.
• Usefluepipeelbowswithclean-outcovers
to facilitate the cleaning of the flue pipe.

20
Central heating boiler connections
Central heating boiler connections
Boiler return Boiler return
Boiler flow Boiler flow
Connection for venting
and safety flow
Sensorwell
Filling / Draining
Connect the heating flow and return to the
respective boiler fittings. For connections, see
below.
Install a check valve downstream of the boiler
circuitpump(s)topreventincorrectcirculation.
Installasafetyassemblycomprising
asafetyvalvewitharesponsepressure
of 3 bar and an automatic air-vent
valve.The pipework between the
boiler and the safety valve must
notbeabletobeshutoff.Severely
excessive boiler pressure due to
excessive boiler temperature, can
burst the boiler body or the boiler
pipework, which would lead to a
suddenexcapeofhotwater(riskof
scalding).
Connect any underfloor heating
system via a three or four-way
mixer.
Note
Providesystemseparationbymeans
of a heat exchanger, when using
pipes which are not impermeable
tooxygen.
This boiler is only suitable for
heating systems with pumped
heatingcircuits.Ifnoheatingcircuit
pumphasbeeninstalled,sufficient
circulation through the radiators
cannot be ensured, putting the
room heating in question.
Recommendation: Convert open
systemsintosealedsystems.
Return temperature raising facility
Heating systems with large water
volume (above 20 litres per kW
output)requireareturntemperature
of 30 °C, as otherwise the longer
heat-uptimeofsuchsystemswould
create condensate and run an
increased risk of boiler body
corrosion.
Note