Wolf TGB-40 User manual

InstaIlationinstructions
---
WOJ,
Technology for life.
Gas~firedwall-mountedcondensingboiler
TGB-40.
TGB-GO

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&J f,i Control unit IFunction IOperation.
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ON/OFFswitch Display
Programming
keys
DHW
temperature
selector
Systempressure
Resetbutton Programselector Heatingwater
temperature
selector
ON/OFFswitchON/OFF
CD ResetAfault isresetbypressingthe reset button whichwill alsorestartthe
system.Thesystemisrestarted ifthe reset keyisactivated when there was
nofault presentinthe system.
Heatingwatertemperaturedisplayorfault codemessage(flashing)
Thecurrent heatingwatertemperatureis displayedbya two digitLCD
display.Adot illuminatesnext to the heating water temperature when a
flamehasbeenestablished.Aflashingfault codeappears inthe LCDdisplay
insteadofthe heatingwater temperature,whenafault hasbeendiagnosed.
Thefollowingtable explainstheir causes:
<II @
Fault code specification
Fault
Gasvalve,fault 2
Gasvalve,fault 1
Lackof air
Differential pressure switch fault
Gasfan,fault
Gasfan,fault
CRCfault, boiler
CRCfault, burner
Fault in 24 VACsupply
Low-water indicator
Internal fault - control PCB
(flashing quickly)
Faultcode Fault Faultcode
1STB- High-limitsafetycut-out 20
4Noflame established 21
5Flamefailure during operation 22
6STW- Excesstemperature 23
7STBA-Excesstemperature 25
11 Flamepretence 26
12 Flowsensor faulty 30
13 Fluegas sensor faulty 31
14 DHWsensor faulty 32
(onlyfor SWconnection) 40
15 Outside temperature sensor XX
fauIty
16 Returnsensor faulty
6

Setting i
. .
9l
2°
JiIif
Anti-seizing pump
protection
Cycle block
~
Control unit IFunction IOperation
The heating program selector enables you to choose four operating modes:
Summer mode(central heating off)onlyDHWheating;frost protectionfor
the centralheatingsystemisensured.Integralanti-seizingpumpprotection.
Winter mode;inwintermode,the boilerheatsthe heatingwater temperature
to the value set at the heating water thermostat. Accordingto the pump
operatingmode,the circulationpumpoperatesconstantly(factorysetti1'19)
or only parallelto the burner control with/without run-on period.
Select this setting .!!iTwhen connecting control accessories.
Emissionstest mode:
Theemissionstest modeisactivated byrotating theprogramselectorinto
position i. A dot illuminates between the heating water temperature
indicationonthe LCDdisplay,whilstthe system isin emissionstest mode.
The program selector returns automatically to winter mode when it is
released.Afteremissionstest modehas been activated,the boilerheats to
the temperature set at the heatingwater thermostat without modulation
orto the maximumheating water temperature adjustedvia parameterno.
8. Any previouscycle blockwill be cancelled.The red dot between the
heating water temperature indication extinguishes when emissionstest
modeends.Inconjunctionwith DRT/ DWT/ DWTM/ DWTK,the emissions
test symbolwillbe transferred to the function display.Activationonlyon
the boiler.
°, DHWtemperature selection
When gas-fired condensing boilers are combinedwith a DHWcylinder,
setting1-9 correspondstoa cylindertemperatureof15-70°c.
°,
Heating water temperature selection
Thesetting range 1-9 correspondsto a heating water temperature of
20-75 (85)°C.Thesetting on the heating water thermostat willbecome
ineffectivewhen the system is used in conjunction with a digital room
thermostat or a weather-compensated controller.
Pressure di~play
Thisindicatesthe water pressurein the heating system.Innormal
operation,the water pressureshould be between 1.5-2.5bar.
Insummer mode, the circulator pump operates for approx. 30 seconds after
a maximum idle period of 24 hours.
Aburnerstart-up delayisintegrated to avoidfrequent burnerstarts during
the heating mode.Thecycleblockcan be adjusted from0-30 minutes.
7
~
Program selector
Setting
or .:=u
11\
Setting m-

Layout
1GB-40 11GB-GO
Fluepipe
Fanmotor
Gasfan
Gas-airmixing chamber
Gasrestrictors
STB/flow sensor
Pressurecell
(in the combustion
chamber)
Fluegassensor
Condensatesiphon
Gas combinationvalve
Central heatingflow
Gassupply pipe
8
Quickacting
air vent valve
Combustionchamber
casing
Burner
Heatingwaterheat
exchanger
Flow switch
Returnsensor
Heating circuit pump
Overflowvalve
Centralheating return

.107
0
M
M
N
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M
r--.
(!)
0
N
200
480
Fig.: DimensionsTGB-40jSO
4
1Heatingflow
2 Gasconnection 3 Heatingreturn
4 Condensatedrain
Fig.: ConnectionsTGB-40jSO
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Dimensions
105
U)
U)
co
370 13
Fig.: DimensionsTGB-40jSO

Initial start-up
~ Onlyqualified personnel may carry out
ili the commissioningand initial operation
of the boiler and instruct the user.
.Checktheboilerfor leaks.Preventwaterleaks-
theboilermaybecometoohot- andtheremay
beariskofscalding.
.Checkthat allfluegasaccessorieshavebeen
properlyinstalled.
.Openthe shut-off valvesonflow and return.
.Openthe gasshut-off valve.
.Switch on the system ON/OFFswitch on the
control unit.
.If thesystemwaterpressurefallsbelow1.0bar,
top upwith wateruntilapressureof 1.0to max.2.5
barhasbeenachieved.
.An error codeflasheson the displayif the
boiler hasnot beenproperly commissioned.
Fordetails about error codes,seethe abridged
operating instructions.
.Position the operating instructions where they
areclearlyvisible.
.Instructthe userintheoperationofthe boilerand
handoverthe operating instructions.
Saving energy
.histruct the customer about energy-saving
options.
.Usethis opportunity for reducing the heating
temperatureduringnight operationusingcontrol
accessories.
.Adjust the temperaturesoyou are comfortable;
everydegreeof roomtemperature reductionwill
achieveenergysavingsof upto 5 0/0.
.Reduce the room temperature in unoccupied
rooms as far as possible; please observefrost
protection.
.Ensurethat all thermostatic radiator valvesare
fully opened in roomswhere room thermostats
areinstalled.Theymustnotbeblockedbyfurniture
or curtains.
.Positionthe operating instructions where they
are clearlyvisible.
22
To ensure the reliable and economic
function of a heating system and to
avoiddangers to individualsand prevent
material losses, the system user should
be advised that an approved specialist
should clean and check the heating
system annually.
ON/OFFswitch \ Gettingstarted
Controlunit display Systempressure
Fig.: Controlunit overview

General
Theheating output will be determinedby the fan
speed. You can modify the heating output by
changing the fan speed in accordancewith the
setting valueslisted in table "Output adjustment".
Lower output limit
.Press both programming keys (+) and (-)
simultaneously;the displaywill show"a.".
.With key(+)selectparameter no. 2forthe lower
output Iimit.
.Pressresetkey;the factory-set parametervalue
accordingtothetablebelowwiIIthenbedisplayed.
.Changethe parameterwith the (+) or (-) key.
.Pressthe reset key; the modified value will be
adopted, and the display will again show the
heatingwater flow temperature.Thisterminates
the adjustment of the loweroutput.
Upper output limit
.Press both programming keys (+) and (-)
simultaneously;the displaywill show"a.".
.With key(+),selectparameter no.3forthe upper
output limit of DHW cylinder loading or
parameter no. 4 for heating mode.
.Pressresetkey;the factory-set parametervalue
accordingtothetable belowwill thenbedisplayed.
.Changethe parameterwith the (+)or (-) key.
.Pressthe reset key; the modified value will be
adopted and the display will again show the
heatingwater flow temperature.Thisterminates
the adjustmentof the upperoutput.
Changingthe output
Resetbutton (-) (+)
Programmingkeys
Fig.: Controlunit display
Table: Output adjustment TGB-40
Table: Output adjustment TGB-60
~-eating
23

Displayinglmodifying control parameters
~Modifications must onlythe carried out
bya recognised heating contractor or by
Wolf service engineers.
~Incorrect operation can lead to the
system developing faults.
Please note when using parameter 5
(frost protection/outside temperature),
that frost protection isnot safeguarded
ifyou set temperatures lowerthan 0 °c.
To'preventdamageto the heating system,
cancel night setback when outside
temperatures fall below -12°C. If this
rule isnot observed,icemayaccumulate
on the flue outlet, which may cause
injury to individuals or damage to
property.
Displaying/modifyi ng control
parameters
.Press both programming keys (+) and (-)
simultaneouslyuntil the displayshows"0.".
.Changethe requiredparameterno.with programming
keys(+)or (-).
.Pressresetkey;the factory-set valuesaccording
to the "Factorysettings" will then be displayed.
.Changethe parametervalue with the (+) or (-)
programmin~keys.
.Pressthe reset key;the modified value will be
adopted and the display will again show the
heatingwaterternperatureo
24
Resetbutton (-) (+)
Programmingkeys
Fig.: Controlunit display

Displaying/modifying control parameters
Control unit parameters
Table:Factorysettings control unit parameters
* Setparameter10to 1 if the control unit accessorytype DWTMisco.nnected.
** When connectinga DWTK,parameter95 will indicate the modulation level,not the setflow temperature.

Gas-air connection adjustment
Implementation
Thisadjustment isonlypermissibleafter changing
the type of gas. or in case of problems.
Implementthe gas-air-connection firstinthe upper
loadrange(emissionstest mode)and then in the
lowerload range (softstart).
Adjusting the CO2value in the upper
load range (emissions test mode)
. Setthe programselectorto Ii emissionstest (a
reddotappearsbetweenthefiguresonthedisplay).
.Removethe cap nut from the r.h. test nipple
"Ventilation air" <ID.
.Check the CO2concentration at the ventilation
air nipple<ID.Theflue pipe is not gas tight ifthe
CO2content> 0.3 °/0;rectifythe leak.
.Checkthe C02contentat full load.
CO2valueinthe upperloadrange in emissionstest
mode:
Table:CO2 content to beselected
.CorrecttheCO2adjustment(ifrequired)bycarefully
rotating the gasflowadjustment screw@ onthe
gas combinationvalve.
.Turnto the right - the C02contentwillbe
reduced
Turnto the left -the CO2content willincrease
26
ON/OFF switch Programselector
Fig.: Control unit overview
Gas flow adjustment
screw@
Adjustmentscrew @
lower load
Fig.: Adjusting the CO2content
Fig.: Testnipples

Gas-air connection adjustment
Adjusting the CO2value in the lower
load (soft start) range
. Setthe heating programme switch to heating
mode.
.Turn to the right - the-CO2content will be reduced
Turn to the left - the CO2content will increase
CO2value in the lower load range:
Table:CO2 content to beselected
Basic setting
Thebasicsetting may onlybe implemented if the
gas combinationvalve has been adjusted and the
burner no longerstarts.
Please carry out the following steps:
-Turnthe gasflowadjustmentvalve@untilit is
flush with the top of the cast component
(gascombinationvalve).Thenturn the screw at
TG6-40three half-turns to the right.
- Turnthe adjusting screw @on the gas
combinationvalvefullyto the right,andthen five
half-turns to the left.
- Then start the boiler and adjust the
gas-air-connection.
ON/OFFswitch Resetbutton
Fig.: Control unit overview
Gas flow adjustment
screw@
Adjustment screw @
lower load
Fig.: Adjusting the CO2content
Programselector

Maintenance
Dismantling the combustion chamber
unit
.Removethe combustion chamberhousingafter
releasingthe toggles.
.Removethe plugconnectionsfrom the following
components:
Ignition, ionisation, flow and return sensor,flue
gastemperaturesensorandgasfan.
.Pullthe anti-radiation panelforwardandunhook
the panel.
.Releasethe fixings betweenthe gasconnection
and mixing chamber.
.Release the nuts (three no.) on the small
combustion chamberlid.
.Removethe wholeunit (mixingchamber,fan and
small combustionchamberlid).
Flowsensor.
plug
Gasfanplug Ignitionplug
lonisationplug
Earthplug
Fluegas
sensorplug
Fig.: Gas-fired condensingboiler with combustion chamber
housing removed
Anti-radiation panel
Fig.: Anti-radiation panel
Fixingsbetweenthe gasconnection and mixing chamber
Fig.: Fixingsbetweenthe gasconnectionandmixingchamber
Nut on the small combustion chamberlid
Fig.: Nut onthe combustion chamberlid

.Slackenthe union nut of the ventilation pipe
towards the quick-acting air-vent valve and
remove the whole quick-acting vent valve
upwards.
.Releasethe flow andreturn compressionfittings.
.Pushthe flue pipe damperupwards.
.Unscrewand drain the boiler siphon.
.Undoscrewfrom the lid/rear panel.
.Lift the complete combustion chamberunit out
until the condensatedrain connectionisfree and
the combustion chamber unit can be removed
towardsthe front.
Maintenance
Screw,lid, rear panel
Fig.: Union nut/rear panel,lid
Flowcompressionfitting Returncompressionfitti ng
Fig.: Compressionfittings
Boilersiphon
Fig.: Boilersiphon
Combustion chamber unit
Fig.: Combustionchamberunit
/
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~
Maintenance
Burner/heatingwater heat exchange
disassembly. cleaning and assembly
.Slackenandremovethethreadedrodsofthe large
combustionchamberlid (four no.).
.Removethe burner upwards.
.Removethe largecombustionchamberlid.
.Removethe combustion chamberbase.
Threadedrod
Fig.: Threadedrodsof the largec:ombustionc:hamberlid
Burner
Fig.: Burner
32
Fig.: Largec:ombustionc:hamberlid
Fig.: Combustionc:hamberunit Ic:ondensatesump
Combustionc:hamberbase
Fig.: Combustionc:hamberbase

.Removecombustionresidueswith aplastic brush
(non-metallic brush).
.Washseverelycontaminated burnersin a soapy
solution andrinsewith tap water.
.Cleanseverelycontaminated heatingwater heat
exchangerswith Fauch600,Fauch610,Sotin230
(230GA)orequivalentcleaningagentsandrinse
with tap water.
.Reassemblein the reverseorder.
Generally,replaceall gasketsonwater andflue
gascomponentswhichhavebeenseparatedand
coatwithsilicongrease(othergreasewilldestroy
the gaskets)priorto reassembly.
.Duringreassembly,checkfor correct positioning
of the combustionchamberunit in relation to the
condensatesump.
.During reassembly,checkfor correct position of
the control cables.
Safety instructions
Carryout the following stepsafter completingthe
abovemaintenancesteps:
.Openthe shut-off valveat the heatingflow
andreturn. Openthe cold water inlet.
.Topupthe heating system,if required,to
approximately 1.5bar,andvent the heating
system.
.Openthe gasshut-off valve.
.Switch on the emergencystopswitch (if
installed).
.Switch on the ON/OFFswitch on the Wolf gas-
fired boiler.
.Checkthe boiler water and gasconnectionsfor
leaks.
.Checkthe boilerfor perfectfunction andflue gas
values.
.Hookin the front casing.
Maintenance
Heating water heatexchangercomplete with the
combustion chambercylinder
I
Fig.: Heating water heatexchanger
Combustionchamberunit Condensatesump
Fig.: Positionof the combustion chamberunit/condensate
sump
Fig.: Controlcableposition
33
cfi
~~

Specification
Ratedoutputat 80/60°C
Ratedoutput at 50/30 DC
Ratedthermal load
Lowestoutput (modulating)at 80/60
Lowestoutput (modulating)at 50/30
Lowestthermal load (modulating)
kW
kW
kW
kW
kW
kW
37.2
40.5
37.9
11.2
12.1
11.4
55.4
60.6
57.2
21.9
23.6
22.3
Gasconnection value:
NaturalgasE/H(Hi=9.5 kWh/m3=34.2MJ/m3)m3/h
Natural gas LL(Hi=8.6 kWh/m3=31.0MJ/m3)m3/h
LPG(Hi= 12.8kWh/kg=46.1MJ/kg) kg/h
Gassupplypressure:
Naturalgas
LPG
4.0
4.4
3.0
6.0
6.7
mbar
mbar 17-25 25-45 17-25
Permissiblesensor temperatures
Fluegas massflow rate
Fluegas temperature 80/60 - 50/30
Availablegas fan draught
Fluegas value group accordingto DVGWG635
DC
g/s
DC
Pa
95
17.3
67- 43
130
G52
95
26.7
80-50
185
G52
*notapplicabletoAustria/Switzerland
36

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T1 (transformer)
YO(Gaskombiventil)
Wiring TGB-40/60
diagram
X6 r.- M2(Fan)
(PE terminal) iA
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go/gn,. I , ,. gO/g~'lbrl gl kmobJ 1:.s
GNol I~WM
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: : ~~~ffl'l~ r~ltf.~~J~lb~.-. -, -,.
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gr/rs "I oG-t!
84 (boiler return sensor)
vio
IIIi '/iiefgn gr/r.
Flow, return, fluegas sensor, differential pressure switch
vii>~!if
Secondary
transformer
.. ..
lonisation / Fan
Earth conductor
Trafa Y2
+-
.' '. .' '.
~B~ ~8~
Pump
PWM
Net Z FV Thermo- Access. AF
stat Bus
LNLNL ab+-+.
Printed wiring board
of control contacts
L N L N
,- .- .go/gn bl
S1 (water flow detector)
"~~~
Rod
casing
X1 (dummy plug)
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1.~~~.~~.~~.~.~~~~.~.~~.~Jr)
85 (Ionisation) L.E1 (igintion devicb)
-'+ Ibr
!)f)f)!)()f:> -~ p~
Brenner @ ibl
-,-,-,-8,-,-,
Burner t;p. go/gn
Bruleur >0;;1
Bruciatore
Brander
ICiCi(i)1
II..............
~2 ~2 X4 (dummy plug) 1~:~"fi'>!I
Bla,ck G~y *When connectin g a roomthermostat i ~il~2
casing casmg . ;..~ ,Vollowcasmg
Vremove Jumper. X5 (plug for 3-way valvel)
PIP: Prior to replacing of fuse isolate [""""""""""""""""1
&appliance from main supply. :~:
The ON/OFFswitch does not provide i ~-~:
main supply isolation of appliance. i ~.~.~~!:...~i
M1(Pump) Y3 (3-way-valve)
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-.
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Q,)
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p";,\ m
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\1',', :.' Z': :, Z
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Y1 Zund Pump
Net
L N L N L N

Troubleshooting
If afault occurs,the BIASoperating,information anddisplaysystemdisplaysafauIt code,to whichcauseand
remedyfromthefollowing tablemaybeallocated.Thistableisdesignedto allowyour localheatingcontractor
to tracethe fault moreeasily.
E= pressthe reset button after a fauIt has been removed
ESTB - High-limitsafety cut-out
Theflow temperaturehasexceeded110°C. The maintenance valves were closed during maintenance,
no fault.
No flow through the heat exchanger due to
- an inadequately vented system
-a faulty overflow valve
-a faulty pump + a faulty flow switch
- a blocked water pipe + a faulty flow switch
The control unit records an incorrect flow temperature due to
- a faulty flow sensor
5 E Flame failure during operation
Flamefailure within 15s after
the flamehasbeensuccessfullyrecognised.
Lack of gas because
- the gas supply pressure is too low.
The gas mixture is difficult to ignite because
- the CO,value is outside the permissible range
- flue gas is getting into the combustion air supply - flue pipe is not gas-tight
- the gas restrictors or their gasket not OK,if required for this boiler
-of wind influence, the wind protection is missing
Faulty components must be replaced with original spare parts.

Troubleshooting
If afault occurs,the BIASoperating,information anddisplaysystemdisplayafault code,to which causeand
remedyfromthefollowing tablemaybeallocated.Thistableisdesignedto allowyour localheatingcontractor
to trace the fault moreeasily.
E = pressthe reset button after a fault has been removed
7 E STBA -Excess temperature
The flue gas temperature has exceeded
the limit for the STBAshutdown of 110 °c.
Flue gas temperature too high because
- the output is too high
- of a contaminated or faulty heat exchanger
Flue gas system protection.
!
I
i~ .~
23 Differential pressure switch fault
The differentia I pressure switch does not
switch OFF.
Gas fan does not switch OFF.
Monitoring interrupted by
-a faulty differential pressure switch
- water or contamination in the hoses to the
differentia I pressure switch.
Faulty components must be replaced with original spare parts.

Lr
,"
,;,;
i
-
I'
:-i
Troubleshooting
If afaultoccurs, the BIASoperating,information anddisplaysystemdisplaysafault code,to whichcauseand
remedyfrom the following table may beallocated. Thistable isdesigned to allowyour local heating contractor
to tracethe fauIt moreeasiIy. .
E = press the reset button after a fau It has been removed
X.y. EControl PCB faulty
Electronic module fault
The internal self-test has discovered
an error.
Faulty components must be replaced with original spare parts.