Wolf CGB-75 Technische Daten

Maintenance instructions

Gas condensing boiler

CGB-75 Wall mounted boiler

CGB-100 Wall mounted boiler

Document no. 30 62 556 Subject to modications 07/09 GB

Wolf GmbH · Postfach 1380 · D-84048 Mainburg · Tel. +49-8751/74-0 · Fax +49-8751/741600 · Internet: www.wolf-heiztechnik.de

230 62 556_0709

Index ......................................................................................................Page

Safety instructions ........................................................................................ 3

Maintenance procedure............................................................................. 4-9

Overview of the steps to be taken and maintenance report .................. 10-11

List of required parts................................................................................... 12

Index

For easy maintenance!

30 62 556_0709

The following symbols are used in conjunction with these

important instructions concerning personal safety, as well

as operational reliability.

"Safety instructions" are instructions with which

you must comply exactly, to prevent risks and

injuries to individuals and material losses.

Danger through 'live' electrical components!

NB: 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 may

lead to injury or death.

The main supply terminals are 'live' even when

the ON/OFF switch is in the OFF position.

"Note" indicates technical instructions that you

must observe to prevent material losses and

boiler malfunctions.

Safety instructions

General notes

Maintenance work must only be carried out by a

qualied heating contractor.

Regular maintenance and the exclusive use of original

Wolf spare parts are necessary preconditions for

trouble-free operation and a long service life.

We therefore recommend you arrange a maintenance

contract with a local heating contractor.

Figure: Terminal box - danger from electrical voltage

Figure: Ignition transformer, high voltage ignition electrode, heat

exchanger

Danger from electrical voltage

Risk of burning from hot components

Figure: Gas combination valve

Danger from electrical voltage

Escaping gas may cause poisoning or an explosion

Figure: Gas connection

Escaping gas may cause poisoning or an explosion

430 62 556_0709

Maintenance procedure

The mains terminals are 'live' even when the

ON/OFF switch has been switched OFF.

Disconnect the system from the power supply.

Pivot the control unit ap down.

Switch OFF the condensing boiler at the ON/OFF switch.

Close the gas tap.

Undo screws on front casing cover. Release the bottom of the

front casing cover and unhook at the top.

Danger of burning

Leave to cool down for half an hour before beginning

maintenance work on the appliance

Seal the front casing tightly with screws after

completing the service. There is a risk of carbon

monoxide poisoning if the ue system is faulty.

Screws

30 62 556_0709

Maintenance procedure

Pull out plug:  Ignition electrode

 Earth conductor

 Monitoring electrode (ionisation)

 Thermostat

 Gas fan

 Fan variable speed control

 Solenoid valve (rst undo Phillips head screw)

 Modulation coil (rst undo Phillips head screw)

New photo!

Undo screws on upper casing cover (left / right).

Pull the cover forwards slightly and lift off.

630 62 556_0709

Maintenance procedure

Undo 6 mm Allen screws (3x) on the heat exchanger cover and

the fan manifold. Remove fan with manifold.

Undo gas connection at the gas combination valve.

Remove burner gasket and burner,

clean burner with a vacuum cleaner or ush with water.

30 62 556_0709

Maintenance procedure

Replace O-ring annually

Remove heat exchanger cover

O-ring

Undo star shaped handles (3x)

Lift heat exchanger cover using maintenance tool

830 62 556_0709

Maintenance procedure

Cleaning the heating surface:

Hook the maintenance tool into the combustion chamber and

pull out the chamber.

Rotate the maintenance tool 90°, hook into the lifting eye of the

rst combustion chamber extension and pull out the chamber

extension.

Repeat for the second combustion chamber extension.

Clean the heat exchanger with the brush. Clean the condensate

pan with a vacuum cleaner or ush with water.

Maintenance

tool

Replace ignition and monitoring electrodes

Monitoring electrode

Ignition electrode

30 62 556_0709

Maintenance procedure

Assembly

Assembly is carried out in reverse order, observing the following

points:

• Before retting the heat exchanger cover, lubricate the O-ring

with silicone grease.

• Check the burner gasket for damage before tting (replace if

necessary) and ensure it is tted correctly.

• Check gasket at gas combination valve for gas supply, tighten

threaded connection.

Restart / ue gas test

• Reset the MCB

• Open the gas tap

• Check the gas supply line for leaks

• Switch ON the boiler

• Set the program selector to emissions test mode

Testing the inlet air

If the CO2 > 0.2%, check that there are no leaks in the

balanced ue:

Flue gas test

Carry out the test in emissions test mode and enter the values

in the maintenance report.

Re-adjust the CO2 content, if required (see installation

instructions).

Leak test on non-return valve in ue gas cascades

Set the rst boiler to emissions test mode.

Test the ventilation air at the other boilers in standby mode.

The CO2 content of the ventilation air must not exceed 0.3% after

one minute. Otherwise, check the non-return valve at the fan.

Carry out the same test for the other boilers.

Before restarting:

• Check the system pressure, and top up heating water if

required.

• When you notice a loss of water, check the expansion vessel

pre-charge pressure and increase it, if required, to 0.75

bar. The heating circuit must be at zero pressure. Fill the

system.

Then clean and rell the siphon.

Siphon

Expansion vessel

Emissions test mode position

Figure: Flue gas test with a closed boiler

Test port

"Flue gas"

Test port

"Intake air"

10 30 62 556_0709

Overview of the steps to be taken

and maintenance report

Overview of the steps to be taken and maintenance report

No.

Step Report item Report item Report item

1Switch OFF the boiler, emergency stop switch is OFF

2Close the gas supply valve

3Remove the casing and the combustion chamber housing

4Unplug the electrical connections from the fan, sensors and

electrodes

5Remove the combustion chamber lid upwards

6Clean the burner, if required OOO

7Clean the heating water heat exchanger OOO

8Clean the condensate pan OOO

9Clean the mixing chamber, if required OOO

10 Check the combustion chamber insulation for damage OOO

11 Check gaskets, and if required, replace them and

lubricate with silicone grease OOO

12 Rell granulate, if a neutralising system is installed OOO

13 Check the protective anode every two years on enamelled

cylinders OOO

14 Assemble the equipment

15 Clean and ll the siphon, install and check for tight t OOO

16 Descale the DHW heat exchanger, if required OOO

17 Clean the DHW strainer OOO

18 Check the expansion vessel in case of water loss OOO

19 Open the gas supply valve and start the boiler

20 Gas leak test OOO

21 Flue gas leak test OOO

22 Check the ignition OOO

23 Check the interaction with control accessories OOO

24 Flue gas test in emissions test mode OOO

25 Gross ue gas temperature °C °C °C

26 Ventilation air temperature °C °C °C

27 Net ue gas temperature °C °C °C

28 Carbon dioxide content (CO2)%%%

29 or oxygen content (O2)%%%

30 Carbon monoxide content (CO) %%%

31 Flue gas loss %%%

Conrm maintenance (company stamp, signature)

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