EasyManua.ls Logo

Wolf FGB-K Series User Manual

Wolf FGB-K Series
104 pages
To Next Page IconTo Next Page
To Next Page IconTo Next Page
Page #1 background imageLoading...
Page #1 background image
GB
IE
Wolf GmbH / Postfach 1380 / D-84048 Mainburg / Tel. +49.0. 87 51 74- 0 / Fax +49.0.87 51 74- 16 00 / www.wolf.eu
Document no.: 3064458_201811 Subjecttotechnicalmodications
Installation and maintenance instructions for contractors
Wall mounted gas
condensing boiler
FGB wall mounted gas condensing boiler
FGB-K wall mounted gas condensing combi boiler
FGB-28
FGB-35
FGB-K-28
FGB-K-35
from FW 1.20

Questions and Answers:

Wolf FGB-K Series Specifications

General IconGeneral
Installation TypeWall-mounted
EmissionsLow NOx
TypeCondensing Boiler
Heat Exchanger MaterialStainless Steel
Ignition TypeElectronic Ignition
Fuel TypeNatural gas
Water ContentVaries by model, refer to specific product data sheet
WeightVaries by model, refer to specific product data sheet
DimensionsVaries by model, refer to specific product data sheet
Operating Pressure30 psi (maximum)

Summary

1. Documentation and Delivery

Document Safekeeping

Guidance on storing manuals and documents safely for system users.

System User Instructions

Key instructions for system users regarding maintenance, parts, and safety.

Recycling and Disposal

Guidelines for environmentally responsible disposal of old equipment and packaging materials.

2. Safety Instructions

Gas and Flue Gas Hazards

Procedures for detecting and responding to gas or flue gas leaks to prevent poisoning or explosion.

Electrical Safety Precautions

Warnings and procedures for safely working with live electrical components to prevent electrocution.

Thermal Hazards: Scalding and Burns

Precautions against scalding from hot water and burns from hot components during operation or maintenance.

2. Safety Instructions (Continued)

Pressurised Water Safety

Warning about potential injuries from high water pressure within the boiler system.

System Operation and Service Safety

Safety guidelines for working on the system and for performing regular inspections and maintenance.

3. Dimensions and Connections

4. Technical Specifications

5. Component Identification (FGB)

5. Component Identification (FGB-K)

6. Standards and Regulations

Local Installation Regulations

Listing local regulations that must be followed for boiler installation and operation.

General Installation Guidelines

General regulations, rules, and guidelines applicable to the installation of heating systems.

6. Standards and Regulations (Continued)

Country-Specific Regulations

Overview of applicable regulations for installation and operation in Germany, Austria, and Switzerland.

6. Standards and Regulations (Continued)

Boiler Operation and Safety Standards

Information on boiler operational standards, approvals, and suitability for specific environments like garages.

Ventilation and LPG Safety

Critical warnings regarding ventilation requirements and precautions for LPG operation to prevent hazards.

DHW Temperature and Water Hardness

Advice on setting DHW temperature to prevent scalding and managing water hardness to avoid scaling.

7. Installation Positioning

Clearance Requirements

Specifies minimum clearances for boiler installation to facilitate maintenance and testing.

Installation Environment Conditions

Requirements for the installation room regarding temperature, air quality, and absence of flammable materials.

Specific Installation Scenarios

Conditions for wet room installation, outdoor restrictions, and system type requirements.

8. Installation Dimensions

Appliance Mounting and Flue System

Instructions for mounting the boiler and identifying flue system components and dimensions.

9. Accessing Internal Components

10. Installation - Hydraulic Connections

Heating Circuit Connections

Recommendations for installing maintenance valves and dirt traps in the heating circuit for system protection.

Water Connections and Safety

Guidelines for cold water and DHW connections, including pressure reducers and non-return valves.

11. Gas Connection

Gas Supply Line Installation

Instructions for connecting the gas supply line, emphasizing licensed fitters and system cleanliness.

Gas Safety Valve and Testing

Requirement for a fire-protected gas valve and safety procedures for gas connection tightness and pressure testing.

12. Fitting the Trap

Condensate Drain Setup

Instructions for fitting the condensate trap, ensuring secure connections and proper hose routing for drainage.

Trap Filling Procedure

Critical procedure for filling the trap with water before commissioning to prevent flue gas escape.

Hydraulic Pipework Pressure Testing

Specifies test pressures for DHW and heating water sides of the hydraulic pipework.

13. Air/Flue Gas Routing

Balanced Flue System Guidelines

Guidance on using original Wolf parts for balanced flue systems and consulting technical information.

Flue Gas Condensation Warning

Warning about flue gas condensation and freezing at low temperatures and measures to prevent ice falling.

14. Electrical Connection

General Electrical Installation Requirements

General information and requirements for electrical installation, including qualified contractors and regulations.

Electrical Safety Warnings

Critical warnings regarding live electrical components and the need to isolate power before work.

14. Electrical Connection (Continued)

Control Unit Access

Instructions for opening the control unit and its back cover to access internal components.

Cable Gland Usage for Sealing

Importance of using cable glands correctly for room-sealed operation and protecting internal components.

14. Electrical Connection (Continued)

Terminal Strip Layout

Diagram showing the terminal strip layout for connecting power, sensors, and control accessories.

Connecting Input Signals

Guidelines for connecting input signals like room thermostat, outside temperature, and DHW sensors.

14. Electrical Connection (Continued)

Permanent Power Connection Steps

Specific steps for making a permanent electrical connection, including cable routing and strain relief.

Fuse Replacement Safety

Safety precautions for changing the fuse, emphasizing power isolation before the procedure.

14. Electrical Connection (Continued)

Connecting Input E1 and External Sensors

Instructions for connecting input E1 and external sensors, including advice on shielded cables.

Connecting Digital Control Accessories

Guidelines for connecting digital Wolf control accessories via eBus, including cable type and shielding.

14. Electrical Connection (Continued)

ISM7e Module Functionality

Description of the ISM7e interface module for remote access and its operating options.

15. Control Unit Functions

Control Unit Key Assignments

Detailed explanation of the function assigned to each key on the control unit for operation.

DHW and Heating Key Operations

How to use DHW and Heating keys to adjust temperatures and select operating modes.

Mode Selection and Test Modes

How to select operating modes and activate emissions test mode using control unit keys.

15. Control Unit (Continued)

Display Menu Navigation and Icons

Explanation of display elements and how to use the info button to access readings and interpret icons.

15. Control Unit (Continued)

Boiler Operating Modes

Description of the Standby, Winter, and Summer operating modes of the boiler.

15. Control Unit (Continued)

Contractor Level Access and Navigation

Steps to access the contractor level for parameter adjustment and navigate menus.

Fault History Management

How to access and reset the fault history to diagnose and clear error codes.

15. Control Unit (Continued)

Emissions Test Mode Operation

Procedure to enable, operate, and disable the emissions test mode for combustion parameter checks.

16. Control Parameters (HG)

Contractor Parameter Access and Table

Introduction to contractor parameters, how to access them, and a table of parameters H01-H25.

16. Control Parameters (HG) (Continued)

Additional Control Parameters Table

Table listing additional control parameters (H34-H55) and their factory settings.

Key Parameter Configuration Notes

Notes on essential parameters (H12, H40, H51) that require specific setting during commissioning.

17. Parameter Description (H01-H08)

H01: Switching Hysteresis

Description of parameter H01, regulating boiler water temperature hysteresis for efficient burner operation.

H02: Lower Burner Output

Description of parameter H02, setting the minimum burner output applicable to all operating modes.

H03: Upper Burner Output (DHW)

Description of parameter H03, setting the maximum burner output for DHW mode operation.

H04: Upper Burner Output (Heating)

Description of parameter H04, setting the maximum burner output for heating mode operation.

H07: Pump Run-on Time

Description of parameter H07, controlling the heating pump run-on time after heat demand ends.

H08: Max Boiler Water Temperature

Description of parameter H08, limiting the upper boiler water temperature in heating mode.

17. Parameter Description (H09-H16)

H09: Burner Cycle Block

Description of parameter H09, defining the burner cycle block duration after shutdown.

H10: eBUS Address Setting

Description of parameter H10, used for setting the eBUS address for heat sources in cascade systems.

H12: Gas Type and Output

Description of parameter H12 for setting the gas type and output, with an associated table.

H15: Cylinder Hysteresis

Description of parameter H15, regulating the start point for cylinder heating based on hysteresis.

H16: Minimum HC Pump Rate

Description of parameter H16, setting the minimum rate for the heating circuit pump.

17. Parameter Description (H17-H34)

H17: Maximum HC Pump Rate

Description of parameter H17, setting the maximum rate for the heating circuit pump.

H19: CLP Run-on Time

Description of parameter H19, setting the run-on time for the cylinder loading pump.

H21: Minimum Boiler Temperature

Description of parameter H21, setting the minimum start temperature for the boiler.

H23: Maximum DHW Temperature

Description of parameter H23, defining the upper limit for DHW set temperature.

H25: Excess Boiler Temperature

Description of parameter H25, selecting excess temperature differential for cylinder heating.

H34: eBUS Feed Configuration

Description of parameter H34, enabling or disabling the eBUS feed for connected consumers.

17. Parameter Description (H37-H40)

H37: Pump Control Type

Description of parameter H37, selecting the type of pump speed control in heating mode.

H38: Set Spread for Pump Control

Description of parameter H38, setting the spread value for pump control when spread is enabled.

H39: Soft Start Time

Description of parameter H39, setting the duration for reduced burner output after start.

H40: System Configuration

Description of parameter H40, selecting system configuration (direct heating circuit, mixer, cascade).

17. Parameter Description (H41, System Configs)

H41: DHW Pump Speed

Description of parameter H41, setting the pump speed for feed/heating circuit in DHW mode.

System Configuration Diagrams

Diagrams illustrating System Configurations 02 (Mixer) and 60 (Cascade) for boiler integration.

17. Parameter Description (H51-H53)

H51: DHW Configuration

Description of parameter H51, used to set the type of DHW heating configuration.

H52: Pasteurisation Setting

Description of parameter H52, enabling or disabling DHW cylinder pasteurisation to prevent bacterial growth.

H53: Pasteurisation Interval

Description of parameter H53, specifying the interval for activating the pasteurisation function.

17. Parameter Description (H54)

H54: Heating Curve Setup

Description of parameter H54, setting the heating curve to match system conditions and climate for optimal performance.

Temperature Correction Calculation

Formula and example for calculating temperature correction based on heating curve and outside temperature.

17. Parameter Description (Temperature Correction)

Temperature Selection Graphs

Graphs illustrating how temperature selection (-4 to +4) affects flow temperature based on outside temperature.

17. Parameter Description (H55, A09)

H55: DHW Quick Start

Description of parameter H55, maintaining DHW temperature in summer mode for increased convenience.

A09: System Frost Protection

Description of parameter A09 for system frost protection and important cautions to prevent damage from freezing.

18. Filling and Water Treatment

Hydraulic Pipework Leak Testing

Procedure for leak testing hydraulic pipework and the required test pressures.

Heating Water Quality Standards

Guidelines for treating heating water according to VDI 2035 to prevent corrosion and ensure system longevity.

Water Quality Limits Table

Table specifying limits for heating water quality parameters like hardness and conductivity.

18. Filling and Water Treatment (Continued)

Top-up Water Management

Information on top-up water requirements, including calculations for desalinated water and total fill water limits.

Commissioning Record Keeping

Instruction to record commissioning parameters in the system log and hand it to the operator.

18. Filling the Heating System

Heating System Filling Procedure

Step-by-step guide for filling the heating system, including flushing, venting, and checking for leaks.

Prohibited Heating System Additives

Important note prohibiting the use of inhibitors and antifreeze in the heating system due to potential damage.

18. Filling the Heating System (Continued)

System Pressure Check and Auto-Venting

Instructions to check system pressure, top up if needed, and information on automatic heating circuit venting.

Using the Integrated Filling Facility

Steps for filling the heating circuit using the integrated filling facility and checking for component tightness.

18. Filling the Trap

18. Installing the Condensate Drain

19. Filling for Optional Appliance Versions

20. Draining the Heating System

21. Determining the Gas Type

Gas Type and Wobbe Index Information

Information on different gas types (Natural gas, LPG) and their Wobbe index values for correct setup.

Gas Categories and Supply Pressures

Table showing gas categories and required supply pressures in mbar for various countries to ensure proper operation.

Gas Restrictor Selection

Instructions on matching the correct gas restrictor based on gas type and appliance category for optimal performance.

22. Checking Gas Supply Pressure

23. Changing the Gas Type

Gas Type Conversion Procedure

Step-by-step guide for changing the gas type of the boiler, including physical component changes and labelling.

Contractor Level Gas Type Setting

How to set the gas type in the contractor level parameter H12 after physical conversion.

Post-Conversion CO2 Testing

Procedure for performing a CO2 test after changing the gas type to ensure correct combustion parameters.

23. Changing the Gas Type (Continued)

CO2 Adjustment at Upper Load

Procedure for adjusting the CO2 content at upper load during emissions testing for optimal combustion.

CO2 Adjustment at Lower Load

Procedure for adjusting the CO2 content at lower load, specifically for zero adjustment, during emissions testing.

24. Adjusting Maximum Heating Output

Output Adjustment via Control Unit

How to adjust the maximum heating output using the control unit parameters and associated tables.

Heating Output vs. Display Value Graph

Graph illustrating the relationship between display value and heating output for different boiler models.

25. Checking Combustion Parameters

Intake Air Parameter Check

Procedure for checking intake air parameters, including temperature and CO2, during emissions testing.

Flue Gas Parameter Check

Procedure for checking flue gas parameters (CO2, O2) at upper and lower loads, with permissible values.

26. High Efficiency Pump Function

Pump Operating Modes

Description of the high efficiency pump's operating modes (modulating, fixed speed, DHW, standby) and control.

Pump Performance Curve

Graph showing the residual head of the high efficiency pump relative to pump rate, indicating performance characteristics.

26. High Efficiency Pump Function (Troubleshooting)

Pump Troubleshooting Guide

Troubleshooting guide for common issues with the high efficiency pump, including problems with radiator warming and room temperature.

27. Commissioning Report

Commissioning Checklist

A checklist of commissioning steps to be performed and confirmed, including system checks and parameter settings.

Recording Commissioning Data

Section for recording test values, confirmations, and gas type information during commissioning.

27. Commissioning Report (Continued)

Parameter and Emissions Test Verification

Checklist items for verifying parameter settings and performing flue gas emissions tests.

Final Checks and Confirmation

Final checks including casing fit, function test, user training, and confirming overall commissioning.

28.1. Maintenance - Fault Messages

Accessing and Viewing Fault History

Instructions on how to access the fault history from the control unit to view recent faults and provide maintenance information.

Resetting Fault History

Procedure for resetting the fault history after a fault has been addressed and remedied to clear error codes.

28.2. Maintenance - Spare Parts

Required Maintenance Sets

List of required maintenance sets and part numbers, including cleaning tools and specialized devices.

FGB Spare Parts Identification

Diagram illustrating the FGB spare parts included in the maintenance set for service and replacement.

28.3. Preparing for Maintenance

Safety: Power and Gas Isolation

Crucial safety steps to isolate the system from power and close the gas ball valve before maintenance.

Accessing Components: Casing Removal

Step-by-step instructions for removing the front casing to access internal components for maintenance.

Burn Hazard Warning

Warning that some components can be very hot, requiring cooling or protective gloves during maintenance.

28.4. Heat Exchanger Soiling Check

Pressure Test Connector Fitting

Instructions for fitting the pressure test connector and adapter plate to the heat exchanger for measurement.

Determining Heat Exchanger Soiling

How to read the pressure differential and determine the soiling level of the heat exchanger, comparing to limits.

28.5. Burner Maintenance

Gas Combination Valve Disconnection

Instruction on how to undo the fitting on the gas combination valve for burner maintenance.

Disconnecting Electrical Connections

Steps for disconnecting plug-in electrical connections like fan, gas valve, and ignition electrode.

28.5. Burner Maintenance (Continued)

Combustion Chamber Cover Removal

Instructions for removing the combustion chamber cover to access and service the burner.

Burner Cleaning and Inspection

Procedure for cleaning the burner, including visual inspection for damage and using compressed air.

Burner Cleaning Safety Caution

Caution against using specific cleaning agents like acids or water for cleaning the burner to prevent damage.

28.6. Checking Ignition Electrode

28.7. Trap Cleaning and Expansion Vessel Check

Trap Cleaning Procedure

Instructions for cleaning the trap, including removing residue and flushing through the inspection port.

Expansion Vessel Pre-charge Check

Procedure for checking the expansion vessel's pre-charge pressure if water loss is noticed, ensuring system integrity.

28.8. Removing the Heat Exchanger

Emptying Boiler Water and Venting

Steps to empty the boiler water and open the manual air vent valve before removing the heat exchanger.

Disconnecting Pipes and Sensors

Instructions for disconnecting sensors, releasing clips, and removing pipes connected to the pump and heat exchanger.

28.8. Removing the Heat Exchanger (Continued)

Heat Exchanger Cleaning Method

Procedure for cleaning the heat exchanger using a cleaning tool, with a caution about cleaning agents and water flushing.

Removing Condensate Pan

Instructions for removing the condensate pan by releasing retaining clips to access the heat exchanger.

28.9. Assembling the Heat Exchanger

Heat Exchanger Assembly Steps

Steps for assembling the heat exchanger, including fitting condensate pans, securing clips, and positioning the flue pipe.

Refitting Pipes and Sensor Connections

Instructions for refitting pipes, connecting sensors, and reconnecting plug-in connections to the pump.

28.9. Assembling the Heat Exchanger (Continued)

Refilling Boiler and Venting System

Steps for refilling the boiler on the heating water side, including venting and opening valves for proper operation.

Refitting Combustion Chamber and Connections

Instructions for refitting the combustion chamber cover, tightening screws, and reconnecting plug-in electrical connections.

28.9. Assembling the Heat Exchanger (Continued)

Gas Combination Valve Tightening and Leak Check

Instructions for tightening the gas combination valve fitting, replacing seals, and checking for gas leaks.

Post-Assembly Heat Exchanger Test

Performing a test after assembly to check the heat exchanger soiling level and measured pressure drop values.

29. Checking DHW Heating

Troubleshooting Low DHW Output

Actions to take if DHW output is too low, including checking filter, heat exchanger, and performing a test run.

Test Run and Combustion Parameter Check

Procedure for the test run after maintenance, including checking gas train, hydraulics, and testing combustion parameters.

30. Safety Devices

Temperature Monitoring Safety Features

Description of safety devices monitoring temperature, including high limit cut-outs, boiler, and flue gas sensors.

System Pressure Monitoring and Dry Fire Protection

Description of system pressure monitoring and dry fire protection function for safe boiler operation.

31. Technical Information - Balanced Flue

Balanced Flue System Overview

Overview of different types of balanced flue systems and their connection possibilities with diagrams.

Flue Gas Routing Options and Lengths

Table detailing flue gas routing options and maximum permissible lengths for various flue types.

Multiple Connection Safety Data

Information on safe differential pressure limits for multiple connections of balanced flue systems.

31. Technical Information - Balanced Flue (Continued)

Balanced Flue Installation Notes

Notes on installation examples, building regulations, and the use of original Wolf components for balanced flue systems.

31. Technical Information - Balanced Flue (Continued)

General Balanced Flue Installation Warnings

General advice for balanced flue installation, including fire resistance, clearances, and combustion air source restrictions.

Flue Gas Condensation and Fire Safety

Warnings about flue gas condensation, ice falling, and fire resistance requirements for shafts and ceilings.

External Wall Flue Output Reduction

Guidance for external wall flues (C13x), including requirements for output reduction.

31. Technical Information - Balanced Flue (Continued)

Vertical Flue Routing Examples (DN 60/100)

Examples of vertical balanced flue routing for DN 60/100 systems with various components and diagrams.

Calculating Balanced Flue Length

Method for calculating balanced flue length, including pipe bends and length equivalences for proper system design.

Minimum Shaft Size for C93x Systems

Information on minimum shaft sizes required for room-sealed operation with C93x balanced flue systems.

31. Technical Information - Balanced Flue (Continued)

C43x, B33, C53/C83x Flue Connections

Instructions for connecting to C43x, B33, C53/C83x flue systems, covering different operational modes.

C63x Flue Connection and Multi-Boiler Systems

Information on C63x flue connections, multi-boiler systems, and requirements for shared chimneys.

31. Technical Information - Balanced Flue (Continued)

31. Technical Information - Balanced Flue (Continued)

Cascade System Tightness Testing

Procedure for performing a tightness test on connections to adjacent appliances in cascade systems using emissions test mode.

31. Technical Information - Balanced Flue (Continued)

Vertical Flue Routing Examples (DN 60/100)

Examples of vertical balanced flue routing for DN 60/100 systems with various components and diagrams.

31. Technical Information - Balanced Flue (Continued)

Horizontal Flue Routing Examples (DN 60/100)

Examples of horizontal balanced flue routing for DN 60/100 systems, including connections to chimneys.

31. Technical Information - Balanced Flue (Continued)

31. Technical Information - Balanced Flue (Continued)

Multi-Draught Chimney Connections (Shaft)

Instructions for connecting to moisture-resistant flues with multiple draught chimneys (shafts), including requirements.

Supplementary Flue Installation Instructions

Supplementary installation instructions for DN80/125 balanced flues, covering flat and pitched roof installations and pipe trimming.

31. Technical Information - Balanced Flue (Continued)

Vertical Concentric Flue C33x Examples (DN80/125)

Examples of vertical concentric balanced flue routing for C33x systems using DN80/125, with installation notes.

31. Technical Information - Balanced Flue (Continued)

Horizontal Concentric Flue Routing Examples

Examples of horizontal concentric balanced flue routing for C13x, C83x, and B33 systems, including external wall routing.

31. Technical Information - Balanced Flue (Continued)

Concentric Flue Inside Shaft (DN80/125, C33x)

Diagram showing concentric balanced flue installation inside a shaft for DN80/125 and C33x systems.

Shaft Flue Connections (C93x)

Diagrams illustrating connections to flues inside shafts for C93x systems.

31. Technical Information - Balanced Flue (Continued)

Eccentric Balanced Flue Installation

Instructions for installing the eccentric balanced flue distributor and its connection requirements, including slope and air supply.

31. Technical Information - Balanced Flue (Continued)

Supplementary Installation for DN80/125 Balanced Flues

Supplementary installation instructions for DN80/125 balanced flues, covering roof installations, adaptor use, and bend calculations.

32. Design Information - Underfloor Heating / DHW

Underfloor Heating System Design

Design considerations for underfloor heating systems, including pipe type, connection, and system pressure drop.

Expansion Vessel Sizing for Underfloor Heating

Recommendation for sizing diaphragm expansion vessels for underfloor heating systems to prevent oxygen ingress and corrosion.

NTC Sensor Resistance Data

Table listing NTC sensor resistances at various temperatures for different sensors used in the system.

33. Service Report

Boiler Service Checklist

A comprehensive checklist of steps to be performed during routine service of the boiler, with sections for recording results.

34. Troubleshooting Guide

General Troubleshooting Principles

General guidance on troubleshooting, safety during repairs, fault display interpretation, and fault resolution steps.

Fault Resolution Procedure

Procedure for identifying, diagnosing, and remedying faults, including acknowledging and resetting error messages.

34. Troubleshooting (Fault Codes 01-05)

Troubleshooting Fault Codes 01-05

Table detailing possible causes and remedies for fault codes 01 through 05, covering sensor errors and flame issues.

34. Troubleshooting (Fault Codes 06-24)

Troubleshooting Fault Codes 06-24

Table detailing possible causes and remedies for fault codes 06 through 24, covering temperature limiter, flue gas, and sensor faults.

34. Troubleshooting (Fault Codes 27-107)

Troubleshooting Fault Codes 27-107

Table detailing possible causes and remedies for fault codes 27 through 107, including supply issues and control unit faults.

35. Electrical Wiring Diagram

36. Product Fiche (FGB)

36. Product Fiche (FGB-K)

37. EU Technical Parameters (FGB)

EU Declaration of Conformity

Declaration Details and Product Information

Details of the EU Declaration of Conformity, including product identification, manufacturer, and conforming documents.

Conformity to Standards and Directives

List of standards and directives that the product conforms to, ensuring compliance with EU regulations.

Related product manuals