Wolf MGK-2-390, Installation Instructions Manual

Page 1: ... Gas condensing boilers MGK 2 390 MGK 2 470 MGK 2 550 MGK 2 630 WolfGmbH Postfach1380 D 84048Mainburg Tel 49 0 8751 74 0 Fax 49 0 8751 74 1600 Internet www wolf heiztechnik de Document no 3063772_201507 Subject to technical modifications GB dt ...

Page 2: ...isplay programming module Installation 32 20 AM display module 32 21 AM display module menu structure 34 22 Operating mode Heating appliance burner status 35 23 BM2 programming module 36 24 HG control parameters 37 25 Parameter description 38 47 26 Flue gas damper power supply 48 Cascade operation 27 Cascade operation 49 51 Commissioning 28 Filling draining the heating system 52 29 Commissioning 5...

Page 3: ...e gas use This applies to the commissioning of specialist companies to maintain the appliance The system operator is obliged to provide documentation 1 4 Applicability of these instructions These installation instructions apply to the MGK 2 gas condensing boiler 1 5 Acceptance Within four weeks of commissioning of the burner the operator must notify the local flue gas inspector accordingly 1 6 Inf...

Page 4: ... the installation of a gas boiler must be notified to and approved by the relevant gas supply company Please note that regional permits may be required for the flue system and the condensate drain into the public sewer Before installation work begins the local flue gas inspector and water authority must be informed The boiler must be installed commissioned and maintained by qualified and trained p...

Page 5: ...appliance is not designed to be operated by persons including children with restricted physical sensory or mental capacities or who lack the necessary experience and or knowledge unless they are supervised by a person responsible for their safety or have received instructions on how to use the appliance from this person We accept no liability for damage caused by technical modifications made to th...

Page 6: ...safety assembly connection 2 D flow pipe DN 80 E return pipe DN 80 F BDF valve connection G flue pipe DN 250 H condensate drain 850 790 without casing Can be split for transportation 1295 1860 565 1460 1420 365 240 525 1290 1420 535 410 160 1180 1480 1700 85 85 C D E G F H A B ...

Page 7: ...essure Natural gas E H LL mbar 20 20 20 20 Water content heating water heat exchanger l 50 56 62 68 Max permissible boiler pressure bar 6 6 6 6 Max permissible flow temperature C 85 85 85 85 Available gas fan draught Pa 150 150 150 150 Standby losses excess temperature 30 50 K 0 11 0 18 0 10 0 17 0 09 0 15 0 09 0 14 Flue gas temperature 80 60 50 30 at Qmax C 65 35 65 35 65 35 65 35 Flue gas temper...

Page 8: ...ached the burner shuts down briefly without a fault message This characteristic must be taken into account when selecting the components e g pumps heat exchanger and cylinder Flow rate Excessive flow velocities may lead to erosion Maximum flow rate volume flow at Qmax MGK 2 390 28 5 m h MGK 2 470 34 4 m h MGK 2 550 39 8 m h MGK 2 630 45 5 m h MGK 2 heating water pressure drop Heating water pressur...

Page 9: ...operation and maintenance Integral attenuation minimises sound emissions ideal for apartment buildings Control unit fully wired may be used for a wide range of heating system applications Cascades with up to four gas condensing boilers provide an output range of up to 2 5 MW No return temperature raising facility or minimum water circulation volume required Additional 2nd HLSC already integrated i...

Page 10: ... and remove from boiler Remove 2 screws on the right side casing of the boiler Tip right side casing forward and lift off Re assemble in reverse order Re assemble in reverse order Remove burner hood e g for servicing the gas air mixing unit Open side casing e g to connect boiler to power supply ...

Page 11: ...rd heat load DIN EN 12828 Heating systems in buildings designing hot water heating systems DIN EN 13384 Flue systems heat and flow rate calculations DIN EN 50156 1 VDE 0116 Part 1 Electrical equipment in combustion systems VDE 0470 DIN EN 60529 Protection through casings VDI 2035 Prevention of damage in hot water heating systems Scaling sheet 1 Corrosion in the primary system sheet 2 Corrosion in ...

Page 12: ... regulatory agencies usually represented by the flue gas inspector Local regulations of the gas supply utility company Regulations and requirements of the local power supply utility company Provisions of regionally applicable building regulations Minimum heating water requirements in accordance with ÖNORM H5195 1 must be observed For installation in Switzerland the following apply SVGW regulations...

Page 13: ...07 13 8 Handling Installation instructions Handling With ground conveyor vehicle With or without a pallet the boiler can be handled easily using a pallet truck or forklift as it can be lifted from any side Example ...

Page 14: ...ch or chain hoist secured to prevent it from sliding down on its own The gas condensing boiler can be separated into a gas air mixing unit and heat exchanger unit measuring 790 mm x 1295 mm for easier handling Remove the burner hood Remove the gas air mixing unit Remove the retainer for the gas air mixing unit Example 1295 mm 790 mm ...

Page 15: ... air supplied to the boiler must be free from halogenated hydrocarbons e g as contained in sprays solvents cleaning fluids paints and adhesives At worst these can lead to pitting of the boiler and even the flue system Never store or use combustible material or liquids near the boiler The ventilation air supply must be ensured and must comply with local regulationsorthoserelatingtogasinstallations ...

Page 16: ...ator Low water indicator Device to prevent incorrect heating when water level or volume flow are insufficient In flow line near MGK 2 Can be substituted by minimum pressure limiter Flow limiter Functions like low water indicator Not required Replaced by maximum pressure limiter Water level limiter Functions like low water indicator Not required Replaced by minimum pressure limiter Pressure measuri...

Page 17: ...otal hardness total alkaline earths Conductivity Total hardness total alkaline earths Conductivity Total hardness total alkaline earths Conductivity kW dH mol m C μS cm dH mol m C μS cm dH mol m C μS cm 1 50 2 16 8 0 36 3 0 60 500 2 11 2 0 36 2 0 60 300 2 3 0 36 0 54 60 100 2 50 200 2 11 2 0 36 2 0 60 300 2 8 4 0 36 1 5 60 200 2 3 0 36 0 54 60 100 3 200 600 2 8 4 0 36 1 5 60 200 2 3 0 36 0 54 60 1...

Page 18: ... due to excessive boiler water temperatures can burst the boiler body or the boiler pipework which would lead to a sudden escape of hot water risk of scalding When using pipes and climate controlled floors that are not impermeable to oxygen always provide system separation by means of a heat exchanger This boiler is only suitable for heating systems with pumped heating circuits If no heating circu...

Page 19: ...50 590 2 6 1 230V DN 50 flange fitting MGK 2 470 20 2 113 Stratos 50 1 12 680 567 590 2 6 1 230V DN 50 flange fitting MGK 2 550 23 7 126 Stratos 65 1 12 730 604 800 3 5 1 230V DN 65 flange fitting MGK 2 630 26 7 118 Stratos 65 1 12 655 537 800 3 5 1 230V DN 65 flange fitting Grundfos Nominal flow rate at 20 K Spread m3 h HE pressure drop at 20 K Spread mbar Grundfos Type Delivery head mbar Residua...

Page 20: ...e explosions may occur during a fire Size the gas supply line in accordance with DVGW TRGI regulations Check the gas line for tightness without the boiler Never release the test pressure via the gas valve Gas fittings on the appliance should be pressure tested to a maximum of 150 mbar Higher pressure may damage the gas train resulting in a risk of explosion suffocation or poisoning Close the gas b...

Page 21: ...s escaping Connect the condensate hoses of both siphons from the condensate pan and condensate trap with a tee and connect to the neutralising system Check tightness of the connections The standard delivery includes 1 x condensate trap under the burner hood on the ventilation air pipe 2 x siphons with 3 condensate hoses and 1 tee on the condensate trap Condensate connection Install condensate trap...

Page 22: ...the crossbar with Velcro strip Fit air hose to the booster Connect the booster cable with the plug on the cable set Always fit the booster above the neutralising system to prevent condensate flowing into the booster The booster pump must always be installed higher than the neutralising system Danger of electrocution Function check The first fill of granulate lasts for at least one year with approx...

Page 23: ...m of space above the granulate The inlet and drain openings must not be completely covered with granulate or a blockage may occur 3 Fit plug in strainer HT pipe DN40 and or hose connection with pipe strainer seal ring and slide ring and fasten the connection fitting Install neutralising system Check connections for leaks Disposal Granulate residue can be disposed of in normal household waste Conde...

Page 24: ... grille on the ventilation air pipe must be removed For type C and pressurised flue gas routing without special tightness requirements a vent measuring 1x150 cm or 2x75 cm is needed in the installation room Connection types Boiler type Gas boiler type 1 Category Operating mode Can be connected to Open flue Room sealed Moisture resistant chimney Balanced flue chimney Balanced flue system Building r...

Page 25: ...y and combustion air through an external wall balanced flue DN250 DN315 Calculation to EN 13384 balanced flue manufacturer C93 Vertical flue for installation in a duct with horizontal eccentric connection line balanced flue ventilation air supply DN200 The terminals are in the same pressure range combustion air supply via existing duct edge length in mm DN250 250 370x370 DN250 315 450x450 DN315 31...

Page 26: ...ve electrical components Please note Turn 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 can result in a risk of electrocution that could lead to injury or death The terminals are live even when the ON OFF switch is in the OFF position During servicing and installation work isolate the entire system f...

Page 27: ...s in the control unit Remove the front casing see Casing chapter then remove the 4 screws on the control unit with a screwdriver 18 Electrical connection HCM 2 control unit GBC P Terminals Fine wire fuse Terminals Cable conduit Burner control unit Remove the HCM 2 casing cover ...

Page 28: ...y pump ZHP internal wiring of heating circuit pump Z1 230 V output when ON OFF switch is in the ON position Power supply internal wiring Max 1 5 A 345 VA per output no more than 600 VA in total for all outputs Connections in the control unit F1 PE N L3 L2 L1 PE N L3 L2 L1 3 2 1 5 4 K1 K2 220V 400V Power supply 230 V 400 V AC 50 Hz ZHP connection feed heating circuit pump 230 V 400 V AC 50 Hz max 4...

Page 29: ...llation information electrical connection heating circuit pump Isolate the system from the power supply before opening Check that the appliance is isolated from the power supply Open the front casing and the cover of the control unit Open the upper cable conduit and the lower casing cover of the HCM 2 Ensure separation of the LV and ELV side Strip approx 70 mm insulation off the power cable Depend...

Page 30: ...ontacts as long as the condensing boiler has not been isolated from the power supply Risk to life Changing the fuse booster fuse Isolate the gas condensing boiler from the power supply before changing a fuse The ON OFF switch on the boiler does not provide separation from the power supply Danger due to live electrical components Never touch electrical components or contacts as long as the gas cond...

Page 31: ...n the control unit Caution Low voltage boiler connection Connection input E2 Insert and secure the connecting cable through the cable gland Connect the connection cable for input 2 to terminals E2 as shown in the wiring diagram Fig Connection input E2 Only one external voltage of max 10 V can be connected to input E2 otherwise the control PCB will be destroyed 1 a 10 V 2 b GND Caution F1 PE N L3 L...

Page 32: ...c parameters and values can be programmed and displayed Specification LCD display 3 4 quick start buttons 1 rotary selector with push button function NB Use when BM2 is used as a remote control or in a cascade circuit AM is always in the heating appliance Switch ON power supply activate MCB and switch ON OFF switch to ON on the MGK 2 Insert the AM or BM2 in the slot above the ON OFF switch Wolf lo...

Page 33: ...e Note If your Wolf heating appliance does not have an AM display module ignore this page Other functions and descriptions can be found in the installation instructions for contractors or the user operating instructions for the AM display module Heating appliance set temperature if BM2 as remote control no function DHW set temperature if BM2 as remote control no function Enable emissions test mode...

Page 34: ...ettings Back Language Button lock Back Emissions test End Rem time in min T_boiler T_return Calibration Extend time End Contractor Contractor code 1111 Back Relay test System Parameter Parameter reset Fault history Delete fault history Acknowledge fault Back Displays Back T_boiler in C System pressure in bar T_flue gas current in C T_outside in C T_return in C T_DHW in C Input E1 Fan speed rpm Mod...

Page 35: ...n has been activated Cascade Cascade module in system active BMS Appliance is controlled by building management system BMS Heating appliance burner status Display indication Function OFF No burner demand Pre flush Fan operation before burner start Ignition Gas valves and ignition unit are active Stabilisation Flame stabilisation after safety time Soft start After flame stabilisation in heating mod...

Page 36: ... installation instructions for contractors or the user operating instructions for the BM2 programming module Button 1 Button 2 Button 3 Button 4 14 12 20 01 2013 1 5 bar 25 2 C 1x Boiler temperature Heating appliance Heating mode Pressure Status display Page heading Time Date Rotary selector with push button function Display of system data content varies Quick start buttons Operating mode Burner s...

Page 37: ... 30 HG08 Maximum boiler water temperature HZ applicable to heating operation TV max C 85 40 90 HG09 Burner cycle block applicable to heating operation Min 10 1 30 HG10 Heat source eBUS address 1 1 5 HG12 No function HG13 Function input E1 Various functions can be allocated to input E1 none div div HG14 Function output A1 230 V AC Various functions can be allocated to output A1 none div div HG 15 C...

Page 38: ...nit parameters Individual settings _________ Parameter HG02 Lower burner output The setting for the minimum burner output minimum device load is applicable to all operating modes This percentage value corresponds approximately to the real device output Parameter HG03 Upper burner output DHW The setting for the maximum burner output in DHW mode maximum device load Valid for DHW cylinder heating Thi...

Page 39: ...ed for the duration of the burner cycle block The burner cycle block is reset by switching the ON OFF switch OFF and ON or by briefly pressing the reset button Parameter HG10 eBUS address of the heat source If multiple heat sources are controlled in one heating system with a cascade module addresses must be allocated to the heat sources Each heat source requires its own eBUS address in order to co...

Page 40: ...set to DHW circulation pump and blocked for further settings When input E1 is closed output A1 is activated for 5 minutes When input E1 has switched off and 30 minutes have elapsed the timer function is re enabled for the next operation Opwithout b Operation without burner burner blocking When contact E1 is closed the burner is blocked Heating circuit pump and cylinder primary pump continue runnin...

Page 41: ...ter a flame has been recognised Timer Timer DHW circulation button Output A1 is activated for 5 minutes when input E1 closes If output E1 is configured as a timer input E1 is automatically set to Circulation tester and blocked for further settings When input E1 has switched off and 30 minutes have elapsed the timer function is re enabled for the next operation Flue gas damper Flue gas damper venti...

Page 42: ...ting mode Parameter HG19 LP run on time cylinder primary pump After completing cylinder heating in summer mode the cylinder has reached the set temperature the cylinder primary pump will run on up to the maximum set run on time The cylinder primary pump will switch OFF prematurely if during the run on time the boiler water temperature cools down to a differential between boiler and set cylinder te...

Page 43: ...urner is switched on subject to the cycle block if this temperature is not achieved when heat is demanded The minimum boiler water temperature TK min is not necessarily achieved when there is no heat demand Parameter HG22 Maximum boiler water temperature TK max The control unit is equipped with an electronic boiler thermostat which has an adjustable maximum shutdown temperature maximum boiler wate...

Page 44: ...e and with BMS Constant fixed pump speed HG17 Linear linear pump speed between HG16 and HG17 corresponding to the current burner output dT speed control between HG16 and HG17 to achieve flow return temperature spread HG38 Parameter HG38 Set dT pump control unit If dT pump control unit is activated in parameter HG37 the set dT specified in HG38 applies The change to the pump speed means the dT is r...

Page 45: ...from the direct heating circuit or optionally connected mixer circuits Feed heating circuit pump ZHP as heating circuit pump for direct heating circuit Boiler thermostat set value is specified by heating circuit or mixer circuits Input E2 not assigned Note If the pressure drop of the boiler incl the pipework is 700 mbar a low loss header must be installed MM 1 System configuration 02 One or more m...

Page 46: ...l the pipework is 700 mbar a low loss header must be installed System configuration 52 BMS set boiler temperature ZHP E2 BMS C Burner is activated subject to demand from the boiler thermostat Feed heating circuit pump ZHP activated as feed pump from 2 V upwards Boiler thermostat Input E2 Control by external controller with 0 10 V 0 2 V burner OFF 2 10 V set boiler temperature TKmin HG21 TKmax HG22...

Page 47: ...ting in longer heat source runtimes and vice versa Parameter HG46 Header excess boiler water temperature The excess temperature differential between the header temperature and the boiler water temperature during header heating is selected with parameter HG46 The boiler water temperature continues to be limited by the maximum boiler water temperature parameter HG22 Factory setting see table chap 24...

Page 48: ... to Fl gas damp and HG14 output 1 must be set to Fl gas damp When the limit switch is open the burner is blocked both for DHW and central heating and for emissions test and frost protection A1 programmable output E1 programmable input e g flue gas damper HCM 2 electrical connection Limit switch Flue gas damper motor NB Flue gas damper limit switch must be potential free Otherwise the MGK 2 control...

Page 49: ... of connection line to the appliance S Nominal diameter of header A Nominal diameter of flue pipe vertical Ø Minimum duct sizes H Achievable height from duct inlet to duct outlet round rectangular 390 2x row DN250 DN250 DN315 420 mm 400 mm 50 m 3x row DN250 DN315 DN315 420 mm 400 mm 42 m 4x row DN250 470 2x row DN250 DN250 DN315 420 mm 400 mm 50 m 3x row DN250 DN315 DN315 420 mm 400 mm 17 m 4x row...

Page 50: ...recommend significantly increasing the minimum pump speed To do this increase parameter HG16 in 20 steps The higher the set header temperature the higher the pump speed that must be selected for the feed pump Set header temperatures of more than 75 C should be avoided if possible Pump speed setting Setting the eBUS address in cascade mode The eBUS address is set in the contractor menu HG10 on the ...

Page 51: ...on rating to DIN 40050 IP 44 for flue gas temperatures up to 120 C Mounting the flue gas damper Switch the ON OFF switch on the gas condensing boiler to OFF The mains terminals are live even when the ON OFF switch has been switched OFF Isolate the system from the power supply otherwise there is a risk to life from electrocution Install flue gas damper in the flue outlet of the condensate pan Dampe...

Page 52: ...sing boiler Fill the heating system to 2 bar pressure In operation the pressure must be between 1 5 and 2 5 bar Check the entire system for water leaks Fill both siphons with water Vent the heating circuit to do this switch the gas condensing boiler ON and OFF again several times Top up with water when the system pressure falls substantially Open the gas ball valve Press the reset button on the AM...

Page 53: ...shut off valves in flow and return Open the gas shut off valve Switch on the power supply Switch the system ON OFF switch on the control unit to ON Check control parameters e g system configuration HG40 If the system water pressure falls below 0 8 bar top up with water until a pressure of 1 5 to max 2 5 bar has been reached Check the condensate drain Familiarise customers with the operation of the...

Page 54: ...e differential pressure tester Switch the ON OFF switch to OFF Close the gas shut off valve Remove the differential pressure tester Re seal the test nipple with the plug Open the gas shut off valve Check the test nipple is gas tight Refit the burner hood If any screws are not tightened there is a danger of gas escaping leading to a risk of explosion suffocation or poisoning Pressure test nipple Co...

Page 55: ...screws on the burner hood top Remove the burner hood Remove screw from the test port of the condensate trap and insert measuring device Press the Emissions test quick start button on the AM display module or BM2 programming module At full load measure the CO2 value which should be 9 3 0 3 for natural gas E H LL If required adjust the CO2 content at the gas combination valve with a screwdriver as s...

Page 56: ...s type CO2 setting 2H G20 20 mbar 2S G25 1 25 mbar 2E G20 20 mbar 2H G20 20 mbar 2Ei G25 25 mbar 2Es G20 20 mbar 2H G20 20 mbar 2H G20 20mbar 2LL G25 20 mbar 2E G20 20 mbar 2H G20 20 mbar Regolato per gas Réglée sur Beállítva Réglée sur Nastaveno na Réglée sur Ajustada a gas Adjusted to Eingestellt auf Eingestellt auf IT LU FR HU FR CZ ES GB DE DE AT 50 11 8610215 C Completing the adjustments Shut...

Page 57: ... water treatment pH value set Total hardness set ________________ pH value ________________ dH 9 No chemical additives inhibitors antifreeze added 10 Boiler and system vented 11 System pressure 1 5 2 5 bar 12 Gas type and output entered on label 13 Function test carried out 14 Flue gas test Gross flue gas temperature Ventilation air temperature Net flue gas temperature Carbon dioxide content CO2 o...

Page 58: ...andinjuriesresultingfromincorrect pipe lengths excessive pressure drop premature wear with escaping flue gas and condensate or incorrect functioning e g through components working loose are excluded from our warranty if CE approved third party equipment is used If the combustion air is drawn from the duct the duct must be free from contamination Connection to a type C63 combustion air and flue sys...

Page 59: ...r fuse Pump contactor Mains contactor Booster ON OFF switch Service PCB AM BM2 contact PCB ISM7i optional Boiler water temperature sensor Condensate pump Water pressure sensor Return temperature sensor Control of variable speed heating circuit pump ZHP Gas pressure switch Fault message condensate pump jumper in plug Front panel 34 HCM2 wiring diagram Reset Reset ...

Page 60: ...valve Monitoring electrode Gas burner Ignition electrodes Connection for safety circuit provided by operator Flue gas pressure switch Fan PWM signal eHLSC sensor 1 eHLSC sensor 2 HLSC Flue gas temperature sensor 34 GBC P wiring diagram ...

Page 61: ...epaired by an expert Caution Faults must only be repaired by qualified expert personnel If a lockout fault message is acknowledged several times without fixing the cause of the problem this can lead to damage to parts or to the system The control unit automatically acknowledges faults such as defective temperature sensors or other sensors if the part concerned has been replaced and plausible test ...

Page 62: ...lue gas temperature has exceeded the limit of the TBA shutdown temperature Clean heat exchanger test sensors check flue system 8 Flue gas damper does not switch Flue gas damper contact E1 closes or does not open on demand output A1 does not activate flue gas damper Check flue gas damper and wiring check settings HG13 and HG14 9 Fault code unknown This fault is not known in this software Check soft...

Page 63: ...ug and fuse 44 Flue gas pressure switch Flue system back pressure too high Heat exchanger contaminated check flue system test flue gas damper press reset 52 Max cylinder heating time Cylinder heating takes longer than permitted Test DHW sensor cylinder sensor and sensor lead press reset 53 IO control deviatn Wind recognition severe storm insufficient ionisation signal during operation burner conta...

Page 64: ...ble press reset test water pressure sensor Button Button BCC Boiler chip card CRC Cyclic redundancy check EEPROM Rewritable memory BCU Burner control unit GCV Gas combination valve IO Ionisation signal HLSC High limit safety cut out eHLSC Electronic high limit safety cut out TL Temperature limiter TBA Flue gas high limit safety cut out TW Temperature limiter ...

Page 65: ... chip card 4 No flame At the last attempt to start the burner no flame was detected Wait for another start attempt test ignition electrode and ignition transformer test monitoring electrode test gas connection pressure 5 Flame failure during stabilisation time Flame failure after safety time Flame failure during operation Monitoring electrode faulty flue gas path blocked condensate drain blocked t...

Page 66: ...225 59 1289 94 406 10 27648 25 5000 60 1244 95 393 9 26189 26 4786 61 1200 96 382 8 24816 27 4582 62 1158 97 371 7 23523 28 4388 63 1117 98 360 6 22305 29 4204 64 1078 99 349 5 21157 30 4028 65 1041 100 339 4 20075 31 3860 66 1005 101 330 3 19054 32 3701 67 971 102 320 2 18091 33 3549 68 938 103 311 1 17183 34 3403 69 906 104 302 0 16325 35 3265 70 876 105 294 1 15515 36 3133 71 846 106 285 2 1475...

Page 67: ...0 Auxiliary electricity consumption at part load elmin kW 0 042 Auxiliary electricity consumption in standby mode PSB kW 0 011 Seasonal space heating energy efficiency ns 93 Useful efficiency at rated heat output and high temperature regime n4 88 9 Useful efficiency at 30 of rated heat output and low temperature regime n1 97 0 Standby heat loss Pstby kW 0 401 Ignition burner power consumption Ping...

Page 68: ...rements specified in the following documents 6 1 BImSchV 26 01 2010 DIN EN 437 09 2009 DIN EN 483 06 2000 DIN EN 677 08 1998 DIN EN 60335 1 10 2012 DIN EN 60335 2 102 07 2010 DIN EN 55014 1 05 2012 In accordance with the following Directives 2009 142 EC Gas Appliances Directive 2004 108 EC EMC Directive 2006 95 EC Low Voltage Directive 2009 125 EG ErP Directive 2011 65 EU RoHS Directive this produ...