Wolf ComfortLine CNK, Installation And Maintenance Instructions Manual

Page 1: ...ons ComfortLine FunctionLine Steel boilers up to 63 kW Technology serving Mankind WolfGmbH Postfach1380 84048Mainburg Tel 498751 74 0 Fax 498751 741600 Internet www wolf heiztechnik de 12 03 TV GB Part No 30 60 917 Subject to modifications ...

Page 2: ...embly 12 15 ComfortLinedecorativepanelinstallation 16 17 FunctionLine decorative panel installation 18 Fluepipeinstallation 19 Central heating boiler connections 20 DHWcylindertoboilerpipework 21 Filling the heating system 22 23 Draining the heating system 24 Pressure jet oil burner installation electrical supply 25 Initialstart up 26 Commissioningreport 27 Maintenance 28 29 Maintenancelog 30 31 S...

Page 3: ...n 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 on electrical components e g control units may only be carried ...

Page 4: ...uring installation Boiler room guidelines or Building Regulations relating to the construction and installation of central boiler rooms and fuel storage facilities Energy Savings Act EnEG and related directives Heating Systems Order DIN standards DIN 1988 Technical rules for DHW installations DIN 4701 Rulesforcalculatingtheheat demand of buildings DIN 4751 Part 3 Safety Equipment forheatingsystems...

Page 5: ...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 Country abbreviation Country Gas device category DE Germany II2ELL3B P AT Austria II2H3B P LU Luxe...

Page 6: ...NK boiler plinth 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 boiler plinth accessory Oil fired steel Unit boiler type CNU CB incl DHW cylinder and pressure jet oil burner ...

Page 7: ...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 boiler plinth accessory Oil fired steel Unit boiler type FNU FB FE incl DHW cylinder and pressure jet oil burner FunctionLine steel boilers ...

Page 8: ...r 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 Drain the boiler the DHW cylinder 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 areassubjecttoaggr...

Page 9: ...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 boiler sides and walls of 400 mm to enable the boiler door with fitted ...

Page 10: ...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 2 6 9 1 5 5 3 14 15 13 13 7 10 11 11 12 4 8 ...

Page 11: ...iler 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 ...

Page 12: ... 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 t...

Page 13: ...ing screws supplied 6 no 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 view X Insert the side casing into the boiler front pushing the spring shackles behind the boiler bracket 5 Side casing inst...

Page 14: ...to the notches in the side casing and secure with the self tapping screws 4 no supplied 8 Locking tabs Control unit bracket Secure tightly Control unit housing installation 9 Push 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 re...

Page 15: ...cket 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 th...

Page 16: ...tivepanelwiththedocument wallet on the holes and push against the front casing until the clips click into place Decorative frame CNK 17 60 single boiler Click the plastic clips 4 no black into the front casing Position the decorative frame onto the clips and push down to their end stop Decorative panel installation single boiler Decorative panel installation ...

Page 17: ...erhood 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 ins...

Page 18: ...ative panel installation For models FNU TH 17 20 25 the following additional work should be undertaken Decorative panel Click the plastic clips 4 no grey into the front casing Decorative panel installation Decorative panel ...

Page 19: ...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 the chimney stack Thoroughly seal in the flue pipe Use flue pipe elbows with clean out covers to facilitate the cleaning of the flue pipe ...

Page 20: ...emperature 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 to oxygen This boiler is only suitable for heating systems with pumped heatingcircuits Ifnoheatingcircuit pumpha...

Page 21: ...any boiler flow and return connections which are not required with caps and gaskets supplied DHW cylinder to boiler pipework Cylinder loading pump incl gaskets Ferrule with union nut Gravity brake Boiler return 2 x Hoses with gaskets Boiler flow 2x Sensor well for DHW cylinder sensor Cold water inlet Elbows DHW circulation DHW outlet Note DHW cylinder to boiler pipework ...

Page 22: ...t a water hose to the filling drain valve on site Open the cap of the quick action air vent valve of the safety assembly accessory by one revolution but do not remove the cap With the boiler in a cold condition fill the heating system slowly via the fill and drain valve until 1 bar pressure is indicated Inhibitors are not permissible Filling the heating system Filling the heating system Connection...

Page 23: ...g time approximately 2 minutes Check the entire system for water leaks Check the safety valve function Ventilate the boiler e g via an automatic air vent valve Fill the system to 1 bar pressure In operation the pressure gauge must indicate between 1 and 2 5 bar Topupwithwaterwhenthesystempressure fallsseverely Inconstantmode theboilerautomatically vents via the air vent valve Filling the heating s...

Page 24: ...FFtheheatingsystem seeoperating instructions and let it cool down to a maximum of 40 C to prevent the risk of scalding Open the drain tap on the boiler Open the radiator bleed valves Drain the heating water off Draining the heating system Connection for venting and safety flow Drain ...

Page 25: ...on is exceeded Observe the control unit installation and operating instructions Note Electrical supply Cable grommets Pressure jet oil burner installation The Unit pressure jet oil burner installation instructions are included in the burner packaging Only use bolts when securing the burner to the boiler flange whose threadpenetratestheboilerflange by a maximum of 15 mm Only use pressure jet gas bu...

Page 26: ... boiler burner fails to start properly For details about error codes see the quick start operating instructions Instruct the customer in the operation of theboiler Completethecommissioninglog and hand over the instructions Position the operating instructions in the boiler room where they are clearly visible Saving energy Instructthecustomeraboutenergy savings options Usethisopportunityforreducingt...

Page 27: ... flue gas temperature tA C Ventilation air temperature tL C Net flue gas temperature tA tL C Carbon dioxide content CO2 or oxygen content O2 Carbon monoxide content CO free of air ppm 6 Casing fitted 7 System user trained technical documents handed over 8 Confirm commissioning Commissioning steps Test values and confirmation Commissioning report ...

Page 28: ...g contractor check local regulations Switch OFF the boiler when cleaning the boiler room We would recommend a maintenance contract Pull the burner plug Release the boiler door screws Boiler door screws Front casing Front casing removal Boiler door removal Switch OFF the heating system see operating instructions and let it cool down Remove the front casing from the boiler ...

Page 29: ... sulphur deposits with the cleaning brush supplied Cleaning using the cleaning brush Open the boiler door Pull out the turbulators only for CNK 40 FNK 40 and CNK 63 FNK 63 Turbulators Turbulator Pull out the hot combustion chamber Hot combustion chamber ...

Page 30: ... boiler 2 Leak test carried out during operation 3 Function test carried out 4 Fluegastest Gross flue gas temperature tA C tA C Ventilation air temperature tL C tL C Net flue gas temperature tA tL C tA tL C Carbon dioxide content CO2 or Oxygencontent O2 Carbon monoxide content CO free of air ppm ppm 5 Confirm maintenance company stamp signature ...

Page 31: ...31 Maintenance log Date tA C tL C tA tL C ppm Date tA C tL C tA tL C ppm Date tA C tL C tA tL C ppm Date tA C tL C tA tL C ppm ...

Page 32: ... CB and FB litres h 410 490 615 FE litres h 410 490 615 Performance factor CB and FB NL60 2 7 2 8 3 0 FE NL60 2 7 2 8 3 0 Boiler water capacity litres 51 51 58 Boiler gas content litres 36 36 41 Heating water pressure drop at T 20K mbar 6 6 6 Max permissible boiler pressure bar 3 3 3 Max permissible DHW cylinder pressure bar 10 10 10 Rel standbylosses Boiler 1 8 1 6 1 2 Boiler DHW cyl 2 5 2 2 1 8 ...

Page 33: ... 4 2 3 2 4 4 4 5 58 68 68 68 105 105 41 61 61 61 130 130 6 10 10 10 22 22 3 3 3 3 3 3 10 10 10 10 10 10 1 2 1 1 1 1 0 9 0 9 0 7 2 0 1 4 1 7 1 3 1 4 1 1 5 5 5 7 7 8 150 170 190 200 190 200 170 185 170 190 165 180 34 42 47 54 47 54 54 68 68 85 85 107 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 129 149 149 149 179 179 615 665 665 665 845 845 141 169 169 169 258 258 10 10 10 15 5 15 5 15 5 83 66 8...

Page 34: ...Silencer hood depth F1 mm 336 336 336 336 345 345 345 Burner hood depth F2 mm 265 265 265 265 210 235 250 Draining filling G mm 385 385 385 360 360 364 364 Central heating return H mm 449 449 449 417 417 420 420 Smoke tube connector J mm 607 607 607 607 607 657 657 Central heating flow K mm 775 775 775 807 807 904 904 Exhaustion L mm 828 828 828 853 853 949 949 Heating connections M mm 260 260 260...

Page 35: ... 345 Burner hood depth F2 mm 265 265 265 265 210 235 250 Draining filling G mm 730 730 730 705 705 709 709 Central heating return H mm 794 794 794 762 762 765 765 Smoke tube connector J mm 952 952 952 952 952 1002 1002 Central heating flow K mm 1120 1120 1120 1152 1152 1249 1249 Exhaustion L mm 1173 1173 1173 1198 1198 1294 1294 Heating connections M mm 605 605 605 605 605 645 645 Cold water inlet...

Page 36: ...p Cylinder loading pump DHW cylinder thermostat Check the safety thermostat does not run faulty and replace if necessary Cylinder loading pump Turn the pump shaft with a screwdriver seized up Cylinder loading pump faulty Replace the DHW loading pump Heating system operational Maximum boiler temperature Raise maximum boiler temperature but room temperature set too low too low Heat up takes too long...