assembly and operating instructions - wolf...

Assembly and operating instructions

Gas condensing boilers

MGK-130MGK-170MGK-210MGK-250MGK-300

Document no. 3062880_201305 Subjecttotechnicalmodifications

These installation instructions are to be retained by the user.We cannot accept any warranty claims if these operating instructions have not been observed.

GB

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

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ContentsContents ................................................................................................. Page

Safetyinstructions .......................................................................................3-4

Standardsandregulations...........................................................................5-6

Layout MGK....................................................................................................6

Specification ...................................................................................................7

Control/Function/Operation .....................................................................8-9

Deliveredcondition/Connections ................................................................10

Installationinstructions ................................................................................. 11

Installationinstructions/Dimensions ...........................................................12

Dismantling,casing ......................................................................................13

Boilersystempipework.................................................................................14

Installation ...............................................................................................15-17

Installation,combustionairsupply/fluesystem ..........................................18

Electricalconnection................................................................................18-22

Fillingthesystem/fillingthesiphon .............................................................23

Checkingthegassupplypressure ...............................................................24

Commissioning/SettingtheBUSaddress...................................................25

Displaying/modifyingcontrolparameters....................................................26

Limitingthemaximumoutput........................................................................27

Changingthegastype/CO2 settings ......................................................28-30

Testingthecombustionparameters..............................................................31

Commissioningreport...................................................................................32

Technicalinformation,watertreatment ....................................................33-34

Systemlog ....................................................................................................35

Engineeringdata ..........................................................................................36

Engineeringinformation,combustionair/fluegasrouting......................37-43

WiringdiagramMGK-130 .............................................................................44

WiringdiagramMGK-170-300 ....................................................................45

Troubleshooting .......................................................................................46-47

Resistancetable ...........................................................................................48

Notice ......................................................................................................49-51

ECdeclarationofconformity ........................................................................52

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The following symbols and references 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 on the boiler.

Danger from '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.

"NB" indicates technical instructions that you must observe to prevent material losses and malfunctions on the boiler.

This unit is neither due to be used by persons (in-cluding children) with physical, sensoric or mental handicaps nor by users missing the required experi-ence and/or knowledge unless being supervised and instructed about its application by a person being }responsible for their security.

NB

Safety instructions

Fig.:GascombinationvalveMGK-170/210/250/300DangerfromelectricalvoltageEscapinggasmaycausepoisoningortheriskofexplosion

Fig.:Ignitiontransformer,highvoltageignitionelectrode,combustionchamberDangerfrom'live'electricalcomponents,riskofburningthroughhotcomponents

Fig.:JunctionboxMGK-170/210/250/300Dangerfromelectricalvoltage

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The following regulations and rules have to be adhered toduring installation, commissioning, maintenance and service:

Theinstallationmayonlybeoperatedintechnicallyperfectcondition.Pertur-bancesanddamagesaffectingsafetyhavetobeeliminatedatonce.

Whensetting thesanitaryhotwater temperatureabove60°Corwhenacti-vatingtheanti-legionellofunctionwithatemperatureexceeding60°Cithastoprovidedacorrespondingfreshwateradmixture(riskofscalding).

Theperfectfunctionoftheelectricalequipmenthastobecheckedperiodically.

Perturbancesanddamagesmayonlybeeliminatedbyexperttechnicians.

DamagedcomponentsmayonlybereplacedbygenuineWolfspareparts.

Prescriptedelectricalfusevalueshavetobeadheredto(seetechnicaldata).

AnydamageresultingfromtechnicalmodificationstoWolfcontrolunitsisex-cludedfromourliability.

TheappropriateEuropeanandelectricalsafetyregulationsaswellasthecor-respondingregulationsoftheEnergySupplyCompanyhavetobeadheredtoduringtheinstallationandexecutionofelectricalworks.

Itisnotallowedtoremove,shuntorinvalidatesafetyandmonitoringfacilities!

Safety instructions

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Note: Please read these instructions carefully before the installation and keep them in a safe place. Please also note the technical information in the appendix.

Requirements

Theinstallationoftheboilermustbeinaccordancewiththerelevant requirements ofGasSafety (Installation andUse)Regulations1998,HealthandSafetyDocumentNo.635(TheElectricityatWorkRegulations1989),BS7671(IEEWiringRegulations)andtheWaterSupply(WaterFitting)Regulations1999,orTheWaterBylaws2000(Scotland). ItshouldalsobeinaccordancewiththerelevantrequirementsoftheLocalAuthority, BuildingRegulations, including amendments totheApprovedDocumentsPart L and J 2002,TheBuildingRegulations(Scotland),TheBuildingRegulations(NorthernIreland)and therelevant recommendationsof the followingBritishStandards:

BS5440: Flues and ventilation of gas fired boilers notexceeding70kWnet:

- Part1:Flues - Part2:VentilationBS5449: Specificationforforcedcirculationhotwaterfor

domesticpremises.BS5546: Specification for gas hot water supplies for

domesticpremises.BS6700: Servicessupplyingwaterfordomesticusewithin

buildingsandtheircurtilages.BS6798: Specificationfor installationofgasfiredboilers

notexceeding60kWinput.BS6891: Specificationforinstallationoflowpressuregas

pipeworkupto28mm(R1")indomesticpremises(2nd familygas).

BS7593: Treatmentofwaterindomestichotwatercentralheatingsystems.

InstituteofGasEngineersPublicationIGE/UP/7/1998:"Guideforgasinstallationsintimberframedhousing"

Important:TheappliancemustbeinstalledandservicedbyacompetentpersonasstatedintheGasSafety(InstallationandUse)Regulations1998. In IE, the installationmust beinaccordancewith thecurrenteditionof I.S,813"DomesticGas Installations", the current BuildingRegulations andreferenceshouldbemadetothecurrentECIrulesforelectricalinstallation.

Whentighteningorlooseningthreadedconnectionsalwaysusesuitableopen-endedspanners(notpipewrench,orextensions,etc.).Incorrectuseand/orunsuitabletoolscanleadtodamage(e.g.gasorwaterleaks)!

Any damage or loss resulting from technicalmodifications to thecontrol unit or to thecontrolcomponentsareexcludedfromourliability.Incorrectusecanleadtoarisktolifeandlimbortoariskofmateriallosses.

Obtain the permission of your mains gas supplier and flue gas inspector prior to the installation of Wolf gas fired boilers [where appropriate].

Wolfgasfiredboilersmustonlybeinstalledbyarecognisedheating contractor. This heating contractor will also beresponsiblefortheproperinstallationandcommissioningoftheheatingsystem.

The following regulations, rules and guidelinesmust beobservedduringinstallation:- VDE0722/EN50165 Electr ical equipment of heat

generators with non-electricalheatingsystems

- DINEN12828 Heating systems in buildings,designinghotwaterheatingsystems

-EN60335-1 Safety of electrical equipment fordomesticuseandsimilarpurposes

- VDE0470/EN60529Protectionthroughhousings

- EN12831 Methodforcalculationofthedesignheat load

- EN13384 Chimneys - Thermal and fluiddynamic calculation method

Standards and regulations

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Gas condensing boiler MGK-...

GascondensingboilersaccordingtoEN437/EN483/ EN 677 and EU 90/396/EEC (Gas ConsumerEquipment), 92/42/EEC (Efficiency Directive), 2006/95/EC(LowVoltageDirective),and2004/108/EC(EMCDirective),withelectronicignitionandelectronicfluegas temperaturemonitoring, for low temperatureheatingandDHWheatinginheatingsystemswithflowtemperaturesupto90°Cand6barpermissiblepressureaccordingtoEN12828.

Standards and regulations /Layout MGK

Open flue gas condensing boilers must only be installed in a room which complies with the appropriate ventilation requirements. Otherwise there is a risk of asphyxiation or poisoning. Read these installation and maintenance instructions before installing the boiler. Also take the technical engineering information into consideration.

Fig.:Wolfgascondensingboiler

Flueoutletwithtestnipple

Heatexchangerasasectionaldesign

FlowconnectionReturnconnection

High limit safetycut-outinsidethesensorwell

Gasconnection

IgnitionelectrodeIonisationelectrode

Gasfan

Mixingchamber

Cylinderburner

Flowsensor

Gascombinationvalvewithgaspressurelimiter

Returnsensor

Waterpressureswitch

Ventilationpipe

Drainvalve

Siphon

Fluegastemperatureswitch

Flue gas pressureswitch

Ventilationairaperture

Layout MGK

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SpecificationType MGK 130 170 210 250 300

Ratedoutputat80/60°C kW 117 156 194 233 275

Ratedoutputat50/30°C kW 126 167 208 250 294

Rated heat input kW 120 160 200 240 280

Lowboileroutput(modul.)at80/60°C kW 23 27 34 39 45

Lowboileroutput(modul.)at50/30°C kW 24 30 37 44 49

Lowheatinput(modulating) kW 23 28 35 41 46

Heatinputmodulationrange % 19-100 17-100 17-100 17-100 17-100

Height A mm 1300 1300 1300 1300 1300

Width B mm 995 1355 1355 1355 1355

Depth C mm 600 600 600 600 600

Fluediameter mm 160 160 160 160 200

Combustionairsupply mm 160 160 160 160 160

Heatingflowoutsidediameter G 1½" 2" 2" 2" 2"

Heatingreturnoutsidediameter G 1½" 2" 2" 2" 2"

Gasconnection R 1" 1½" 1½" 1½" 1½"

Balancedfluerouting Type

B23,B33C33,C43C53,C63

C83

B23,B33C33,C43C53,C63

C83

B23,B33C33,C43C53,C63

C83

B23,B33C33,C43C53,C63

C83

B23,B33C33,C43C53,C63

C83

Gascategory II2H3P II2H3P II2H3P II2H3P II2H3P

Gassupplydetails:

Naturalgas H(Hi=9.5kWh/m³=34.2MJ/m³) m³/h 13.1 16.8 21 25.2 29.4

LPGP(Hi=12.8kWh/kg=46.1MJ/kg)1) kg/h 9.7 12.5 15.6 18.7 21.8

Gassupplypressure: NaturalgasE/LL mbar 20 20 20 20 20

LPGP mbar 50 50 50 50 50

Watercapacity,heatingwaterheatexchanger l 12 15.4 16 20 22

Max.permissibleboilerpressure bar 6 6 6 6 6

Max.permissibleflowtemperature °C 90 90 90 90 90

Availablegasfandraught Pa 10-200 10-150 10-150 10-150 10-150

Fluegastemperature80/60-50/30atQmax °C 65-45 65-45 65-45 65-45 65-45

Fluegastemperature80/60-50/30atQmin °C 55-35 55-35 55-35 55-35 55-35

Fluegasmassflowrate g/s 56.7 72.6 90.8 108.9 127.1

FluegasgroupaccordingtoDVGWG635 G52 G52 G52 G52 G52

Pressuredrop,heatingwater mbar 95 100 115 135 160

Electricalconnection V~/Hz 230/50 230/50 230/50 230/50 230/50

Integralfuse(mediumslow) A 5 5 5 5 5

Powerconsumption W 30-200 45-280 45-280 45-280 45-350

Protection IP40 IP40 IP40 IP40 IP40

Soundpressurelevelinsidetheinstallationroomatfullload1) dB(A) <54 <54 <54 <54 <54

Totalweight(dry) kg 195 250 271 292 313

Condensatevolumeat40/30°C l/h 12 16 20 24 28

CondensatepHvalue approx.4.0 approx.4.0 approx.4.0 approx.4.0 approx.4.0

CE ID 0085BR0117 0063BQ3805 0063BQ3805 0063BQ3805 0063BQ3805

1) Thisvalueisdependentonthegeneralsystemconditions,suchas:Type/versionofthefluesystem,sizeandnatureoftheinstallationroom

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Control / Function / Operation

ON/OFF switchThecondensingboilerisOFFinposition0.

ON/OFFswitch DHWtemperatureselector

Resetbutton

Heatingwatertemperatureselector

Illuminatedring

Thermometer

Reset Afaultisresetbypressingtheresetbuttonwhichwillalsorestartthesystem.Pressingtheresetbuttonre-activatesthesystem,iftherewasnofault.

Illuminated status indicator ring

DHW temperature selection (onlywith3-wayvalve)WhengascondensingboilersarecombinedwithaDHWcylinder,setting1-9corresponds toacylinder temperatureof15-65 °C.TheDHW temperatureselectorsettingbecomesineffectivewhenthesystemiscombinedwithadigitalroomthermostatoraweather-compensatedcontroller.Thetemperaturewillthenbeselectedatthecontroller(accessory).

91

2 8

3 7

4 65

Heating water temperature selectionSettings2-8correspond,whenfactory-set,toaheatingwatertemperatureof 20-85°C.Theheatingwaterthermostatsettingbecomesineffectivewhenthesystemiscombinedwithadigitalroomthermostatoraweather-compensatedcontroller.

2 8

3 7

4 65

Display ExplanationFlashinggreen

Standby (powersupplyON,noheatdemand)

Constantgreenlight

Heatdemand:Pumprunning; burnerOFF

Flashingyellow

Emissionstestmode

Constantyellowlight

BurnerON;flamesteady

Flashingred Fault

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Control / Function / Operation Settings

Anti-seizing pump protectionIn summermode,anyconnectedcirculationpumpoperates forapprox.30secondsafteramaximumidleperiodof24hours.

Note: Thenumberoftimesthecondensingboilercanbestartedinheatingmodeislimitedelectronically.Thislimitcanbebypassedbypressingtheresetbutton.Then,theboilerstartsimmediately,assoonasaheatdemandhasbeenissued.

Winter mode(position2to8)Inwintermode,theboilerheatstheheatingwatertothetemperatureselectedat theheatingwatercontroller.According to thepumpoperatingmode, thecirculationpumpoperatesconstantly(factorysetting)oronlyinparallelwiththeburneractivation/run-onperiod.

Summer modeWintermode isdisabledbyrotating theheatingwater temperatureselectorintoposition .Inotherwords,theboilerwillthenoperateinsummermode.Summermode(heatingOFF)meansonlyDHWheating.Frostprotectionfortheheatingsystemandpumpanti-seizingprotection,however,remainenabled.

Thermometer Thecurrentheatingflowtemperatureisdisplayed.

Emissions test modeTheemissionstestmodeisactivatedbyrotatingtheheatingwatertemperatureselectorintoposition .Theindicatorringflashesyellow.Aftertheemissionstestmodehasbeenactivated,theboilerwillheatwiththesetmaximumoutput.Anypreviouscycleblockwillbecancelled.Theemissionstestmodeterminatesafter15minutesorwhenthemaximumflowtemperaturehasbeenexceeded.Toreactivate,turntheheatingwatertemperatureselectoranti-clockwiseandthenbackintoposition .

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Delivered condition / ConnectionsDelivered condition

Thestandarddeliveryincludes:

1 Gascondensingboiler,fullywired 1 Technicalguideandinstallationinstructions 1 Operatinginstructions 4 Liftingslings

Connections

FlueoutletwithintegraltestnippleØ160/Ø200

HeatingreturnHeatingflow

Gasconnection

Combust ion ai rsupply*Ø160

Cableinlet24V

Powercableinlet230V

Condensatedrainconnection

Condensatedrainconnection(optional)

GrommetCondensatehose

*Connectionforbalancedflueoperationwithventilationairadaptor(accessory)

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Recommended minimum wall clearances

Theboilercanbepositionedclosetothewall,bothatitsbackanditsleftside.On the right side, a clearanceof at least 500mm isrequiredtoenabletheburnerremovalandinstallation.

Anadequateamountofspacemustalsobeprovidedinfrontoftheboilertoenablecleaningandservice.

Installation instructionsGeneral tips regarding location

• Theboilershouldbeinstalledonalevelsurfacewhichissubstantialenoughtocarryitsweight.

• Theboilermustbelevel(levelwithadjustablefeet).

Theboilermustonlybeinstalledinaroomthatisprotectedfromfrost.Draintheboilerandtheentireheatingsystemifthereisariskoffrost,whenthesystemhasbeenshutdown,topreventpipesfrombursting.

Boilersshouldnotbeinstalledinareassubjectto aggressive vapours, very dusty or highlyhumidconditions(workshops,laundryrooms,hobbyroomsetc.).Thispreventstheoptimumburnerfunctionfrombeingachieved.

Thecombustionairsuppliedtotheboilermustbefreefromhalogenatedhydrocarbons(e.g.as contained in sprays, solvents, cleaningfluids,paintsandadhesives).Underthemostunfavourable conditions, thesemay lead topitting of the boiler and even the flue gassystem.

Never store or use combustiblematerial orliquidsneartheboiler.

The ventilation air supplymust be ensuredand comply with local regulations or thoserelating to gas installations. When there isan insufficient supply of ventilation air, flue gas can escape leading to a risk to life (poisoning/asphyxiation).

Prior to commissioning, ensure with theappropriateauthorities,whetheraneutralisingsystemforcondensateisrequired.

NB

NB

2boilersintheinstallationroom,backtoback

2boilersintheinstallationroom

2-4boilersintheinstallationroom,sidebyside

Boilerintheinstallationroom

Dim. B MGK-130 995 mmDim. B MGK-170/210/250/300 1355 mm

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Installation information / Dimensions

Levelling the boiler with the adjustable feet

Atthefactorytheboilerisequippedwithfouradjustablefeet.

• Leveltheboilerwiththeadjustablefeet,spannersize13).

Fig.:Feet

Transportation into the installation room

Toeasethetransportation into theboiler room, liftingslingsaresuppliedwiththeboiler.

Neverusesacktrucks.NB

Dimensions

Fig.:Connectiondimensions

MGK-130

MGK-170/210/250/300

Fig.:Dimensions (Totalheightincl.connector MGK-130 ... 250 = 1460 mm MGK-300=1510mm)

Fig.:Liftingeyesforliftingslings

Liftingeyesforliftingslings

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Dismantling, casingDismantling the casing

Fig.:Dismantlingthefrontandsidecasing

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Boiler system pipeworkHeating systemflowand returnareat the topof theboiler.Forconnections,seeFig.Alwaysprovideshutoffvalvesfortheflowandthereturn.Installacheckvalvedownstreamoftheheatingcircuitpump(s)topreventincorrectcirculation.Fornewsystemswerecommendthe installationofablow-downtank(alternativelyadirtfilter)intothereturn.Foroldersystemsthisinstallationiscompulsory.

Installasafetyassemblycomprisingasafetyvalve with a response pressure of 6 bar, apressuregaugeandanautomaticairventvalve.The line between the boiler and the safetyvalvemustnotbeabletobeshutoff.Severelyexcessive boiler pressure due to excessiveboilerwatertemperatures,canbursttheboilerbody or the boiler pipework, which wouldleadtoasuddenescapeofhotwater(risk of scalding).

HeatingreturnHeatingflow

Fig.:Heatingconnections

Providesystemseparationbymeansofaheatexchanger,whenusingpipeswhicharenotimpermeabletooxygen.

Thisboilerisonlysuitableforheatingsystemswith pumped heating circuits. If no heatingcircuit pump has been installed, sufficientcirculation through the radiators cannot beensured,sothattheroomheatingcannotbeguaranteed.

NB

TheMGK is suppliedwithout circulation pump.Thepumprateofthepumptobeinstalledonsitemustbedeterminedsubjecttothesystemandboilerpressuredrop.SwitchingviatheMGK(seeelectricalconnections).

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InstallationNote:Provideadrain&fillvalveatthelowestsystempoint.

Safety equipmentTheminimumsystempressureis1.0bar.Thegascondensingboilersareapprovedexclusivelyforsealedunventedsystemsupto6bar.Themaximumflowtemperatureisfactory-setto85°Candmaybeadjustedto90°Cifrequired.Generally,theflowtemperatureis80°CforDHWoperation.Thereisnoneedforaminimumthroughputatmaximumflowtemperaturesbelow85°C.

Heating water

General requirementsThere is a danger of damage to the wall-mounted boiler leading to the escape of water, poorer heat transmission or corrosion.

- Theheatingsystemistobeflushedthroughbeforetheconnectionofthewallmountedgascondensingboilerinordertoremoveresiduesfromthepipeworksuchasweldingsputter,hemp,putty,sludgedepositsetc.

- Installation of a sieve/dirt trap in the return andregularmaintenanceofthesieve/dirttrap;seeWolfaccessories(5μm).

- Theautomatic vent of theappliancemust beopenduringoperation

- Potablewaterorsaline-freepotablewateristobeusedasfillingandsupplementarywater.Thehardnessofthesystemwatermaynotfallbelow2°dH.Thesystem-specificfillingandsupplementarywaterqualitiesaretobetakenfromthesection‘Watertreatmentplanningnotes’.

- Ahydraulicseparatormustbeprovidedforiftheentryofoxygencannotbeexcluded

- ThepHvalueoftheheatingwatermustliebetween8.2 and 8.5

- Ingeneral,fillingandsupplementarywatermustbesubmittedtoadesalization;softeningviaasingle-stageion exchanger is not permissible.The permissiblemethodsand limit values are to be taken from thesection entitled ‘Water treatment planning notes’(ATTENTION:thelimitvaluesareplant-specific)

- Inhibitorsandanti-freezearenotapproved.- A system logbook is to bemaintained; see ‘Watertreatmentplanningnotes’.

Afterproperfillingofthesystem,thesystemmustbeheatedtothemaximumandthetotalhardnessandpHvaluemeasuredagainandadjusted.Thesevaluesmustbecheckedagainandadjustedafter6-8weeks.

Additional requirements for operation without low-loss header

- SystemswithonlyoneMGK- SludgeseparatorinthedevicereturnoftheMGK- Desalizationoftheheatingwaterto2-3°dH- Control of the calorifier charging only via theMMmodule(configurations1and10)

- CalorifierchargepumpatleastDN25withaliftingheightofatleast6m

- Themax.inlettemperaturemustbesetto75°CwiththeparameterHG08

The water treatment planning notes must be observed, as otherwise damage to the system may occur leading to the escape of water.

Themanufacturercannotacceptanyliabilityfordamagetotheheatexchangerresultingfromoxygendiffusionintotheheatingwater.Inthecasethatoxygencanpenetrateintothesystem,werecommendahydraulicseparatorbyinstallinganintermediateheatexchanger.

Note from VDI 2035

Limescale formation can be influenced above all throughthetypeandmethodofcommissioning.Heatupthesystematthelowestpowerwithanevenandsufficientflowrate.Inthecaseofmulti-boilersystemsitisrecommendedtoputallboilersintooperationatthesametimesothatthetotalamountoflimecannotconcentrateontheheattransfersurfaceofanindividualboiler.

To submit pipework to a leak test:Test pressure on hot water side max. 8 bar.Before the test, close the shut-off valves in the heating circuit to the device, since otherwise the safety valve (accessory) will open at 3 bar. The device has already been tested for leaks at 6 bar in the factory.If there are leaks there is a danger of escape of water leading to damage to property.

Withaspecificsystemvolumeof>50l/KWthetotaldegreeofhardnessmustbeadjusted to2-3°dHusingadesaltingprocess.

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Installation

Fig.:Siphon

Siphon

Condensate connection Fillthesiphonwithwaterpriortocommissioning.

Otherwisethereisariskoffluegasescaping.

Whenroutingcondensateintothepublicsewersystem,observelocalregulations.Ifcondensateisdirectlyroutedtothepublicsewer,ensureventilation,sothatthepublicsewercannotaffectthecondensingboiler.

Useonlyplasticforallcondensatedrainpipes.NB

Neutralising system (accessory)

Theneutralisingsystemcanbeconnecteddirectly totheappliance.Consumptionapprox.10-30g/kWp.a.Observetheassociatedinstructions.

Trim the connection hoses, so that- the condensate can drain fully- backup loops are prevented- a perfect seal is ensured.

NB

Fig.:Neutralisingsystem(accessory)

Condensate drain, single boiler systems

WheninstallingtheMGKasanindividualappliance,fitacondensatedrain(DN160-partno.2651341,DN200-partno.2651389).Theconnectionsofthecondensatesourcecanbejoinedwiththe"Condensatehoseset"(partno.8905844)andcanbeconnectedtotheneutralisingsystem.

Fig.:Condensatehose

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Installation

• Priortoinstallation,ensurethattheboilerissettotheavailablegastype.

At the factory, the boiler is set up for natural gas H 15.0: Ws = 11.4 - 15.2 kWh/m3 = 40.9 - 54.7 MJ/m3

Whenchangingthegastype,settheapplianceinaccordancewithchapter"Changingthegastype/CO2settings".

• Onlycommissiontheappliancewhentheratedsupplypressurehasbeenreached.

Gas connectionRoutingthegaspipeaswellasmakingthegasconnectionsmustonlybecarriedoutbyalicensedgasfitter.

Removeallresiduesfromtheheatingpipeworkandthegaslinepriortoconnectingthecondensingboiler,particularlyinoldersystems.Priortocommissioning,testallpipeandgasconnectionsforleaks.Inappropriateinstallationorusingunsuitablecomponentsorassembliesmayleadtogasescaping,whichresultsinariskofpoisoningandexplosion.

InstallagasballvalvewithfireprotectioninthegassupplylineupstreamoftheWolfcondensingboiler.Otherwiseexplosionsmayoccurduringafire.Sizethegassupplylineinaccordancewithlocalregulations.

Check the gas line for tightness without the boiler.Never release the test pressure via the gas valve.

Gas fittings on the appliance may be pressure tested to 150 mbar. Higher pressure may damage the gas train, resulting in a risk of explosion, asphyxiation or poisoning.Close the gas ball valve on the gas condensing boiler to pressure test the gas line.

Mount the gas ball valve in an easily accessible place.

Connection of a Wolf cylinder,solar cylinder SEM or third party cylinder

WerecommendtheMMorKMcontrollersfromtherangeofWolfaccessoriesforoptimumswitchingofheatingcircuitandcylinderprimarypumps.

Whensizingthecylinderensurethatthelowestconstantcylinderoutputcorrespondsatleasttothelowestheatinputfromtheboiler.Asolarcylinder(withoutsolarthermalsystem)canbeconnectedtoincreasetheconstantDHWoutput.Forthis,bothinternalindirectcoilsneedtoreceiveavolumeflowinseries.Otherwiseitcannotbeassuredthatthecylinderwillbefullyheatedup.

Condensateliftingsystem(accessory)

Condensate lifting system (accessory)

TheWolfcondensate liftingsystem is fullywiredandcanbeintegratedintotheMGK.Thepowersupplyandthealarmoutputof thecondensate liftingsystemareconnectedtotheboilercontrolunit.6mPVChosefordrainingoffthecondensateisincluded.

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Installation, combustion air supply / flue system / electrical connection

Only use original Wolf components or CE-designated flue systems to create flue lines. Observe the technical information regarding ventilation air supply / flue systems prior to installing the flue or the ventilation air connection.

Differentcountrieshavedifferentregulations.Wewouldthereforerecommendyoucontacttheappropriateauthoritiesincludingthelocalfluegasinspector,tochecklocalrequirementspriortotheboilerinstallation.

NB

With low outside temperatures, thewatervapourcontainedinthefluegasmaycondenseandformiceontheflue.Useon-sitemeasurestopreventicefromfalling,e.g.theinstallationofasnowcatchergrille.

The boiler power supply terminals are 'live' even when the ON/OFF switch has been switched OFF.

General information, electrical connection The installation must be carried out by a

licensed electrical contractor. Observe local electrical regulations and those of the local power supply utility.

Fig.:ControlunitMGK-170/210/250/300

24VControlunit 230VJunctionbox

Do not route sensor leads with 230 V mains cables.

Flue

Fig.:Example:Ventilationair/fluesystem

Combustionair

Integraltestnippleforcheckingthefluegas

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Electrical connection

Installation information, electrical connection, mains

- Isolate the system from the power supply beforeopening.

- Opentheterminalbox.- Insertthestrainreliefintotheholesprovided.- Stripapprox.70mminsulationoffthepowercable.- Pushthecablethroughthestrainreliefandsecurethestrainrelief.

- PullofftheRast5plug.- Terminate theappropriatecoresat theRast5plug.Leavethecoresfortheearthconductorgr/yeapprox.10mmlongerthanthoseforLandN.

- Pushtheinsertsbackintotheterminalboxcasing.- PushtheRast5plugsbackintotheircorrectpositions.

Fig.:Junctionbox

Fuse5A(fast)

Rast5plug

Strainrelief

Terminal box

Thecontrol,regulatingandsafetyequipmentarefullywiredandtested.You only need to connect the power supply and theexternalaccessories.

Power supplyCreateapermanentconnectionforthepowersupply.

Providethepowersupplyviaamainisolator(heatingsystememergencystopswitch) thatensuresat least3mmcontactseparationforallpoles.

Power cable, flexible, 3 x 1.0 mm² or rigid, up to 3x1.5mm².

Powersupply230V AC/50Hz

Powersupply,heatingcircuitpump230VAC/50Hz/max.400VA

Programmableoutput230VAC/50Hz

Programmableinput,floating

Outsidetemperaturesensor

BUS(Controller,radioclock,AFwithradioclock,receiver,outside

radiosensor)

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 through ‘l ive’ electrical components. Never touch electrical components or contacts as long as the gas condensing boiler has not been isolated from the power supply. Risk to life.

Changing a fuse

Fig.:Terminalboxcoveropen

Fuse

NB:

The electrical installation may only be executed by an authorized company. VDE-standards and local regulations of the En-ergy Supply Company have to be adhered to.

20 3062880_201305

Fig.:Connection,heatingcircuitpump

Heating circuit pump connection (230 V AC; max. 400 VA)

Insertthecableglandsintotheterminalbox.Insertandsecurethecablethroughthecableentry.Connecttheheatingcircuitpump230VACtoterminalsL1,Nand .


Wiring diagram, ventilation air damper (not for MGK-130)

Schaltplan fürZuluftklappeMGK 170-250

1

von 1

AFE1 eBUS+ - 1 2a b

Netz Z A1N

N

NL1L1 L1

o o o o o o

MT3,15 A

F1

1 2 1 21 2L1N L1L1 NN L1N L1N

Supply air damper with servomotor

ElektroanschlußkastenMGK

24VDC

Limit switch

NB:Limit switch for supply air damper must be floating!Otherwise the MGK control unit will be destroyed.

Note:The contractor parameter

(input 1)(factory setting for supply air damper) and

(input 1)(factory setting for supply air damper)

With the contact open, the burner remains blocked for DHW and central heating, even for emissions test and frost protection.

HG13/GB13 must be set to 5

HG14/GB14 must be set to 7

Power supply 230 V AC

brbl

M230V~

51-10-018-045Benennung Zeichnungsnummer

CorelDraw

Art.- / Materialnummer

Blatt

Bl.NameName Ausg.Ausg. ÄnderungÄnderung AntragAntrag DatumDatum

TerminalboxMGK

5 A

213062880_201305


Code Explanation0 No function

OutputA1isnotswitched1 DHW circulation pump 100%

OutputA1isswitchedbycontrolaccessory(BM)ifDHWcirculationhasbeenenabled.OutputA1isconstantlyactivatedwhennoaccessorycontrollerisinstalled.

2 DHW circulation pump 50% OutputA1isswitchedbycontrolaccessories(BM)incyclesifDHWcirculationhasbeenenabled.5minutesONand5minutesOFF.OutputA1isconstantlycycledin5minuteintervalswhennoaccessorycontrollerisinstalled.

3 DHW circulation pump 20% OutputA1isswitchedbycontrolaccessories(BM)incyclesifDHWcirculationhasbeenenabled.2minutesONand8minutesOFF.OutputA1cyclesconstantlywhennoaccessorycontrollerisinstalled.

4 Alarm output OutputA1isswitchedafterafaultandafterexpiryof4minutes.

5 Flame detector OutputA1isswitchedafteraflamehasbeendetected.

6 3-way valve OutputA1isswitchedduringcylinderheating.

7 Ventilation damper OutputA1isswitchedfirstpriortoeachburnerstart.Theburnerwill,however,onlybeenabledafterinputE1hasbeenclosed.

Important:Inanycase,inputE1mustalsobeprogrammedas"Ventilationdamper"

ThefeedbacktoinputE1mustbemadewithafloatingcontact.Otherwise,useanon-siterelayforpotentialseparation.

8 External ventilation OutputA1isswitchedinversetothegascombinationvalve. SwitchingOFFexternalventilation(e.g.extractorfan)duringburneroperationisonlyrequired,iftheboilerisoperatedasanopenfluesystem.

9 External gas valve OutputA1isswitchedinparalleltothegascombinationvalve.

The functionsofoutputA1canbescannedandadjustedwitheBUS-enabledWolfcontrolaccessories.ThefollowingfunctionscanbeallocatedtooutputA1:

Fig.:ConnectionoutputA1

Connection output A1 (230 V AC; 200 VA)Insertthecableglandsintotheterminalbox.Insertandsecuretheconnectingcablethroughthecablegland.TerminatetheconnectingcableatterminalsL1,Nand .TheparametersforoutputA1aredescribedinthetable.

22 3062880_201305

Electrical connectionConnection input E1 (24 V)Connecttheconnectingcableforinput1atterminalsE1inaccordancewiththewiringdiagram;firstremovethejumperbetweenaandbfromtherespectiveterminals.

Fig.:Connection,roomthermostat

Floatingconnection

Code Explanation

0 Without functionInputE1isnottakenintoconsiderationbythecontrolunit.

1Room thermostat WithopeninputE1,heatingoperationwillbeblocked(summermode),independentlyofanydigitalWolfcontrolaccessories.

2Maximum thermostat / system pressure switch AclosedcontactisaprerequisiteforenablingtheburnerinheatingandDHWmode.Whenthecontactisopened,theapplianceswitchestheburneroffandthepumprun-onstarts.

3 Not allocated

4Flow switchOptionalconnectionforanadditionalwaterflowswitch.InputE1mustbeclosedwithin12secondsafterthepumphasbeenswitched.Wherethisisnotthecase,theburnerwillbeswitchedOFF,andfault41willbedisplayed.

5 Monitoring, ventilation air damper (factory setting E1)SeeparametersofoutputA1,no.7ventilationdamper.

8 Burner disablement (operation without burner) Operationwithoutburner Closedcontact,burnerlockout Heatingcircuitpumpandcalorifierchargepumpruninnormalmode Theburnerisenabledinchimneysweepmodeandforfrostprotection Openedcontactenablestheburneragain

The functionsofinputE1canbescannedandadjustedwitheBUS-enabledWolfcontrolaccessories.ThefollowingfunctionscanbeallocatedtoinputE1:

Connection, digital Wolf control accessoriesOnly connect control units from theWolf accessoryrange. Each accessory is supplied with its ownconnectiondiagram.Useatwo-corecable(cross-section>0.5mm²)astheconnecting cable between the control unit accessoryandthecondensingboiler.

Fig.:DigitalWolfcontrolaccessoriesconnection(eBUSinterface)

Connection, outside temperature sensorThe outside temperature sensor for digital controlaccessoriesmaybeconnectedtotheterminalstripoftheAFboiler connection, or the terminal strip of thecontrolaccessories.

Fig.:Connection,outsidetemperaturesensor

233062880_201305

Filling the system / filling the siphonFillthesystemandventitcorrectlyinlinewiththedetailsinthechapter"Watertreatment"toensuretheperfectfunctionofthecondensingboiler(seepage30).

Beforeconnectingthegascondensingboiler,flushtheheatingsystemtoremoveresiduessuchasweldingpearls,hemp,putty,etc.fromthepipework.

• Thegastapmustbeshut.

• Opentheairventvalves.

• Openallheatingcircuits.

• Openallradiatorormixervalves.

• Slowlyfilltheentireheatingsystemandboilerwhencold,forexampleviatheBDFvalveatthereturn,toapprox.2barpressure.

Inhibitors are not permissible.

• Opentheflowvalvesonthecondensingboiler.

• Filltheheatingsystemto2barpressure.Inoperation,thepressuregaugemustindicatebetween1.5and5.5bar.

• Checktheentiresystemforwaterleaks.

• Removethesiphon.

• Fillthesiphonwithwater.

• Refitthesiphon.

• Start the condensing boiler, set the heating waterselector to position "2" (pump running, illuminatedstatusindicatorringconstantlygreen).

• Vent the heating circuit; for this, switch the gascondensingboilerONandOFFagainseveraltimes.

• Top upwithwaterwhen the systempressure fallssubstantially.

• Openthegasballvalve.

• Presstheresetbutton.

NB

NB

Note: In constant mode, the heating circuit isautomatically vented via the air vent valve(accessory).

Fig.:Siphon

Siphon

Fig.:Controlunitoverview

ON/OFFswitch ThermometerResetbutton

Fig.:BDFvalve

BDFvalve Waterpressureswitch

Thecondensatehoseattachedtothesiphonmustnotformalooporrollup,otherwisetheoperationmightbeimpaired.

NB

24 3062880_201305

Checking the gas supply pressure (Gas flow pressure)

• SettheON/OFFswitchto"0".

• Openthegasshut-offvalve.

• Releasetheplugattestnippleandventthegassupplyline.

• Connectthedifferentialpressuretesterattestnippleto"+",with"-"againstatmosphere.

• SwitchONtheON/OFFswitch.

• Afterstartingtheboiler,checkthesupplypressureatthedifferentialpressuretester.

Work on gas components must only be performed by a licensed gas fitter. Work which is carried out incorrectly may lead to gas escaping, resulting in a risk of explosion, asphyxiation or poisoning.

Checking the gas supply pressure

• SwitchOFFtheON/OFFswitch.Closethegasshut-off valve.

• Remove the differential pressure tester and re-seal the test nipple with plug .


• Checkthetestnippleisgas-tight.

• Closetheboileragain.

• Check and if necessary amend the type plateregardingthegastype.

Natural gas: If the supply pressure (flow pressure)

lies outside the 18 to 25 mbar range, adjustments must not be carried out and the boiler must not be taken into use.

NB

If any screws are not tightened, there is a danger of gas escaping, leading to a risk of explosion, asphyxiation or poisoning.

Fig.: Testnippleforcheckingthegassupplypressure

MGK-170/210/250/300MGK-130

Gas-Brennwert-Heizgerät

1234567890Herstellnummer

Nennwärmebelastung

HeizenNennleistungHeizen50/30°CHeizen80/60°C

Netzanschluß

Q=28-160kW

P=30-167kWP=27-156kW

90°C

230V~50Hz280 WElektrischeLeistungsaufnahme

Schutzart

Max.VorlauftemperaturMax.BetriebsdruckHeizkreis PMS=6bar

IP40

WasserinhaltHeizwärmetauscher

087511121234567890

0875

1112

1234

5678

90

875111

2Art.-N

r.

CE-0063BQ3805

A/D/CH123

456789

0Herst.

-Nr.

08

Typ MGK-170

NOx Klasse 5

Kategorie

-G20-20mbar

Bestimmungsland

Eingestelltauf

B23,B33,C33,C43,C53,C83C63gem.Montageanleitung

15 l

Warmwasser Q=28-160kW

AbgaswertegruppenachDVGW635 G 52

Art

8751156 06/08

DE/AT/CH

DerKesseldarfnurineinemRauminstalliertwerden,derdiemaßgeblichenBelüftungsanforderungenerfüllt.LesenSiedieMontage-bzw.BetriebsanleitungbevorSiedenKesselinstallierenbzw.inBetriebnehmen.

MGK-1

70 E/H

II2ELL3PDE

II2H3PAT

2H2E

CHI2H2H

Fig.: TypeplateMGK

Fig.: ConversiontypeplateMGK

253062880_201305

Saving energy

• Instruct the customer about energy saving options.

• Refer your customer to section "Information for energy efficient operation" in the operating instructions.

Only qualified personnel must carry out the commissioning and operation of the boiler, as well as instruct the user.

Fig.:Controlunitoverview

ON/OFFswitch

ThermometerResetbuttonIlluminatedring

Commissioning

• Check that the power supply has been switched OFF.

• Check the boiler and system for leaks.

Prevent water leaks.

• Checklocationandseatingoffittedcomponents.

• Checkallconnectionsandcomponentlinksforleaks.

Iftightnesscannotbeensuredthenthereisariskofwaterdamage.

• Checkthatallfluegasaccessorieshavebeencorrectlyinstalled.

• Opentheshut-offvalvesinflowandreturn.


• Switchthepowersupply'live'.

• SwitchONthesystemON/OFFswitchonthecontrolunit.

• Checktheignitionandtheregularflamestructureoftheburner.

• Ifthesystemwaterpressurefallsbelow1.5bar,topupwithwateruntilapressureof2.0tomax.5.5barhasbeenachieved.

• Theilluminatedringshowsagreencolour,iftheboiler

Setting the BUS address for multiple heating appliances

Whenoperatingseveralheatingappliances,settheBUSaddressinconjunctionwithaKMcontrolunitinaccordancewiththetable.

Holddowntheresetbutton;after5seconds,thecorrespondingflashingcodewillbedisplayed(seetable).Selectthecorrespondingaddresswiththe"DHWtemperaturerotaryselector";thenreleasetheresetbuttonagain.

BUS address Rotary selector positionDHW

Illuminated ring indication

1 1 flashingred

2 2 flashingyellow

3 3 flashingyellow/red

4 4 flashingyellow/green

5 5 flashinggreen/red

0 6 flashinggreen (factorysetting)

startscorrectly.

• Checkthecondensatedrain.• Familiarise the customerwith the operation of theboilerusingtheoperationand/orassembly instruc-tionsandpointoutanynecessarytreatmentoffillingandsupplementarywater

• Completethecommissioningreportandhandovertheinstructionstothecustomer.

26 3062880_201305

Displaying / modifying control parameters

Modifications must only be carried out by a recognised heating contractor or by Wolf customer service.

Incorrect operation can lead to system faults.When selecting parameter GB 05 (frost protection, outside temperature) note that frost protection is no longer ensured at temperatures below 0 °C. This can lead to heating system damage.

NB

NB

To prevent damage to the heating system, cancel night setback when outside temperatures fall below −12 °C. If this rule is not observed, ice may build up on the flue outlet which may cause injury or material losses.

You can check the output data for the boiler on the type plate.

ThecontrolparameterscanbemodifiedordisplayedviacontrolaccessorieswitheBUScapability.Forprocedures,checktheoperatinginstructionsoftherelevantaccessories.

Parameter Setting range Factory setting Ind. setting

Column 1 Column 2

GB01 HG01 Flowtemperaturehysteresis 5 to 30 K 8 K

HG02 Lowerfanspeed 20 to 100% 20%

HG03 Higherfanspeed,DHW 20 to 100% 100%

GB04 HG04 Higherfanspeed,centralheating 20 to 100% 100%

GB05 A09 Frostprotectionlimit -10to+10°C +2°CWithconnectedoutsidetemperaturesensorandinsufficienttemperature, pumpON

GB06 HG06 Pumpoperatingmode 0 to 1 00→PumpONinwintermode1→PumpONwithburneroperation

GB07 HG07 Boilercircuitpumpsrun-ontime 1 to 30 min 1 minGB08or

HG08HG22

Maximumlimit,boilercircuitTV-maxappliestoheatingmode 40to90°C 85°C

GB09 HG09 Burnercycleblock 1 to 30 min 7 min

Appliestoheatingmode

HG10 eBUSaddress(displayonly) 0 to 5 0

HeatsourceBUSaddress

GB13 HG13 ProgrammableinputE1 0 to 5 5Variousfunctionscanbeassignedto input E1(Seechapter"ConnectioninputE1")

GB14 HG14 ProgrammableoutputA1 0 to 15 7VariousfunctionscanbeassignedtooutputA1(Seechapter"ConnectionoutputA1")

GB15 HG15 Cylinderhysteresis 1 to 30 K 5 K

Switchingdifferentialforcylinderre-heatingHG21 MinimumboilertemperatureTK-min 20to90°C 20°C

Column1:ControlaccessoriesART,DWT,DWTM,DWTKColumn2:ControlaccessoriesWRS(Wolfcontrolsystem)

273062880_201305

MGK-130 / MGK-170 / MGK-210 / MGK-250 / MGK-300Output setting (parameter GB04)

TheoutputsettingcanbemodifiedwithWolfcontrolaccessorieswitheBUScapability.Theheatingoutputwillbedeterminedbythegasfanspeed.Byreducingthegasfanspeedinaccordancewiththetable,themaximumoutputwillbematchedat80/60°CtonaturalgasH.

Limiting the maximum output

MGK-130Output (kW) 23 31 38 46 53 61 68 76 83 91 99 106 114 121Display value (%) 20 25 29 34 38 43 47 52 56 61 65 70 75 100


MGK 210Output (kW) 34 40 55 70 85 100 115 130 145 160 175 190 200Display value (%) 20 23 30 37 45 52 59 66 73 81 88 95 100

MGK 250Output (kW) 40 55 70 85 100 115 130 145 160 175 190 205 220 240Display value (%) 20 26 32 38 44 50 56 62 68 74 80 86 92 100


Table:Outputsetting

Limitingthemaximumoutputrelativetoaflow/returntemperatureof80/60°C

Settings for parameter GB04 with eBUS-enabled Wolf connection accessories in [%]

Max

imum

out

put i

n [k

W]

28 3062880_201305

Changing the gas type / CO2 settings Adjusting the gas / air connection Carry out the adjustments in the following

sequence: At the factory, the gas combination valve has been set up for natural gas E (G20). Only adjust the gas combination valve after the system has been changed to a different gas type.

NB

Conversion MGK-170/210/250/300 to PAseparateconversionkitwithboilercodingcardisrequiredforthisconversion.Observetheinformationintheconversioninstructionssupplied.

AstandardadjustmentattheGCVisalwaysrequiredforachangeofgastypetobeeffective.

Make the standard settings at the gas combination valve in accordance with the table. Otherwise there is a risk of damage to the appliance.

Carefullyturnthescrewfullyhomeandthenundoasfollows:Standard setting for different gas types: Turnanti-clockwiseConverting the MGK-130 to LPG P

Aseparateconversionkitwithgasrestrictor,gascombinationvalveandboilercodingcardisrequiredforthisconversion.Observetheinformationintheconversioninstructionssupplied.

Natural gas HType Zeropoint

adjustingscrewMGK-130 1¾turns Gasrestrictor1000

ConversionkitsMGKLPGType Partno.conversionkitMGK-130 87 51 351MGK-170 and MGK-250 87 51 293MGK-210 87 51 295MGK-300 87 51 298

OverviewboilercodingcardsMGKType Partno.

boilercodingcardfornaturalgasH

Partno. boilercodingcardforLPGP

MGK-130 27 44 358 27 44 356MGK-170 27 44 238 27 44 354MGK-210 27 44 237 27 44 355MGK-250 27 44 170 27 44 354MGK-300 27 44 359 27 44 357

For other standard settings relating to the gas type, see the conversion instructions.

Natural gas HType Zeropoint

adjustingscrewThroughputadjustingscrew

MGK-170 2turns 1½turnsMGK-210 1½turns 1¾turnsMGK-250 1½turns 1¾turnsMGK-300 1¾turns 2turns

293062880_201305

B) CO2 adjustment at the lower load (soft start)

• Restart the gas condensing boiler by pressing the"Resetbutton".

• Check and if necessary correct the CO2 content approx.30safterburnerstartusingtheCO2tester,byfineadjustingthezero point adjusting screw in accordancewiththetable.Makethisadjustmentwithin120softheburnerstart.Ifnecessary,repeatthestartphase for setting procedures by pressing the resetbutton.

•Turn clockwise - raises CO2 content•Turn anti-clockwise - lowers CO2 content

Appliance open(withoutcasing)atlower loadNaturalgasH9.0% ± 0.2%

Changing the gas type / CO2 settingsA) CO2 setting at the upper load (emissions test mode)

• Undothefourscrewsfromthefrontcasingandremovethecasing.

• Removethescrewfromthe"fluegas"testport.

• InsertthetestprobeoftheCO2testinstrumentintothe"fluegas"testport.

• Turnthetemperatureselectorto "Emissionstest" . (Illuminatedstatusindicatorringflashesyellow.)

• ChecktheCO2contentatfullload,andcomparetheactualvalueswiththoseinthetablebelow.

• CorrecttheCO2settingasrequiredusingthegas throughput adjusting screwonthegascombinationvalveinaccordancewiththetable.

• Turn clockwise - lowers CO2 content• Turn anti-clockwise - raises CO2 content

• Terminatetheemissionstestmodebyreturningthetemperatureselectortoitsoriginalposition.

Fig.:Fluegastestattheintegraltestport

Testport,fluegas

Fig.:Gascombinationvalve

Gasthroughputadjustingscrew(undercover)Allenscrew3mmfortheMGK-170-MGK-300)SlottedscrewfortheMGK-130

MGK-170/210/250/300MGK-130

Appliance open(withoutcasing)atupper loadNaturalgasH9.2% ± 0.2%


Zeropointadjustingscrew,Tx40Torx(underthecover)

MGK-170/210/250/300MGK-130

30 3062880_201305

Changing the gas type / CO2 settingsD) Completing the adjustments

• Shutdowntheboilerandclosethetestportsandhosenipples;checkfortightness.

C) Checking the CO2 setting

• Aftercompletingthework,refitthecasingcoverandchecktheCO2valuewiththeapplianceclosed.

ObservetheCOemissionswhilstmakingCO2adjustments. Thegascombinationvalveisincorrectlyadjusted,iftheCOvalueis>200ppm,whentheCO2valueiscorrect.

Takethefollowingsteps:

•RepeattheadjustingprocessfromsectionA.

• ThecondensingboileriscorrectlyadjustedwhentheCO2valuescorrespondtothoseinthetablebelow.

Appliance closed(withoutcasing)atupper loadNaturalgasH9.3% ± 0.3%

Appliance closed(withcasing)atlower loadNaturalgasH9.1% ± 0.3%


MGK-170/210/250/300MGK-130

Zeropointadjustingscrew,Tx40Torx(underthecover)

Gasthroughputadjustingscrew(undercover)Allenscrew3mmfortheMGK-170-MGK-300)SlottedscrewfortheMGK-130

313062880_201305

Testing the combustion parametersTestthecombustionparameterswiththeboilerclosed!

Testing the flue gas parameters

Flue gas can escape into the installation room, if the test port is left open. This results in a risk of asphyxiation.

- Removethescrewfromthe"fluegastestport".- Startthegascondensingboilerandturnthetemperatureselectortotheemissionstestsymbol[chimneysweep]. (Theindicatorringflashesyellow.)

- Insertthetestprobe.- Readofffluegasvaluesandentertheminthecommissioningreport.- Afterthetesthasbeencompleted,removethetestprobeandclosethetestportagain.Ensurethescrewsareseatedfirmly.

- Returnthetemperatureselectorintoitsoriginalposition.

Testing the combustion air

- Holdthetestprobeintothecombustionairsupplyandcalibratethetesteror

- forbalancedflueoperation,insertthetestprobeintotheventilationairadaptor.

Startthegascondensingboilerandturntheheatingwater temperatureselectortotheemissionstestsymbol.

(Thestatusdisplayringflashesyellow.) -Checkthetemperatureandenteritinthecommissioningreport. -Afterthetesthasbeencompleted,switchtheboilerOFF,remove thetestprobeandclosethetestport.Ensurethescrewsare seatedfirmly. -Returnthetemperatureselectorintoitsoriginalposition.

ON/OFFswitch Temperatureselector

"Inletair"testport

Testport, fluegas

32 3062880_201305

Commissioning reportCommissioning steps Test value or confirmation

1.) Gastype NaturalgasH□LPG□Wobbeindex___________kWh/m³Calorificvalue,heating___________kWh/m³

2.) Gassupplypressurechecked? □3.) Gasleaktestcarriedout? □4.) Balancedfluesystemchecked? □5.) Waterconnectionscheckedforleaks? □6.) Siphonfilled? □7.) Systemflushed? □8.) Systemfilledandwatertreatmentcarriedoutaccordingto

’Watertreatmentplanningnotes’? pHvalueadjusted Totaldegreeofhardnessadjusted

□

________________pHvalue ________________°dH

9.) Hasthesystembeenfilledinacc.withthetechnicalinformationregardingwatertreatment?

□

10.)Boilerandsystemvented? □11.) Systempressure1.5-2.5bar? □12.)Enteredgastypeandoutputontolabel? □13.)Functiontestcarriedout? □14.)Fluegastest

Grossfluegastemperature

Inletairtemperature

Netfluegastemperature

Carbondioxidecontent(CO2)oroxygencontent(O2)

Carbonmonoxidecontent(CO)

_____________ tA[°C]

_____________ tA[°C]

_____________(tA - tL)[°C]

_____________ %

_____________ ppm

15.)Casingfitted? □16.)Systemusertrained,documentationhandedover? □17.)Confirmcommissioning? _____________ □

333062880_201305

Technical information, water treatmentBeforecommissioning,thesystemmustbethoroughlycleaned/flushedthroughandasludgefilter(5μm),e.g.Wolfaccessories, installed in the returnand indirectproximitytotheboiler.The filling and supplementarywatermay be treatedonlybymeansofadesaltingprocedure.Thenecessarydegreeofwatertreatmentcanbetakenfromthetable‘Maximumpermissibletotalhardness’.Thetotaldegreeofhardnessofthesystemwatermaynotfallbelow2°dH;thiscorrespondstoaconductanceof ≈60μS/cm.Themax.permissible total degreeofhardnessandthecorrespondingmax.conductancearesystem-specificandmustbecalculated(seealso thetable‘Maximumpermissibletotalhardness’).Tothisendthesaline-freewater(conductance<=30μS/cm)mustbemixedwithuntreatedpotablewater.The addition of chemical agents as well as limeelimination via single-stage ion exchangers is notpermissible,sinceotherwisedevicedamagecanoccurleadingtotheescapeofwater.Werecommendregularemptyingofthesludgefilterandthemaintenanceofasystemlogbook.

Permissiblemethods:- Deionisation viamixed-bed cartridges.These aremulti-stageionexchangers.WerecommendcartridgesfromtheGrünbeckorJudocompaniesfortheinitialfillingandlaterifrequired.

- Deionisationbyreverseosmosis- Toppingupwithdistilledwater

Limit values in relation to the specific system volume VA (VA = system volume / smallest individual power)Conversion of total hardness: 1 mol/m³ = 5.6 °dH

Tota

l heating

power

Vsys≤10l/kW Vsys>10l/kWand<40l/kW Vsys≥40l/kW

Totalhardness/ totalalkalineearths

Conduct-ance


Conduct-ance


Conduct-ance

[kW] [°dH] [mol/m³] LF[μS/cm] [°dH] [mol/m³] LF[μS/cm] [°dH] [mol/m³] LF[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 -100 2 - 3 0,36-0,54 60 -100

4 >600 2 - 3 0,36-0,54 60 -100 2 - 3 0,36-0,54 60 -100 2 - 3 0,36-0,54 60 -100

*)forcirculatingwaterheaters(<0.3l/KW)andsystemswithelectricalheatingelements

Gradualtighteningofthespecificationsduetothespecificsystemvolume (Vsys=systemvolume/lowestindividualpowersetting)andthetotalheatingpower

Thetotalfillingquantityofwateroverthelifetimeoftheappliancemaynotexceedthreetimesthenominalvol-umeoftheheatingsystem.

Warning:thetotalhardnessmaynotfallbelow2°dH

Treatment of the heating water based on VDI 2035:We recommenda pH value of between 8.2 and 8.5for the heatingwater also in the case of combinedinstallationsofdifferentmaterials.Awater analysismust be requested from thewatersupplycompany.Thismustbeusedtocheckwhetherthetotalhardnessislowenough.WithaspecificsystemvolumeVsys,specific>=10 l/KWthe next smaller value from the following tablemustbe applied,withVsys,specific >= 20 l/KW the next-but-onesmallervalueandwithVsys,specific>=40 l/KWthesmallestvalue.With a specific systemvolumeof >50 l/KW the totaldegreeofhardnessmustbeadjustedto2-3°dHusingadesaltingprocess.Thiscorrespondstoaconductanceof60-100μS/cm.Iftheboilerisintegratedintothesystemwithoutalow-lossheader,thetotalhardnessmustbeadjustedto2-3°dH(conductance=60-100μS/cm).

34 3062880_201305

Technical information, water treatmentExample:

Systempower=170KW;

SystemvolumeVsystem=4000l; VolumeofthesupplementarywaterVsupplement = 1000 l

TotalhardnessofthepotablewaterCpot.water=18.5°dH; MaximumpermissibletotalhardnessCmax=8.4°dH

Systempower=170KW; SystemvolumeVsystem=4,000l; VolumeofthesupplementarywaterVsupplement=1,000l

Vsys,specific=4000l/170KW=23.53l/KW

TotalhardnessofthepotablewaterCpot.water=18.5°dH;

MaximumpermissibletotalhardnessCmax=8.4°dH

Proportionofthefillingwatertobetreated: A=100%-(8.4-0.1)/(18.5-0.1)x100%=54.9%

54.9%ofthefillingandsupplementarywatermustbedesalted.

Vtreated=54.9%x(4,000l+1,000l)=2,746l

Whenfillingthesystem,2,745ldeionisedwatermustbefilled.Subsequently,thesystemcanbetoppeduptoVmaxwithpotablewater.

Whentoppingupitmustbecheckedregularlythatthemaximumpermissibletotalhardnessisnotexceeded.

Example:

Systemwitha170KWboiler;

SystemvolumeVsystem= 4000 l

Vsys,specific=4000l/170KW=23.5l/KW

This is larger than 10 l/KW, hence stage 3must beselectedinsteadofstage2.Thefillingandsupplementarywater must lie within the range of 2 to 8.4 °dH Ifthetotalhardnessoftheuntreatedpotablewateristoohigh,partofthefillingandsupplementarywatermustbedesalted:

A%saline-freewatermustbeadded:

A=100%-(Cmax-0,1°dH)/(Cpot.water-0.1°dH)x100%

Cmax Maximumpermissibletotalhardness in°dH Cpot.water Totalhardnessoftheuntreatedpotable waterin°dH

We recommend that you include the supplementarywater expected for the initial filling in the calculation.Untreatedpotablewatercanthenbeusedfortoppinguplater.

Vtreated=Ax(Vsystem+Vsupplement)

Inthecaseoflargesystemsinstage4thesupplementarywatermaynotbeincludedinthecalculationfortheinitialfilling.

Vtreated=Ax(Vsystem)

353062880_201305

System log

PlanningLocationBoileroutput QK1 kW

QK2 kWQK3 kWQK4 kW

Lowestboileroutput QBmin kW Lowestboileroutputforthesystem

Systemoutput QB,tot kW QB,tot=QB1 +QB2 +QB3 +QB4

Systemvolume Vsystem lMaximumexpectedtop-upwatervolume

Vtop-up l Totalvolumeexpectedduringthesystemservicelife

Volumeoffillandtop-upwater

Vmax l Vmax=Vsystem+Vtop-up

TotalhardnessoftheDHW

CDHW °dH e.g.fromananalysisofthewatersupply

Checkingthespecificsystemvolume

VA,specific l/kW VA,specific=Vsystem/QKminimum greater/lessthan20l/kW

Permissibletotalhardness

Cmax °dH Maximumpermissibletotalhardnessaccordingtothetable

ProportionofdesalinatedDHW

A % A=100%–[(Cmax–0.1°dH)/(CDHW–0.1°dH)]x100%

Fillwatertobetreated Vtreatment l Vtreatment=AxVmaxorVtreatment = A xVsystematstage4

Check: WatervolumeV> Vmax ? □ Yes □ NoIfthewatervolumeVisgreaterthanVmax,topupwithdesalinatedwater.

Commissioning: Fill and top-up water volumesCommissioningbyMeterreadingbeforefirstfillZold in l

Date Explanation Abbreviation Meterreading Znew in l

WatervolumeV=Znew- Zold in l

Total hardnessin°dH

pHvalueofsystemwaterafterheatingprocessandsufficientflushing

Signature

Softenedfillwater Vtreatment 0,1

Untreatedfillwater VuntreatedTop-upwater Vtop-up,1

Top-upwater Vtop-up,2









36 3062880_201305

Engineering data

Max. spread A cast section protection functionisintegratedintheMGK.Thispreventsstresses in thematerial by limiting themaximum temperature differentialbetween the flowand return.Asof 28K, theoutput is reduced. If 38K isneverthelessreached,theburnershutsdownbrieflywithoutafaultmessage.Thischaracteristicmustbetakenintoaccountwhenselectingthecomponents(e.g.pumps,heatexchangerandcylinder).

Max. flow rate Excessiveflowvelocitiesmayleadtoerosion.MaximumflowrateatQmax: MGK-130 9.4m³/h MGK-170 13.6m³/h MGK-210 16.4m³/h MGK-250 19.1m³/h MGK-300 21.9m³/h

Heating water pressure drop

Pressuredropontheheatingwaterside[mbar]

Throughput[m³/h]

Pump sizing MGK 130/170/210/250/300

Thefollowing230VpumpsrepresentrecommendationsinconjunctionwiththeinstallationofaMGKwithalowlossheader.Selectpumpsinaccordancewiththerespectivesystemifnolowlossheaderistobeinstalled.

MGK Wilo Grundfos130 Stratos25/1-8

screwed1½“Magna25-80screwed1½“

170 Stratos30/1-10screwed2“

Magna32-80screwed2“

210 Stratos30/1-12screwed2“

Magna32-100screwed2“

250 Stratos32/1-12flanged

Magna32-120Fflanged

300 Stratos32/1-12flanged

Magna32-120Fflanged

373062880_201305

Ventilation air/flue gas routing

Engineering information, combustion air / flue gas routing

1) FortypeB23,thecombustionairisdrawnfromtheinstallationroom(openfluecombustionequipment).

For typeC, thecombustionair isdrawn throughasealedsystem from theoutside (balancedfluecombustionequipment)

Connection types

Boilertype

Gasboiler type1)

CategoryGermany

Operatingmode Can be connected toOpenflue Balanced

flueMoisture-resistantchimney

Room sealed

balancedflue

Room sealed

balancedflue

BuildingRegulationapprovedFlue

Moisture-resistantflue

MGK B23,B33,C33,C43,C53,C63,

C83

II2H3P 2)

Yes Yes C83 C43 C33,C53,C63

C53,C63 B23,C53,C83

38 3062880_201305

1) Available fan draught: MGK-130 Qmax/Qmin = 200 Pa / 10 Pa MGK-170, -210, -250, -300 Qmax/Qmin = 150 Pa / 10 Pa

2) Flue DN 160 made from PP with approval number CE 0036CPD91690033) Flue DN 200 made from PP with approval number CE 0036CPD91690034) Use exclusively original Wolf components

Ventilation air / flue gas routingImplementation versions, condensing boiler Maximum length 1)

MGKDN -130 -170 -210 -250 -300

B23 Flueinaductandcombustionairdirectlyviatheboiler(openflue)

160 2) 50 m 50 m 47 m 35 m 20 m200 3) 50 m 50 m 50 m 50 m 50 m

B33 Connectiontoamoisture-resistantchimneywithhorizontalconnectionline

160 2)Calculation 1) to EN 13384-1

200 3)

C33 Combustionairsupplyandfluegasroutingviatheroofinacommonpressurerange4)

160 2) Calculation 1) to EN 13384-1(SeealsoexampleC33)200 3)

C33Verticalconcentricroofoutletthroughapitchedorflatroof,verticalconcentricbalancedflueforinstallationinaduct(eachbalancedflue)

160/225 15 m 15 m 13 m 8 m 3 m

200/300 - - - 15 m 15 m

C43 Connectiontoamoisture-resistantbalancedfluechimney(balancedflue)

160 2)Calculation 1) to EN 13384-1

200 3)

C53 Terminalsoftheventilationairandflueareindifferentpressureranges(balancedflue)

160 2) 50 m 50 m 47 m 35 m 20 m200 3) 50 m 50 m 50 m 50 m 50 m

C53Connectiontoafluerunonanexternalwallwithahorizontalconcentricconnectionline(length:2.5m);balancedflue

160/225 50 m 50 m 35 m 5 m -

200/300 - - - 50 m 50 m

C63Thefluegassystemhasnotbeentestedandcertifiedwiththeappliance.Itmustmeetthebuildingrequirementsoftherelevantcountry.

160Calculation 1)toEN13384-1(RLU)

200

C93 Verticalflueforductinstallationwithhorizontalconcentricconnectionline(length:2.5m);balancedflue

160 25 m 16 m 6 m - -

200 30 m 32 m 32 m 26 m 32 m


393062880_201305


Examples for MGK system layout

1Gascondensingboilerwithintegralfluegastestnipple

2 Inspectionbend87°DN1603 FluepipeDN160 Length:500/1000/20004Wallbezel5 87°supportbendDN160withsupportrail6 Spacer7 Ventilationairadaptor(forbalancedflueoperation)

Maintainthefollowingclearancebetweentheinternalductwallandtheflue:-30mmforcircularducts-20mmforsquareducts

Example: open flue B 23

Installallhorizontalventilationairlines/flueswithapprox.3%slope(5cm/m)towardstheappliance.Anycondensatemustflowbacktothe appliance.

Example: balanced flue C 53

Installallhorizontalventilationairlines/flueswithapprox.3%slope(5cm/m)towardstheboiler.Anycondensatemustflowbacktotheappliance.

40 3062880_201305

Note:AnyothersystemconfigurationsmustbecalculatedinaccordancewithEN13384-1.

*Calculationprinciples:Fluegas:0.5m+87°+2m+87°+ductlengthVentilationair:87°+2mWallunevenness5mmAttheclipoftheslideconnection,theexternalfluepipediameteris183mm.


a in mm

Maximum

lengtho

nlyforfluegas*

Combustionair:Intheadjacentdiagram,thefollowingpipeworkhasbeentakenintoconsiderationforthecombustionair.1x87°inspectionbend=2m1xhorizontalpipe=2m

Examples for MGK system layout

1Gascondensingboilerwithintegralfluegastestnipple

2 Inspectionbends87°DN1603 FluepipesDN160 Length:500/1000/20004Wallbezel5 87°supportbendDN160withsupportrail6 Spacer7 Ventilationairadaptor(forbalancedflueoperation)

Maintainthefollowingclearancebetweentheinternalductwallandtheflue:-30mmforcircularducts-20mmforsquareducts

Example: balanced flue C93

Maximum length acc. to EN 13384-1 for DN 160.(DN 200 for MGK-300) subject to the duct cross-sectionExampleforC93

Installallhorizontalventilationairlines/flueswithapprox.3%slope(5cm/m)towardstheboiler.Anycondensatemustflowbacktotheappliance.

413062880_201305

MGK scheme with vertical roof outlet, balanced flue

Verticalroofoutlet Ø160/225Mat.no.2651346+Mat.no.2651347+Mat.no. 2651350

Flatroofcollar Ø 225Mat.no. 2651458

AdaptorforbalancedflueoperationMat.no. 2651332

FluegasfromtheMGK

Ventilationairto the MGK


42 3062880_201305


MGK concentric C93 scheme

MGK façade C53 scheme

433062880_201305

With low outside temperatures, the watervapourcontainedinthefluegasmaycondenseand freeze on the balanced flue. This ice may fall from the roof causing injuries or material losses. Use on-site measures topreventicefromfalling,e.g.theinstallationofasnowguard.

Securethebalancedflueorfluethatisoutsideductswith spacer bracketswith aminimumclearance of 50 cm from the flue outlet orupstream/downstreamofdiverterstopreventthepipejointsbeingpulledapart.Ifthisisnotdone,thereisadangerofpoisoningcausedbyescapingfluegas.Furthermore,boilerdamagemayresult.

General information

Wherenecessary,adapttheinstallationexamplestotherelevantBuildingRegulationsandrequirementsofyourcountry/region.Discussanyquestions relating to theinstallationofinspectioncoversandventilationapertureswithyourlocalfluegasinspector.

Flues inside chimney ductsmust have secondaryventilationalongtheirentirelengthandmustterminateabovetheroof.

Fluegascascadesmustbesized inaccordancewithEN 13384-1.

The requirements for installation roomsare specifiedin Building Regulations or Combustion EquipmentOrdinances of the relevant countries. Observe alllocal regulations regarding the room ventilation.

Flues must not be routed through other installation rooms without ducts, otherwise there would be a risk of the transfer of fire and there would be no mechanical protection.

OriginalWolfcomponentshavebeenoptimisedovermanyyearsandarematchedtotheusewithWolfcondensingboilers.WhenusingthirdpartyequipmentthatisonlyCE-designated,theinstallerwillberesponsibleforthecorrectsizingandperfectfunctionofsuchsystems.Faults,materiallossesandinjuriesresultingfromincorrectpipelengths,excessivepressuredrop,prematurewearwithescapingfluegasandcondensateorincorrectfunction,e.g.throughcomponentsworkingthemselvesloose,areexcluded fromourwarranty if non-CE-approved thirdpartyequipmentisused.

If the combustion air is taken from a duct the coonduit has to be free of contaminations!

NB

Connection to a combustion air and flue system type C63 that has not been tested together with the gas combustion equipment.

Theunobstructedcross-sectionoffluesmustbeabletobe inspected.Therefore, install an inspectionand/ortestapertureinsidetheboilerroom;agreesuitablearrangementswithyourlocalfluegasinspector.

Flue connections are created using couplings andgaskets.Alwaysarrangecouplingsagainstthedirectionofthecondensateflow.

Install the ventilation air system / flue with a slope of at least 3° towards the gas condensing boiler. Spacer brackets should be fitted to secure the equipment in position.In the worst case scenario, a lesser slope of the balanced flue may lead to corrosion or operating faults.

Connection to the ventilation air system and the flue

Generally bevel or deburr trimmed flues toensureagas tight installationofpipe joints.Ensure that gaskets are correctly fitted.Removeallcontaminationpriortoinstallation-neverfitdamagedparts.

NB

To prevent flue gas escaping, a positivepressurefluecascadeisonlypermittedwithatestedfluegasdamper(partno.2482896).

FortheMGK-130,thisisalreadyintegrated.

WhensizingfluegassystemsinaccordancewithEN13384-1,maintainamaximumbackpressureofupto130Paintoheaderline;thisshouldalsonotbeexceeded.

NB

Keepthedoorofthecondensingboilershutduringthebuildingphase.Aftercompletingthebuildingphase,removethefilter.

NB

Asprotectionagainstcontaminationduringthebuildingphase,werecommendtheuseofthecompleteventilationairfilter forMGK-130 to300(partno.9751390).Theventilationairfilterispluggedintotheairintake.


Thecombustionairmustnotbedrawnfromchimneysthatusedtocarryfluegasesfromoilorsolidfuelboilers.

NB

44 3062880_201305

Wiring diagram MGK-130

Junc

tion

box:

Pow

er

supply230VAC50Hz

Z

Heatingcircuitpum

pA1

Program

mableoutput

E1

Program

mableinput

eBUS

BUSconnectionforexternal

controlaccessories

AF


A1ControlPCB

A2LE

DPCB

B1Flow

sensor

B2Returnsensor

B3Ionisationelectrode

B4.1Cylindersensor

E1Ignitionunit

F1Mainsfuse

M2Fan

S1TW

-flow

S2TW

-fluegas

S3Waterpressuresw

itch

S4Fluegaspressuresw

itch

S5Gaspressuresw

itch

X9Boilercodingcard

X10Earthterminal

Y0Gascom

bivalve

Y0(gascom

bivalve)

gn/ye

B3(ionisation

Burner

E1(ignitionunit)

M2(fan)

wh

ye

wh

S5(gaspressuresw

itch)

Network

condensate

pum

p

black

B2

return

sensor

wh

wh

ye

ye

S2

(TWfluegas

S4

(fluegas

pressure

switch

B1(flow

sensor)

S3(water

pressure

switch)

S1

(TW-flow)

Faultm

essage,

condensatepum

p

grey

Jumper

X10

(earth

terminal)

Mains

Output

wh

Accessories

ye

ye

HCpump

Ignition

Fan

InputOutsidetemperaturesensor

ReturnsensorTWfluegas

TWflowFlowsensor

PWMSpeed

GND

Earth

Cylindersensor/hallsensor

PWMpum

p

Casing

blue

B4.1cylindersensor

ye

ye

ye

ye

ye

ye

(param

eterplug)

eBusplug

ye

ye

453062880_201305

Wiring diagram MGK-170-300

5 4 3

3

2

2

1

1

M2

(Ven

tila

tor)

gn

/ge

br

br

bl

ws gn

21

12

E1

(Zü

nd

ein

heit

)B

3(I

on

isa

tio

n)

bl

br

gn

/ge

sw

Bren

ner

Netz

Ko

nd

en

sat-

pu

mp

e

Ge

hä

us

e

bla

u

Brü

ck

e

Stö

rm

eld

un

g

Ko

nd

en

sa

tpu

mp

e

21

12

Y0

(Ga

sk

om

biv

en

til)

Y2

Y1

X10

(Sch

utz

-

leit

er-

kle

mm

e)

345 2 1

32

1

LN

LN

LL

NL

NL

NL

N+

-~

+-

+-

~~

~~

~+-

++-

~~

~+

+-

Netz

AusgangA1

Zubehör

V1

V2

HK-Pumpe

Zündung

Ventilator

Ionisation

eBUS

eB

US

eB

US

-Ste

cke

r

gngertGND

GND

R6

80

12V

+

+

-

-

eBus

EingangE1

Außenfühler

Rücklauffühler

TW-Abgas

TW-Vorlauf

Vorlauffühler

PWMDrehzahl

GND

3WU-WW3WU-HZ

Masse

Speicherfühler/HallsensorGND

12VDC

B2

(Rü

ckla

uf-

füh

ler)

S2

(TW

-Ab

gas)

S4

(Ab

gas-

dru

ck-

wäch

ter)

>

X1

X2

X3

X6

X4

X7

X5

X9

(Pa

ra

me

ters

tec

ke

r)

X8

br

gn

gra

u

sc

hw

arz

ws

B4

.1S

pe

ich

erfü

hle

r

br

wsgn

brgnws

gewsbrgnbrgngews

ge/gn

sw

bl

br

bl

br

bl

bl

br

sw

br

bl

sw

ws

sw

bn

rs

br

ws

gr

gn

ge

ws

ge

gn br

A2

A1

br

bl

ws

sw

gn

/ge

ge

AF

E1

eB

US

+-

12

ab

Ne

tzZ

A1

N

N

NL

1L

1L

1

oo

oo

oo

MT

3,15

A

F1

12

12

12

br

bl

gn/ge

sw

ws

rt

L1

N

gn

ws

gr

rs

br

ge

L1

NL1

NL1

NL1

N

rt

rt

B1

(Vo

rla

uf-

füh

ler)

S1

(TW

-

Vo

rla

uf)

>

ws

ge

gn br

S3

(Wasser-

dru

ck-

sch

alt

er)

P<

P>

2

2

11

1

2

3

3

3

S5

(Ga

sd

ru

ck

wä

ch

ter)

P>

1 2

3

Junctionbox:

Pow

er

supply230VAC50Hz

Z

Heatingcircuitpum

pA1

Program

mableoutput

E1

Program

mableinput

eBUS

BUSconnectionforexternal

controlaccessories

AF


A1ControlPCB

A2LE

DPCB

B1Flow

sensor

B2Returnsensor

B3Ionisationelectrode

B4.1Cylindersensor

E1Ignitionunit

F1Mainsfuse

M2Fan

S1TW

-flow

S2TW

-fluegas

S3Waterpressuresw

itch

S4Fluegaspressuresw

itch

S5Gaspressuresw

itch

X9Boilercodingcard

X10Earthterminal

Y0Gascom

bivalve

5 A

B3(ionisation)

E1(ignitionunit)

M2(fan)

Y0(gascom

bivalve)

blk

yel

Burner

ye

ye

wh

S5(gaspressuresw

itch)

Network

condensate

pum

p

black

S4(fluegas

pressure

switch)

faul

t ind

icat

ion

condensatepum

p

B2

(Rück-

lauffühler)

S2

(TW-flue

gas)

B1

(flow

sensor)

S1

(TW-flow

)

S3

(water

pressure

switch)

grey

Jumper

Casing

blue

B4.1cylindersensor

X10

(earth

terminal)

yeye

ye

ye

ye

ye

ye

Mains

Output

Accessories

HCpump

Ignition

Fan

Input E1


Returnsensor

Tlfluegas

TWflowFlowsensor

Speed

Earth

Cylindersensor/hallsensor

X9

(param

eterplug)

eBUSplug

46 3062880_201305

TroubleshootingAny faultswill bedisplayedas fault codesbyWolf controllerswitheBUScapability.Causeand remedymaybeallocatedtothesefaultsusingthefollowingtable.Thistableisdesignedtoallowyourlocalheatingcontractortotracethefaultmoreeasily.

Fault code

Fault Cause Remedy

1 TBVexcesstemperature,waterpressuretoolow,faultcondensatepump

TheflowtemperaturehasexceededthelimitfortheTBVshutdowntemperature,orthecondensateliftingpump(accessory)hasdevelopedafaultorthewaterpressureswitchswitchesoffatapressure<1.0bar

Checkthesystempressure.Checktheheatingcircuitpump.Ventthesystem.Presstheresetbutton Checkthecondensatepump Increasesystempressure

4 Noflamebuilds Noflamebuildsduringburnerstart Checkthegassupplylineandopenthegasvalve,ifnecessary Checktheignitionelectrodeandignitioncable. Pressreset

5 Flamefailureduringoperation

Flamefailurewithin15safterflamedetection

CheckCO2values.Checkionisationelectrodeandcable.Presstheresetbutton

6 TWexcesstemperature

Theflow/returntemperaturehasexceededthelimitfortheTWshutdowntemperature

Checkthesystempressure.Ventthesystem. Increasepumpspeed

7 TBAexcesstemperature,overpressureinthefluegassystem

ThefluegastemperaturehasexceededthelimitfortheTBAshutdowntemperature,fluegassystemisblocked,ventilationairisblocked

Cleantheheatexchanger,checkthefluegassystem CheckventilationairsystemCheckfluegaspressureswitch

11 Flamepretence Aflameisrecognisedbeforetheburnerstarts

Presstheresetbutton

12 Faultyflowsensor,gaspressuretoolow

Theflowtemperaturesensororleadisfaulty.Gaspressure<thanthevaluesetatthegaspressureswitch(onlydisplayedafter15min)

Checklead Checktheflowsensor Checkgaspressure Checkthegaspressureswitchsettings

14 Cylindersensorfaulty

DHWtemperaturesensororleadfaulty Checksensorandlead

15 Outsidetemperaturesensorfaulty

Theoutsidetemperaturesensororcableisfaulty

Checklead Checktheoutsidetemperaturesensor

16 Returnsensorfaulty Thereturntemperaturesensororleadisfaulty

Checklead Replacethereturnsensor

20 Fault,gasvalve"1" Aflameisdetectedfor15safterburneroperation,eventhoughgasvalve1hasreceivedashutdowncommand

Replacethegascombinationvalve

21 Fault,gasvalve"2" Aflameisdetectedfor15safterburneroperation,eventhoughgasvalve2hasreceivedashutdowncommand

Replacethegascombinationvalve

24 Gasfanfault Thegasfandoesnotreachtherequiredpre-purgingspeed

Checkthegasfansupplycableandthegasfan;presstheresetbutton

25 Gasfanfault Thegasfandoesnotreachtheignitionspeed

Checkthegasfansupplycableandthegasfan;presstheresetbutton

26 Gasfanfault Thegasfandoesnotstop Checkthegasfansupplycableandthegasfan;presstheresetbutton

30 CRCfault,gascondensingboiler

TheEEPROMrecord"Gascondensingboiler"isinvalid

SwitchthepowersupplyOFFandON. Ifunsuccessful,replacethecontrolPCB

31 CRCfaultburner TheEEPROMrecord"Burner"isinvalid SwitchthepowersupplyOFFandON. Ifunsuccessful,replacethecontrolPCB

32 24VACsupplyfaulty

24VACsupplyoutsidethepermissiblerange(e.g.shortcircuit)

Checkthegasfan

473062880_201305

Fault code

Fault Cause Remedy

33 CRCfault;defaultvalues

TheEEPROMrecord"Masterreset"isinvalid

ReplacethecontrolPCB

34 CRCerrorBCC Parameterplugerror Exchangeparameterplug35 BCCmissing Parameterplughasbeenremoved Pluginthecorrectparameterplug36 CRCerrorBCC Parameterplugerror Exchangeparameterplug37 WrongBCC Theparameterplugisnotcompatiblewith

thecontrolboardPluginthecorrectparameterplug

38 BCC no. invalid Parameterplugerror Exchangeparameterplug39 BCCsystemerror Parameterplugerror Parametersteckerwechseln41 Flowmonitoring Returntemperature>Flow+25K Venttheheatingsystem,checkthesystem

pressure.Checktheheatingcircuitpump43 Burnerstarts

>20perhourFlowratethroughtheheatexchangertoolowor,incaseofcascade,measuringpointoftheheadertemperatureunsuitable,orpowerconsumptionofthecalorifierchargingtoolow.

Checktheflowrate;Headersensormustmeasurethecommonfeedtemperatureofthecascade.

50 Activation of the parameterplug

Theparameterplugisstilltobeactivated Presstheresetbuttontwice

52 Activation of the parameterplug

Theparameterplugisstilltobeactivated Presstheresetbuttontwice

60 Ionisationcurrentfluctuates

Thesiphonisblocked,orthefluegassystemisblocked,severestorm

Cleansiphon,checkfluegassystem,checkventilationair,checkmonitoringelectrode

61 Ionisationcurrentfails

Poorgasquality,monitoringelectrodefaulty,severestorm

Checkmonitoringelectrodeandlead

LEDconstantlyred Ionisationcableshortedoutorionisationelectrodeearthed(casing)

Checkionisationcableandpositionofelectrodetoburner.Presstheresetbutton

Troubleshooting

48 3062880_201305

Resistance tableNTCSensor resistances

Boilersensor,cylindersensor,solarcylindersensor,outsidetemperaturesensor,returnsensor,flowsensor,headersensor

Temp.°C Resist.Ω Temp.°C Resist.Ω Temp.°C Resist.Ω Temp.°C Resist.Ω-21 51393 14 8233 49 1870 84 552-20 48487 15 7857 50 1800 85 535-19 45762 16 7501 51 1733 86 519-18 43207 17 7162 52 1669 87 503-17 40810 18 6841 53 1608 88 487-16 38560 19 6536 54 1549 89 472-15 36447 20 6247 55 1493 90 458-14 34463 21 5972 56 1438 91 444-13 32599 22 5710 57 1387 92 431-12 30846 23 5461 58 1337 93 418-11 29198 24 5225 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 3020 16325 35 3265 70 876 105 2941 15515 36 3133 71 846 106 2852 14750 37 3007 72 818 107 2773 14027 38 2887 73 791 108 2704 13344 39 2772 74 765 109 2625 12697 40 2662 75 740 110 2556 12086 41 2558 76 716 111 2487 11508 42 2458 77 693 112 2418 10961 43 2362 78 670 113 2359 10442 44 2271 79 670 114 22810 9952 45 2183 80 628 115 22211 9487 46 2100 81 608 116 21612 9046 47 2020 82 589 117 21113 8629 48 1944 83 570 118 205

493062880_201305

Notice

50 3062880_201305

Notice

513062880_201305

Notice

GerdewanJacobsExecutiveBoardEngineering

Mainburg,23.11.2012

Declaration of conformity(acc. to ISO/IEC 17050-1)

No. 3062880

Issuedby: Wolf GmbH

Address: Industriestraße1,D-84048Mainburg

Product: GascondensingboilerMGK

Theproductdescribedaboveconformstotherequirementsspecifiedinthefollowingdocuments:

§6,1.BImSchV,26.01.2010DINEN437,09/2009DINEN483,06/2000DINEN677,08/1998DINEN60335-1,02/2007DINEN60335-2-102/2010DINEN55014-1,06/2007

InaccordancewiththefollowingDirectives:

2009/142/EEC(GasAppliancesDirective)92/42/EW(EfficiencyDirective)2004/108//EC(EMCDirective)2006/95/EC(LowVoltageDirective)

Thisproductisidentifiedasfollows:

0085

i.V.KlausGrabmaierProductapproval