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Operation instructions for contractors COB-2 / TS OIL CONDENSING BOILER COB-2 for central heating TS for central heating with stratification cylinder English | subject to modifications 3066501_201910...
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Taking the heat generator out of service in an emergency ................ 69 Taking the heat generator out of service permanently ................69 Recycling and disposal ......................71 Specifications ........................... 72 11.1 COB-2 oil condensing boiler ........................72 11.2 TS stratification cylinder ..........................73 11.3 Cascade ..............................73 11.4...
► Follow the instructions in this document. Failure to observe these instructions voids any WOLF GmbH warranty. Scope This document contains instructions for the COB-2 and COB-2-TS oil condensing boiler. Target group This document is intended for gas, plumbing, heating and electricity contractors.
Any faults or damage that impact or might impact safety must be remedied immediately by a qualified contractor. ► All faulty components of the heat generator must be replaced with original WOLF spare parts. General safety information...
► Make the operator aware of the following: – Annual inspections and maintenance must be performed by a contractor. – WOLF recommends concluding an inspection and maintenance contract with a contractor. – Repair work must be performed by a contractor.
Description Description Layout of COB-2-TS oil condensing boiler Fig. 3.1 Layout of COB-2-TS oil condensing boiler COB-2-15/20/29/40 oil condensing boiler DHW draw-off at the highest point TS-15/20/29 stratification cylinder Cylinder heating from above with deflector and Condensate pan divider Trap...
The following apply to installation and operation in Austria: – ÖVE regulations – Provisions of the ÖVGW and the corresponding Austrian standards (ÖNORMs) – Local regulations from building and industry regulatory agencies (generally represented by the chimney sweep) 12 | WOLF GmbH 3066501_201910...
– BUWAL and local regulations must be observed. Installation location The COB-2 and TS are installed adjacent to the wall, which means that a clearance only needs to be observed at the front. A surface temperature of 40°C is not exceeded during proper use.
– Make sure that a drain outlet and safety assembly is provided. The safety assembly from the WOLF accessories range includes an integral 3 bar safety valve. – A minimum flow rate prevents damage to the hot water heat exchanger as a result of overheating or steam hammers.
(e.g. more than 10 % of the system volume per year), the cause must be sought immediately and the fault remedied. 4.3.3 WOLF accessories - heating system We recommend making the connection to the heating system with the following parts from the WOLF accessories range. Image Item name...
Oil lines too large! Faults due to trapped air ► Use an oil line with an interior line diameter of 4 mm. ► A filter/air vent valve combination with an integrated shut-off valve from the WOLF product range must be installed. 3066501_201910...
The maximum possible suction line length results from the pressure losses on the pipes and fittings and the inlet height. The line length includes all vertical and horizontal pipes. The maximum suction line length recommended by WOLF is 40 m. Fig. 4.3...
– If this is not possible, neutralisation is required. Air/flue gas routing For safety reasons, use only original WOLF flues and concentric balanced flue systems. DANGER Fire and smoke will travel to other floors! Risk of suffocation, poisoning and burning in the event of exposure to fire from outside.
Route the air/flue gas lines over the heat generator in such a way that the displacement device can be removed. Minimum clearance above the heat generator: – COB-2-15/-20/-29: 30 cm – COB-2-40: 40 cm Air / flue gas routing via roof (type C33x) Routing air / flue gas above the roof is permitted under the following conditions: –...
– Fitted to the heat generator at the factory – Alternatively, install immediately after the 87° bend connected directly to the heat generator If replacing a WOLF COB with a WOLF COB-2, reuse the existing connection with a flue gas test port.
The necessary type plates and certificates are included with the relevant WOLF accessories. 4.6.4 Air/flue gas routing lengths The calculation was made taking the pressure conditions into account (geodetic height: 325 m). The specified lengths refer to concentric balanced flues and standard flues and apply to original WOLF components only. Maximum length Maximum length [m]...
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DN 110 Available fan draught: COB-2-15: 32 - 65 Pa / COB-2-20: 45 - 65 Pa / COB-2-29: 55 - 105 Pa / COB-2-40: 70 - 150 Pa (maximum length corresponds to the total length from the heat generator to the flue outlet) Table 4.9...
Minimum shaft sizes Room sealed operation C93x Assuming: 1 x 87° bend + 1.5 m horizontal with 87° support bend Ø DN60 (COB-2-15) a x a [mm] Ø [mm] DN80 (COB-2-15/20/29), DN110 (COB-2-40) COB-2-15/-20 COB-2-15/-20 COB-2-29 COB-2-29 COB-2-40 COB-2-40 a x a [mm] Ø...
>20 >30 Fig. 4.6 Minimum shaft size [mm] 4.6.6 Notes on connection Original WOLF components have been optimised over many years and are designed for use with WOLF heat generators. Connection type Maximum length Please note the following: horizontal air/flue gas routing Type B23 –...
MM-2 mixer module installation and operating instructions for contractors BM-2 programming unit installation and operating instructions for contractors The heat generators have control PCBs with functions which are tailored to the WOLF control modules. Configuration only in conjunction with a KM-2 cascade module.
If there is only one oil storage installation, this supply must be arranged centrally via a suction unit. The suction unit must be installed as close to the boiler cascade as possible. Fig. 4.8 Fuel supply Oil storage installation Suction unit 3066501_201910 WOLF GmbH | 27...
150 cm². In addition to the bends connected to the heat generator, a maximum of two 87° diverters may be installed. 28 | WOLF GmbH 3066501_201910...
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► If the conditions at the installation site are different, an individual calculation is required. Number COB-2 Installation Type B23 Flue internal diameter Total flue gas mass flow rate 26.6 26.6 40.0 53.3 35.0 52.5 70.0 Maximum flue gas °C temperature Maximum effective building height Table 4.13 Maximum height - flue gas routing with header 3066501_201910 WOLF GmbH | 29...
► Remove strap and packaging. ► Remove the fixing screws on the pallet. ► Lift the heat generator and cylinder off the pallet. Checking the delivery The following parts are included with the COB-2 and COB-2-TS: Standard delivery COB-2 COB-2-TS COB-2-15/20/29/40 oil condensing boiler ●...
Maintain minimum wall clearances! This will simplify installation, maintenance and servicing (4.2.1 Minimum wall clearances to the front and side). ► Remove the casing (Fig. 5.2 Removing the casing). ► Use the adjustable feet to level the heat generator and cylinder 3066501_201910 WOLF GmbH | 31...
Safety assembly with levelling part Pipe assembly ► Install the pipe assembly on the safety assembly. Fig. 5.6 Pipe assemblies Pipe assembly for 1 heating circuit Pipe assembly for 2 or 3 heating circuits with manifolds 32 | WOLF GmbH 3066501_201910...
Installation 5.5.1 Installation examples Fig. 5.7 Connection set next to heat generator on the wall Fig. 5.8 Connection set behind heat generator on the wall 3066501_201910 WOLF GmbH | 33...
DHW. Failure to observe Fig. 5.10 Cold water connection to DIN 1988 in the installation voids any WOLF GmbH warranty. Parallel DHW operation is not possible for heat generators with a TS stratification cylinder. If the system parameter (A10: enable parallel mode) is set to parallel DHW operation despite this, the heating circuit pump will not be activated during cylinder heating.
Heating return Connecting the oil line ► Connect the system. ► A filter/air vent valve combination with an integrated shut-off valve from the WOLF product range must be installed. ► Check the oil line in accordance with TRÖl for the following: –...
5.8.2 Connecting the condensate pump ► Feed the drain hose of the trap into the condensate pump. ► Connect the condensate pump and the on-site drain. Fig. 5.12 Trap with condensate pump Trap Condensate pump 36 | WOLF GmbH 3066501_201910...
► The neutralising box must be filled with water prior to commissioning to check for leaks. ✔ All connections are fitted without leaks. ► Observe the neutralising box installation instructions. Fig. 5.13 Trap with neutralising box Trap Neutralising box (optionally with condensate pump) 3066501_201910 WOLF GmbH | 37...
(Fig. 5.14 Example: balanced flue [mm]) at the connection point of the heat generator (1). Fit inspection piece If an inspection aperture is required for the balanced flue, ► insert a balanced flue pipe with inspection aperture. 38 | WOLF GmbH 3066501_201910...
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► The outlets of flue lines in ducts must be designed so that the following requirements are met: – no ingress of precipitation – secondary ventilation can flow freely ► It must be possible to remove removable covers without tools and they must be secured to prevent them falling. 3066501_201910 WOLF GmbH | 39...
The maximum current carrying capacity of the outputs is 1.5 A. Do not exceed a total of 4 A. ► In case of a permanent connection, connect the power supply via a mains isolator (e.g. fuse, heating system emergency stop switch) that ensures at least 3 mm contact separation. 40 | WOLF GmbH 3066501_201910...
In the delivered condition, the terminal box is fitted to the back panel of the heat generator. The control and safety devices are fully wired and tested. Fig. 5.18 COB-2 terminal box delivery condition Lines for connections to stratification cylinder Opening for heat generator cable feed through...
► Push the cable through the strain relief. ► Screw the strain relief into place. ► Terminate the appropriate cores at the Rast5 plug. ► Push the inserts into the terminal box casing. ► Insert the Rast5 plug ► Fit the cover. 42 | WOLF GmbH 3066501_201910...
► Make the electrical connection at the TS stratification cylinder as shown in the image. Fig. 5.22 Electrical connection at the TS stratification cylinder Regulated TS stratification pump A1 programmable output Control signal, stratification pump Cylinder primary pump (PP) Stratification sensor ► Make the electrical connection at the terminal box as shown in the image. 3066501_201910 WOLF GmbH | 43...
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230 V output when ON/OFF switch is in the ON position Maximum of 1.5 A per output, no more than 600 VA in total ZHP (FHP) Feed / heating circuit pump control Maximum of 1.5 A per output, no more than 600 VA in total 44 | WOLF GmbH 3066501_201910...
PCB 1(a) = 10 V, 2(b) = GND. 5 k NTC outside sensor 5kNTC cylinder sensor eBus (WOLF control accessories e.g. BM-2, MM-2, KM-2, SM1-2, SM2-2) NOTE Increased electromagnetic interference at the installation site! Possible control faults. ► Fit screened sensor leads and eBus cables.
The control modules are used to set or display specific parameters of the heat generator. BM-2 programming unit This control module communicates with the heat generator and all connected extension modules via eBus. AM display module This control module functions as a display module for the heat generator. 46 | WOLF GmbH 3066501_201910...
Selecting a slot Either an AM display module or a BM-2 programming unit must be installed on the heat generator for operation. ► Select the slot for the control module. Fig. 5.26 Possible slots for control modules 3066501_201910 WOLF GmbH | 47...
► Check the heat generator and system for water tightness. Putting the heat generator into service ► Open the shut-off valves for heating flow and return. ► Open oil shut-off valves (tank, oil line, filter). ► Switch on the heating emergency stop switch. 48 | WOLF GmbH 3066501_201910...
Commissioning Plugging in the control module Fig. 6.1 Plugging in the control module ► Place the control module in the slot above the WOLF logo. ► Fit casing (Fig. 5.3 Attaching the casing). Turning on the heat generator Fig. 6.2 ON/OFF switch ►...
► Set the ON/OFF switch of the cylinder primary pump to venting. ► Vent the system completely at the maximum system temperature. ► Set the cylinder primary pump to constant pressure again. Fig. 6.3 Cylinder primary pump ON/OFF switch Constant diff. pressure Venting Variable diff. pressure 50 | WOLF GmbH 3066501_201910...
► Measure the CO level again. level remains below 0.2%, no leak in the flue system: ► End emissions test mode. ✔ The heat generator shuts down. ► Close the test port. Ensure the cap is seated firmly! 3066501_201910 WOLF GmbH | 51...
► Check oil nozzle and air nozzle. ► Change the oil pump pressure (6.7.4 Changing the oil pump pressure) If the heat generator fails to start with factory settings active, the parameters can be adjusted after waiting for three minutes. 52 | WOLF GmbH 3066501_201910...
► adjust pressure regulating screw, stage 2 (2) or stage 1 (1). – Tool: 4 mm Allen key (Danfoss) or AF 8 open-ended spanner (Suntec) – Rotate to the right to increase the pump pressure – Rotate to the left to decrease the pump pressure 3066501_201910 WOLF GmbH | 53...
✔ The heat generator will deactivate and be locked out with fault code 8. ✔ The fan will continue to run at a low speed. ► Reconnect E1. ► Acknowledge fault message. ► Check that the flue damper closes when the system is on standby. 54 | WOLF GmbH 3066501_201910...
– Select the rotary selector icon and switch to Standby. ✔ The heat generators will switch to standby mode. ► Press the emissions test quick start button to turn the first COB-2 on. ✔ COB-2 turns on. ► Wait for at least 5 minutes.
Standard settings for heat generator on the control module. ► Set parameters (7.1 Parameter list). 6.10 Finishing the commissioning process ► Document values in “System and operator's log”. ► Complete commissioning report (12.1 Commissioning report). 56 | WOLF GmbH 3066501_201910...
Parameter settings BM-2 programming unit installation and operating instructions for contractors AM display module installation and operating instructions for contractors Parameter list Changes may only be made by a contractor or WOLF customer service. NOTE Improper use! System faults. ► Arrange for a contractor to set and change parameters.
Each time the burner is shut down in heating mode, it will be disabled for the duration of the burner cycle block. The burner cycle block is reset by turning the ON/OFF switch off and on or by briefly pressing the 58 | WOLF GmbH 3066501_201910...
CO configuration will remain enabled. DHW disabled/enabled With input E1 open, DHW heating will be disabled, regardless of any digital WOLF control accessories. When heating is disabled, frost protection mode, emissions test mode and CO configuration will remain enabled.
For HG40 system configuration 1, output A1 is switched parallel to the feed/heating circuit pump. If HG40 system configuration is set to 12, output A1 is automatically enabled as the output for a heating circuit pump (direct heating circuit). Table 7.3 Function output A1 60 | WOLF GmbH 3066501_201910...
The burner is switched on subject to the cycle block if this temperature is not achieved when heat is demanded. The minimum boiler water temperature BTmin is also not necessarily achieved when there is no heat demand. 3066501_201910 WOLF GmbH | 61...
The burner is switched off if this temperature is exceeded. The burner is switched back on once the boiler temperature has decreased by the burner hysteresis. Only for COB-2-29 with TS cylinder: A BTmax of 85°C is recommended if the Pasteurisation function (A07) is active.
Based on the maximum burner hysteresis (HG01), there is a linear reduction of the burner shutdown point after the burner starts. After the hysteresis time (HG33), the burner switches off at the minimum burner hysteresis (HG60). Also see parameter HG01 diagram. 3066501_201910 WOLF GmbH | 63...
Cylinder primary pump upstream of low loss header. Control on boiler sensor; feed pump off during cylinder heating. Header sensor Cylinder primary pump downstream of low loss header. Control on header sensor; feed pump on during cylinder heating. 64 | WOLF GmbH 3066501_201910...
Fault Fault BM-2 programming unit installation instructions for contractors AM display module installation instructions for contractors WOLF Service App: Fault code inspector NOTE Fault reset without rectifying the cause! Damage to components or the system. ► Faults must be rectified by a contractor.
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► Check air ducts. – Air ducts not connected or incorrectly connected. Differential – Differential pressure sensor fails ► Check differential pressure pressure sensor not to switch back. sensor. deactivating – Infiltrating air flowing through the heat generator. 66 | WOLF GmbH 3066501_201910...
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– Burner control unit is controlled No action. by PC. Reset – Reset button pressed too many ► Switch power supply OFF/ON. times. System error – Internal burner control unit fault. ► Switch power supply OFF/ON. Burner control unit 3066501_201910 WOLF GmbH | 67...
► Check if supply line is faulty. faulty. Pressure sensor: – Pressure sensor faulty. ► Check cables and plug-in connections. If OK but no function: ► Replace pressure sensor. ► Press reset button. Table 8.2 Warning messages 68 | WOLF GmbH 3066501_201910...
► Isolate the entire system from the power supply. ► Switch OFF the heat generator at the ON/OFF switch. ► Isolate the system from the power supply. ► Safeguard the system against reconnection. ► Disconnect the heat generator from the power. 3066501_201910 WOLF GmbH | 69...
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► Open the drain valve (e.g. heat generator BDF valve). ► Open the air vent valves on the radiators. ► Drain off the heating water. Shutting off the oil supply ► Close the oil shut-off valve. 70 | WOLF GmbH 3066501_201910...
► Dispose of packaging made of cardboard, recyclable plastics and synthetic filler materials in an environmentally compatible manner through appropriate recycling systems or a recycling centre. ► Please observe the applicable national and local regulations. 3066501_201910 WOLF GmbH | 71...
Ω 1733 1669 1608 1549 1493 1438 1387 1337 1289 1244 1200 1158 Temperature °C Resistance Ω 1117 10178 1041 1005 Temperature °C Resistance Ω Temperature °C Resistance Ω Temperature °C Resistance Ω Temperature °C Resistance Ω Table 11.4 NTC sensor resistances 76 | WOLF GmbH 3066501_201910...
Condensate pump Fault message, condensate pump (jumper in plug) Stratification pump ISM7i (optional) X1: OBC ON/OFF switch Water pressure sensor Reset PWM feed / heating circuit pump Service PCB DHW outlet temperature sensor AM/BM contact PCB 80 | WOLF GmbH 3066501_201910...
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Fan 230 V AC Oil pump Boiler temperature sensor Oil valve 1 High limit safety cut-out Oil valve 2 Flue gas temperature sensor Oil burner Fan PWM signal Ignition electrodes Differential pressure sensor Ignition unit with flame detection 3066501_201910 WOLF GmbH | 81...
Hydraulic and electrical details: "Hydraulic System Solutions" technical guide. Shut-off valves, air vent valves and safety equipment are not depicted in these hydraulic diagrams. ► These should be provided for each system individually, in line with the applicable standards and regulations. 82 | WOLF GmbH 3066501_201910...
– Boiler temperature controller; set value is specified by mixing circuits – Input E2: not assigned – Feed/heating circuit pump not enabled as a heating circuit pump 12.3.3 System configuration 11 There are three possible hydraulic schemes for system configuration 11. 3066501_201910 WOLF GmbH | 83...
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– Header temperature control (heating mode only) – Input E2: Header sensor (heating mode only) – In case of cylinder heating, the reference temperature is provided by the boiler sensor. – Heating circuits with MM-2 84 | WOLF GmbH 3066501_201910...
– Feed/heating circuit pump enabled as a feed pump from 2 V. – Boiler temperature controller – Input E2: Control by external controller with 0 - 10 V 0 - 2 V burner OFF 2-10 V set boiler temperature BTmin (HG21) - BTmax (HG22) 86 | WOLF GmbH 3066501_201910...
– Header temperature control via cascade module – Input E2: not assigned – Automatic output reduction when approaching BTmax (HG22) is enabled. Shutdown when BTmax is reached – Use a low loss header or plate heat exchanger for hydraulic separation. 3066501_201910 WOLF GmbH | 87...
See installation See installation See installation See installation when the space heater is assembled, installed instruction instruction instruction instruction or maintained WOLF GmbH, Postfach 1380, D-84048 Mainburg, Tel. +49-8751/74-0, Fax +49-8751/741600, http://www.WOLF.eu Material number: 3021946 06/2018 88 | WOLF GmbH 3066501_201910...
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Sound power level, indoors Any specific precautions that shall be taken See installation when the space heater is assembled, installed instruction or maintained WOLF GmbH, Postfach 1380, D-84048 Mainburg, Tel. +49-8751/74-0, Fax +49-8751/741600, http://www.WOLF.eu Material number: 3021969 06/2018 3066501_201910 WOLF GmbH | 89...
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Any specific precautions that shall be taken See installation See installation See installation when the space heater is assembled, installed instruction instruction instruction or maintained WOLF GmbH, Postfach 1380, D-84048 Mainburg, Tel. +49-8751/74-0, Fax +49-8751/741600, http://www.WOLF.eu Material number: 3021992 06/2018 90 | WOLF GmbH 3066501_201910...
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Any specific precautions that shall be taken See installation See installation See installation when the space heater is assembled, installed instruction instruction instruction or maintained WOLF GmbH, Postfach 1380, D-84048 Mainburg, Tel. +49-8751/74-0, Fax +49-8751/741600, http://www.WOLF.eu Material number: 3022015 06/2018 3066501_201910 WOLF GmbH | 91...
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Sound power level, indoors Any specific precautions that shall be taken See installation when the space heater is assembled, installed instruction or maintained WOLF GmbH, Postfach 1380, D-84048 Mainburg, Tel. +49-8751/74-0, Fax +49-8751/741600, http://www.WOLF.eu Material number: 3022038 06/2018 92 | WOLF GmbH 3066501_201910...
Contact WOLF GmbH, Industriestraße 1, 84048 Mainburg, Germany High temperature operation means a return temperature of 60°C at the boiler inlet and a flow temperature of 80°C at the boiler outlet. Low temperature operation means a return temperature (at the boiler inlet) of 30°C for condensing boilers, 37°C for low temperature boilers and 50°C for other heating appliances.
Number: 3066501 Issued by: WOLF GmbH Address: Industriestraße 1, D-84048 Mainburg Product: COB-2 oil condensing boiler The product conforms to the requirements specified in the following documents: §6, 1. BImSchV, 26.01.2010 DIN EN 267, 02/2017 (N-E) DIN EN 298, 11/2012 DIN EN 303, 11/2017 (N) DIN EN 304, 02/2018 (N)
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2009/125/EC (ErP Directive) EU Regulation 812/2013 EU Regulation 814/2013 and is identified as follows: This declaration of conformity is issued under the sole responsibility of the manufacturer. Mainburg, 1 April 2019 Gerdewan Jacobs Jörn Friedrichs Technical Director Head of Development 3066501_201910 WOLF GmbH | 95...
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