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Assembly and operating instructions

1. JeUng LN BBE Yooper 47 007979 am uej ZW un UOHU I L3 t uones uol Eg VVL F 3062880_201305 44 diagram MGK 170 300 iring W WI F SAJBA IQUI09 seg OA leulu UVEF OLX ples UIPO9 sajlog 6X UJJIMS ainssaid seg GS UJJIMS ainssaud seb ni i YS UJJIMS ainssaid ES seb nil ML ZS NO ML LS ued ZW asnj sule L4 yun UOMU I LI JOSU9S JOPUIA yd UONESIUOJ 68 JOSUSS 28 JOSUSS MOJ4 LA 804 G31 cv qod 104 U0D LV JOSU9S Japuii a L y g Bulseo Snid sng Bnjd 4 Josuas pisino NA x JOSUSS MOJA 686 nil LL EG Ex uonesiuol uoniuby En x Jodunr ainssaid gt iq pp zz 5 44 duind uoneorpul JJNEJ yous ainssaid seb gs youMs ainssaid seb any vs se6 eny ML o zs yoelq b du 405uas ONE dund 86 Mol Ane sm za ayesuapuoo La JJOMJAN um aq 9 jub iq gt okjub Jung gt Ed 37 MS T 099999 m uej zW un uomuBi 13 Y uonesiuol Eg Josuas pisino JY S HOSS E 0J1UO9 JEUJ9JX9 J
2. 000000000 000000000 000000000 000000000 000000000 Example balanced flue C 53 Install all horizontal ventilation air lines flues with approx 3 slope 5 cm m towards the boiler Any condensate must flow back to the appliance ab o al nizin ox 2 mam EH gt JIEA c 000000000 000000000 000000000 000000000 000000000 39 WI JEF Engineering information combustion air flue gas routing Examples for MGK svstem lavout 1 Gas condensing boiler with integral flue gas test nipple 2 Inspection bends 87 DN 160 3 Flue pipes DN 160 Length 500 1000 2000 4 Wall bezel 5 87 support bend DN 160 with support rail 6 Spacer 7 Ventilation air adaptor for balanced flue operation Maintain the following clearance between the internal duct wall and the flue 30 mm for circular ducts 20 mm for square ducts Combustion air In the adjacent diagram the following pipework has been taken into consideration for the combustion air 1 x 87 inspection bend 2 m 1 x horizontal pipe 2 m Note Any other system configurations must be calculated in accordance with EN 13384 1 40 Example balanced flue C93 Install all horizontal ventilation air lines flues 7 N with approx 3 slope 5 cm m towards the
3. Planning Location Boiler output Qka kW Qk2 kW Qka kW Qka kW Lowest boiler output Qemin kW Lowest boiler output for the svstem Svstem output QB tot kW Qs tot QBz Qg3 Qp4 System volume V svstem Maximum expected top 1 Vtop up l Total volume expected during the up water volume system service life Volume of fill and top up Vmax Vmax Vsystem Vtop up water Total hardness of the Conw dH e g from an analysis of the water DHW supply Checking the specific VA specific KW Va specific V system Qkminimum system volume greater less than 20 I kW Permissible total C max dH Maximum permissible total hardness hardness according to the table Proportion of desalinated A A 100 Cmax 0 1 dH DHW Cpuw 0 1 dH x 100 Fill water to be treated Vireatment V treatment A X Vmax OF Vireatment A X V system at stage 4 Commissioning Fill and top up water volumes Commissioning by Meter reading before first fill Z in Water Total pH value of svstem Date Explanation Abbreviation Meter volume V hardness water after heating Signature reading Znew Zola in dH process and sufficient Znew in I in I flushing Softened fill water V treatment 0 1 Untreated fill water Vuntreated Top up water V top up 1 Top up water Viop up 2 Top up water Viop up 3 Top up water Viop up 4 Top up water Viop up 5 Top up vvater Vtop up 6 Top up water Viop up 7 Top up water Viop up 8 Top up water Viop u
4. boiler Any condensate must flow back to the A x appliance 3 6 2 3 m EY 2 3 Maximum length acc to EN 13384 1 for DN 160 DN 200 for MGK 300 subject to the duct cross section Example for C93 MGK 130 DN160 MGK 170 DN160 MGK 300 DN200 MGK 210 DN160 28 30 32 MGK 250 DN160 Maximum length only for flue gas 11 7 3 13 yt MGK 300 DN160 0 225 250 275 300 325 350 375 ainmm Calculation principles Flue gas 0 5 m 87 2 m 87 duct length Ventilation air 87 2 m Wall unevenness 5 mm At the clip of the slide connection the external flue pipe diameter is 183 mm 3062880_201305 Vu LE Engineering information combustion air flue gas routing MGK scheme with vertical roof outlet balanced flue Flue gas from the MGK Vertical roof outlet 160 225 Mat no 2651346 Mat no 2651347 Mat no 2651350 R orton air to the MGK Flat roof collar Mat no 2651458 Adaptor for balanced flue operation Mat no 2651332 3062880_201305 41 WI JEF Engineering information combustion air flue gas routing MGK concentric C93 scheme t 000000000 000000000 000000000 MGK fa ade C53 scheme 000000000 000000000 000000000 000000000 000000000 42 3062880 2013
5. 50m 50m 300 The flue gas system has not been tested and 160 C63 certified with the appliance t must meet the building Calculation 1 to EN 13384 1 RLU requirements of the relevant country 200 Vertical flue for duct installation with horizontal 160 25m 16m 6m l concentric connection line length 2 5 m balanced flue 200 30 m 32 m 32 m 26 m 32 m 1 Available fan draught MGK 130 Qmax Qmin 200 Pa 10 Pa MGK 170 210 250 300 gt Qmax Qmin 150 Pa 10 Pa 2 Flue DN 160 made from PP with approval number CE 0036CPD9169003 3 Flue DN 200 made from PP with approval number CE 0036CPD9169003 4 Use exclusively original Wolf components 38 3062880_201305 WI F Examples for MGK svstem lavout 1 Gas condensing boiler with integral flue gas test nipple 2 Inspection bend 877 DN 160 3 Flue pipe DN 160 Length 500 1000 2000 4 Wall bezel 5 87 support bend DN 160 with support rail 6 Spacer 7 Ventilation air adaptor for balanced flue operation Maintain the following clearance between the internal duct wall and the flue 30 mm for circular ducts 20 mm for square ducts 3062880 201305 Engineering information combustion air flue gas routing Example open flue B 23 Install all horizontal ventilation air lines flues with approx 3 slope 5 cm m towards the appliance Anv condensate must flow back to the appliance N gm ta
6. lt 54 195 12 IP40 lt 54 250 16 IP40 lt 54 271 20 IP40 lt 54 292 24 IP40 lt 54 313 28 approx 4 0 0085BR0117 approx 4 0 0063BQ3805 approx 4 0 0063BQ3805 approx 4 0 0063BQ3805 approx 4 0 0063BQ3805 1 This value is dependent on the general system conditions such as Type version of the flue system size and nature of the installation room 3062880 201305 WI F ON OFF switch Control Function Operation ud Thermometer Reset DHW temperature button selector Illuminated ring Heating water temperature selector ON OFF switch The condensing boiler is OFF in position 0 Reset A fault is reset bv pressing the reset button which will also restart the svstem Pressing the reset button re activates the svstem if there was no fault Illuminated status indicator ring Displav Explanation Flashing Standbv green power supplv ON no heat demand Constant Heat demand Pump running green light burner OFF Flashing Emissions test mode vellow Constant Burner ON flame steadv vellow light Flashing red Fault DHW temperature selection only with 3 vvay valve When gas condensing boilers are combined with a DHW cvlinder setting 1 9 corresponds to a cvlinder temperature of 15 65 C The DHW temperature selector setting becomes ineffective when the svstem is combined with a digi
7. Oniv use original Wolf components or CE designated flue systems to create flue lines Observe the technical information regarding ventilation air supplv flue svstems prior to installing the flue or the ventilation air connection Different countries have different regulations We would therefore recommend vou contact the appropriate authorities including the local flue gas inspector to check local requirements prior to the boiler installation With low outside temperatures the water vapour contained in the flue gas mav condense and form ice on the flue Use on site measures to prevent ice from falling e g the installation of a snow catcher grille General information electrical connection A A 18 The installation must be carried out by a licensed electrical contractor Observe local electrical regulations and those of the local power supply utility Do not route sensor leads with 230 V mains cables Installation combustion air supply flue system I electrical connection Combustion air Integral test nipple for checking the flue gas 000000000 000000000 000000000 000000000 000000000 Fig Example Ventilation air flue system The boiler power supply terminals are live even when the ON OFF switch has been switched OFF Control unit Junction box Fig Control unit MGK 170 210 250 300 3062880 201305 WI F NB The electrical installation may only be executed bv an authorized com
8. W JIF Assembly and operating instructions Gas condensing boilers MGK 130 MGK 170 TALH o MGK 210 MGK 250 B MGK 300 These installation instructions are to be retained by the user We cannot accept any warranty claims if these operating instructions have not been observed Wolf GmbH Postfach 1380 D 84048 Mainburg Tel 49 8751 74 0 Fax 49 8751 741600 Internet www wolf heiztechnik de Document no 3062880_201305 Subject to technical modifications WI JEF Contents Contents i ie R SNA RUGA CRP GAR CRA SCI A CNRS COA at Page Safety Instructlons insr liega iqies ad ik tab la kr ta a i Tat 3 4 Standards and regulations ne eee ens nar nanna rna 5 6 Layout MGK sie b re i l A ee 6 Specification isir A a B a Ba 7 Control Function Operation iini iii iiiias 8 9 Delivered condition Connections nn eseri nn nt 10 Installation instructions nn 11 Installation instructions DIMENSIONS nn 12 Dismantling CASING nn GAN CA ae nanna nn 13 Boiler system pipework nn rna 14 Installatieii EAR E P A P bade pada 15 17 Installation combustion air supply flue system 18 Elecifical connection eire et ee 18 22 Filling the system filling the 23 Checking the gas supply pressure semen eennnnnnznnnannzznnenznnzzznzznani 24 Commissioning S
9. bv fine adjusting the zero point adjusting screw in accordance with the table Make this adjustmentwithin 120 s of the burner start f necessary repeat the start phase for setting procedures bv pressing the reset button Turn clockwise raises CO content Turn anti clockwise lowers CO content Appliance open without casing at lower load Natural gas H 9 0 0 2 MGK 130 MGK 170 210 250 300 Zero point adjusting screw Tx40 Torx under the cover Fig Gas combination valve 29 WI JEF Changing the gas tvpe CO settings C Checking the CO setting D Completing the adjustments After completing the work refit the casing cover and check the CO value with the appliance closed Shut down the boiler and close the test ports and hose nipples check for tightness Observe the CO emissions whilst making AN CO adjustments The gas combination valve is incorrectly adjusted if the CO value is 7200 ppm when the CO value is correct Take the following steps Repeat the adjusting process from section A The condensing boiler is correctly adjusted when the CO values correspond to those in the table below Appliance closed without casing at upper load Natural gas H 9 3 0 3 Appliance closed with casing at lower load Natural gas H 9 1 0 3 MGK 130 MGK 170 210 250 300 Zero point adjusting screw Tx40 Torx under the cover Gas
10. JEUJ9JX9 JO UONJ8UU09 SNE 5 989 6njd 6X niq JOSUSS J9PUIMA g Bulseo z u al 17 ery L wl 6 qi FEE x ql Fm AAN tp FE QE gt FF gt i il YMS ainssaid duind WMd moy ML mol ML IS ue4 ZN jndui LI ee jndjno ojgewWwebolq LY x asnj SUley L4 i dwnd BuneaH Z yun uomubl LI 5 BA 0 aris ZH OG OV A 062 Iddns 555 it p JEMOd m a w gt JOSUSS JSPUIA L vg 2 Tigi G L il o xoq uon unr uonesiuol Eg 3 E Josuas Winey 28 38 ix ex zx ix G JOSUSS MOLI LE z og 235 9 3 i z 804 031 27 S pe oop 3358 88 a z Od 104U09 LV BRE dE 8868 28 oN Sm IS seb any vs yoyms ainssaid 4 seb any ML Jedwnr Aei6 ES zs yoelq See Josuas duind men dna A BA IQLIOD seb OA ecessouunined 1osues yesu puoo HON noy LE uojims ainssaid seb Gs TE aq afjub 19
11. 201305 WI F 3062880 201305 Notice Declaration of conformitv acc to ISO IEC 17050 1 No 3062880 Issued by Wolf GmbH Address IndustriestraRe 1 D 84048 Mainburg Product Gas condensing boiler MGK The product described above conforms to the requirements specified in the following documents 8 6 1 BlmSchV 26 01 2010 DIN EN 437 09 2009 DIN EN 483 06 2000 DIN EN 677 08 1998 DIN EN 60335 1 02 2007 DIN EN 60335 2 102 2010 DIN EN 55014 1 06 2007 In accordance with the following Directives 2009 142 EEC Gas Appliances Directive 92 42 EW Efficiencv Directive 2004 108 EC EMC Directive 2006 95 EC Low Voltage Directive This product is identified as follows Mainburg 23 11 2012 SN i V Klaus Grabmaier Executive Board Engineering Product approval
12. Flue connections are created using couplings and gaskets Always arrange couplings against the direction of the condensate flow 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 Generally bevel or deburr trimmed flues to ensure a gas tight installation of pipe joints Ensure that gaskets are correctly fitted Remove all contamination prior to installation never fit damaged parts When sizing flue gas systems in accordance with EN 13384 1 maintain a maximum back pressure of up to 130Pa in to header line this should also not be exceeded As protection against contamination during the building phase we recommend the use of the complete ventilation air filter for MGK 130 to 300 part no 9751390 The ventilation air filter is plugged into the air intake Keep the door of the condensing boiler shut during the building phase After completing the building phase remove the filter 43 IQWOD seg OA sng Bnd snge 1 011 OLX Sulpo 19 109 6X UJJIMS ainssaid seg GS UJJIMS ainssaid seb ni i YS UJJIMS 95 J9JEM ES seb nil ML ZS JOSU9S SJNJEJSdUWS pisino JY S91JOSS990E
13. between 8 2 and 8 5 for the heating water also in the case of combined installations of different materials A water analvsis must be requested from the water supplv companv This must be used to check whether the total hardness is low enough With a specific system volume V s specific gt 10 KW the next smaller value from the following table must be applied with Vsys specific gt 20 KW the next but one smaller value and with Vsys specific gt 40 I KW the smallest value With a specific system volume of 250 I KW the total degree of hardness must be adjusted to 2 3 dH using a desalting process This corresponds to a conductance of 60 100 uS cm If the boiler is integrated into the system without a low loss header the total hardness must be adjusted to 2 3 dH conductance 60 100 uS cm Conversion of total hardness 1 mol m gt 5 6 dH Limit values in relation to the specific system volume VA Va system volume smallest individual power Veys 10 VKW Vsys gt 10 I kW and 40 kW Veys 2 40 I kW Total heating power Total hardness Conduct Total hardness Conduct Total hardness Conduct total alkaline earths ance total alkaline earths ance total alkaline earths ance kW dH mol m LF uS cm PdH mol m LF uS cm PdH mol m LF uS cm 1 lt 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
14. condensing boilers according to EN 437 EN 483 EN 677 and EU 90 396 EEC Gas Consumer Equipment 92 42 EEC Efficiencv Directive 2006 95 EC Low Voltage Directive and 2004 108 EC EMC Directive with electronic ignition and electronic flue gas temperature monitoring for low temperature heating and DHW heating in heating svstems with flow temperatures up to 90 C and 6 bar permissible pressure according to EN 12 828 Open flue gas condensing boilers must only A be installed in a room which complies with the appropriate ventilation requirements Otherwise there is a risk of asphvxiation or poisoning Read these installation and maintenance instructions before Fig Wolf gas condensing boiler installing the boiler Also take the technical engineering information into consideration Lavout MGK Ventilation air aperture Flue outlet with test nipple as Cylinder burner d ih Heat exchanger a sectional design Flue gas pressure switch Flue gas temperature switch H oe Siphon Flow connection Return connection Gas connection High limit safetv cut out inside the sensor well Gas fan Ignition electrode lonisation electrode Mixing chamber Flow sensor Gas combination valve with gas pressure limiter Return sensor Water pressure switch Drain valve Ventilation pipe 3062880 201305 WI F Rated output at 80 60 C Rated output at 50 30 C Rated
15. heat input Low boiler output modul at 80 60 C Low boiler output modul at 50 30 C Low heat input modulating Heat input modulation range Height Width Depth Flue diameter Combustion air supply Heating flow outside diameter Heating return outside diameter Gas connection Balanced flue routing Gas category Gas supply details Natural gas H H 9 5 kVVh m 34 2 MJ m LPG P H 12 8 kWh kg 46 1 MJ kg Natural gas E LL LPG P Water capacity heating water heat exchanger Gas supply pressure Max permissible boiler pressure Max permissible flow temperature Available gas fan draught Flue gas temperature 80 60 50 30 at Qmax Flue gas temperature 80 60 50 30 at Qmin Flue gas mass flow rate Flue gas group according to DVGW G 635 Pressure drop heating water Electrical connection Integral fuse medium slow Power consumption Protection Sound pressure level inside the installation room at full load 1 Total weight dry Condensate volume at 40 30 C Condensate pH value CE ID Specification B23 B33 C33 C43 C53 C63 C83 B23 B33 C33 C43 C53 C63 C83 B23 B33 C33 C43 C53 C63 C83 B23 B33 C33 C43 C53 C63 C83 B23 B33 C33 C43 C53 C63 C83 230 50 230 50 230 50 230 50 230 50 5 5 5 5 5 30 200 45 280 45 280 45 280 45 350 IP40
16. line Connect the differential pressure tester at test nipple to with against atmosphere Switch ON the ON OFF switch After starting the boiler check the supply pressure at the differential pressure tester 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 Switch OFF the ON OFF switch Close the gas shut off valve Remove the differential pressure tester and re seal the test nipple with plug Open the gas shut off valve Check the test nipple is gas tight Close the boiler again Check and if necessary amend the type plate regarding the gas type A f any screvvs are not tightened there is a danger of gas escaping leading to a risk of explosion asphyxiation or poisoning 24 MGK 130 MGK 170 210 250 300 Fig Test nipple for checking the gas supplv pressure Elngestellt auf Erdgas E H Anschlufsdruck Eingestellt auf Erdgas LL Anschlufsdruck Fig Conversion type plate MGK 087511121234567890 F C 108 Wolf GmbH Mainburg 0085 CE 0063BQ3805 1234567890 A Herstellnummer A Gas Brennwert Heizgerat Typ MGK 170 Bestimmungsland DE AT CH Kategorie N2ELL3P 12H3P 12H Eingestellt auf 2E 2H 2H G20 20 mbar Art B23 B33 C33 C43 C53 C83 C63 gem Montageanleitung Nennw rmebelastung Warmwasser Q 2
17. the jumper between a and b from the respective terminals a Floating m mi connection Fig Connection room thermostat The functions of input E1 can be scanned and adjusted with eBUS enabled Wolf control accessories The following functions can be allocated to input E1 Code jExplanation o Without function nput E1 is not taken into consideration by the control unit Room thermostat VVith open input E1 heating operation vvill be blocked summer mode independently of any digital VVolf control accessories Maximum thermostat system pressure svvitch 2 A closed contact is a prerequisite for enabling the burner in heating and DHW mode When the contact is opened the appliance svvitches the burner off and the pump run on starts 3 Not allocated Flow switch 4 Optional connection for an additional water flow switch Input E1 must be closed within 12 seconds after the pump has been switched Where this is not the case the burner will be switched OFF and fault 41 will be displaved 5 Monitoring ventilation air damper factorv setting E1 See parameters of output A1 no 7 ventilation damper 8 Burner disablement operation without burner Operation without burner Closed contact burner lockout Heating circuit pump and calorifier charge pump run in normal mode The burner is enabled in chimnev sweep mode and for frost protection Opened contact enables the burn
18. 05 WI F General information Where necessary adapt the installation examples to the relevant Building Regulations and requirements of vour countrv region Discuss anv questions relating to the installation of inspection covers and ventilation apertures with vour local flue gas inspector Flues inside chimnev ducts must have secondarv ventilation along their entire length and must terminate above the roof Flue gas cascades must be sized in accordance with EN 13384 1 The requirements for installation rooms are specified in Building Regulations or Combustion Equipment Ordinances of the relevant countries Observe all local regulations regarding the room ventilation With low outside temperatures the water AN vapour contained in the flue gas may condense and freeze on the balanced flue This ice may fall from the roof causing injuries or material losses Use on site measures to prevent ice from falling e g the installation of a snow guard Flues must not be routed through other A installation rooms without ducts otherwise there would be a risk of the transfer of fire and there would be no mechanical protection The combustion air must not be drawn from chimnevs that used to carrv flue gases from oil or solid fuel boilers Secure the balanced flue or flue that is outside A ducts with spacer brackets with a minimum clearance of 50 cm from the flue outlet or upstream downstream of diverters to prevent the pipe joints b
19. 100 2 1 50 200 2 11 2 0 36 2 0 60 300 2 84 0 36 1 5 60 200 2 3 0 36 0 54 60 100 3 1 200 600 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 5600 2 3 0 36 0 54 60 100 2 3 0 36 0 54 60 100 2 3 0 36 0 54 60 100 for circulating water heaters 20 3 I KW and systems with electrical heating elements Gradual tightening of the specifications due to the specific system volume Vsys svstem volume lowest individual power setting and the total heating power The total filling quantity of water over the lifetime of the appliance may not exceed three times the nominal vol ume of the heating svstem Warning the total hardness may not fall below 2 dH 3062880 201305 WI F Example Svstem with a 170 KW boiler System volume Vsystem 4000 Vsys specific 4000 I 170 KW 23 5 I KW This is larger than 10 I KW hence stage 3 must be selected instead of stage 2 The filling and supplementary water must lie within the range of 2 to 8 4 dH If the total hardness of the untreated potable water is too high part of the filling and supplementary water must be desalted A saline free water must be added A 100 Cmax 0 1 dH Coot water 0 1 dH x 100 Crax Maximum permissible total hardness in dH Coot water Total hardness of the untreated potable water in dH We recommend that you include the supplementary water expected for the initial
20. 8 160 kW Heizen Q 28 160 kw Nennleistung Heizen 50 30 C P 30 167 kw Heizen 80 60 C Max Vorlauftemperatur Max Betriebsdruck Heizkreis PMS 6 bar Wasserinhalt Heizw rmetauscher 151 Netzanschluf3 230V 50 Hz Elektrische Leistungsaufnahme 280 W Schutzart NOx Klasse Abgaswertegruppe nach DVGW 635 Der Kessel darf nur in einem Raum installiert werden der die makgeblichen Beluftungsanforderungen erf llt Lesen Sie die Montage bzw Betriebsanleitung bevor Sie den Kessel installieren bzw in Betrieb nehmen DE AT CH 8751156 06 08 Fig Type plate MGK tist 1234567890 3 xs 2 s s 8 8751112 MGK 170 EH 3062880_201305 WI JEF Commissioning A Only qualified personnel mustcarry outthe starts correctiv commissioning and operation of the boiler e Check the condensate drain as well as instruct the user e Familiarise the customer with the operation of the e Check that the power supply has been switched boiler using the operation and or assembiv instruc OFF tions and point out anv necessarv treatment of filling e Check the boiler and system for leaks and supplementarv water e Complete the commissioning report and hand over the instructions to the customer Prevent water leaks Check location and seating of fitted components Checkall connections and component links for leaks If tightness cannot be ensured then there is a Saving energv risk of wat
21. British Standards BS 5440 Flues and ventilation of gas fired boilers not exceeding 70 kW net Part 1 Flues Part 2 Ventilation BS 5449 Specification for forced circulation hot water for domestic premises BS 5546 Specification for gas hot water supplies for domestic premises BS 6700 Services supplying water for domestic use within buildings and their curtilages BS 6798 Specification for installation of gas fired boilers not exceeding 60 kW input BS 6891 Specification for installation of low pressure gas pipework up to 28 mm R1 in domestic premises 2nd familv gas BS 7593 Treatment of water in domestic hot water central heating systems nstitute of Gas Engineers Publication IGE UP 7 1998 Guide for gas installations in timber framed housing mportant The appliance must be installed and serviced by a competent person as stated in the Gas Safety Installation and Use Regulations 1998 In IE the installation must be in accordance with the current edition of 1 5 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ECI rules for electrical installation When tightening or loosening threaded connections alwavs use suitable open ended spanners not pipe wrench or extensions etc Incorrect use and or unsuitable tools can lead to damage e g gas or water leaks WI JEF Standards and regulations Lavout MGK Gas condensing boiler MGK Gas
22. Neutralising system accessory Condensate drain single boiler systems When installing the MGK as an individual appliance fit a condensate drain DN 160 part no 2651341 DN 200 part no 2651389 The connections of the condensate source can be joined with the Condensate hose set part no 8905844 and can be connected to the neutralising system Fig Condensate hose 16 3062880_201305 WI JEF Installation Condensate lifting svstem accessorv The Wolf condensate lifting svstem is fullv wired and can be integrated into the MGK The power supplv and the alarm output of the condensate lifting svstem are connected to the boiler control unit 6 mPVC hose for draining off the condensate is included Condensate lifting system accessory Connection of a Wolf cylinder solar cylinder SEM or third party cylinder We recommend the MM or KM controllers from the range of Wolf accessories for optimum switching of heating circuit and cylinder primary pumps A When sizing the cvlinder ensure that the lowest constant cvlinder output corresponds at least to the lowest heat input from the boiler A solar cvlinder without solar thermal svstem can be connected to increase the constant DHW output For this both internal indirect coils need to receive a volume flow in series Otherwise it cannot be assured that the cvlinder will be fullv heated up Gas connection gt b P gt gt Routing the gas pipe as well as making th
23. OJ UONDSUUO sng Sng jndui LI jndjno ajqewweJ6Bol4 LV dwnd BuneaH Z ZH 0S OV A 062 Alddns J MOd xoq uonounr 2 111 an AM Av kizi i 9AJBA Iquwoo 566 45 3062880_ 201305 WI F Anv faults will be displaved as fault codes bv Wolf controllers with eBUS capabilitv Cause and remedv mav be allocated to these faults using the following table This table is designed to allow vour local heating contractor to trace the fault more easilv Troubleshooting Fault Fault Cause Remedy code 1 TBV excess The flovv temperature has exceeded the Check the system pressure Check the heating temperature limit for the TBV shutdovvn temperature or circuit pump Vent the system Press the reset water pressure too the condensate lifting pump accessory button low has developed a fault or the water pressure Check the condensate pump fault condensate switch switches off at a pressure lt 1 0 bar Increase svstem pressure pump 4 No flame builds No flame builds during burner start Check the gas supplv line and open the gas valve if necessarv Check the ignition electrode and ignition cable Press reset 5 Flame failure during Flame failure within 15 s after flame Check CO values Check ionis
24. ad emissions test mode Undo the four screws from the front casing and remove the casing Remove the screw from the flue gas test port Insert the test probe of the CO test instrument into the flue gas test port Turn the temperature selector to Emissions test A Illuminated status indicator ring flashes yellow Check the CO content at full load and compare the actual values with those in the table below Correct the CO setting as required using the gas throughput adjusting screw on the gas combination valve in accordance with the table Turn clockwise lowers CO content Turn anti clockwise raises CO content Appliance open without casing at upper load Natural gas H 9 2 0 2 Terminate the emissions test mode by returning the temperature selector to its original position Test port flue gas E ca 00000000 00000000 00000000 00000000 000000000 o o o o Fig Flue gas test at the integral test port MGK 130 MGK 170 210 250 300 Gas throughput adjusting screw under cover Allen screw 3 mm for the MGK 170 MGK 300 Slotted screw for the MGK 130 Fig Gas combination valve 3062880_201305 Changing the gas type CO settings B CO adjustment at the lower load soft start Restart the gas condensing boiler by pressing the Reset button e Check and if necessary correct the CO content approx 30 s after burner start using the CO tester
25. ating systems DIN EN 12828 Heating systems in buildings designing hot water heating systems EN 60335 1 Safety of electrical equipment for domestic use and similar purposes VDE 0470 EN 60529 Protection through housings EN 12831 Method for calculation of the design heat load EN 13384 Chimneys Thermal and fluid dynamic calculation method Any damage or loss resulting from technical A modifications to the control unit or to the control components are excluded from our liabilitv Incorrect use can lead to a risk to life and limb or to a risk of material losses 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 3062880 201305 Standards and regulations Requirements The installation of the boiler must be in accordance with the relevant requirements of Gas Safetv Installation and Use Regulations 1998 Health and Safetv Document No 635 The Electricitv at Work Regulations 1989 BS 7671 IEE Wiring Regulations and the Water Supplv Water Fitting Regulations 1999 or The Water Bvlaws 2000 Scotland It should also be in accordance with the relevant requirements of the Local Authority Building Regulations including amendments to the Approved Documents Part L and J 2002 The Building Regulations Scotland The Building Regulations Northern Ireland and the relevant recommendations of the following
26. ation electrode operation detection and cable Press the reset button 6 TW excess The flow return temperature has exceeded 1 Check the system pressure Vent the system temperature the limit for the TW shutdown temperature Increase pump speed 7 TBA excess The flue gas temperature has exceeded Clean the heat exchanger check the flue gas temperature the limit for the TBA shutdown temperature system overpressure in the 1 flue gas system is blocked ventilation air is 1 Check ventilation air system flue gas system blocked Check flue gas pressure svvitch 11 Flame pretence A flame is recognised before the burner Press the reset button starts 12 Faulty flow sensor The flow temperature sensor or lead is Check lead gas pressure too faultv Check the flow sensor low Gas pressure lt than the value set at the Check gas pressure gas pressure switch only displayed after 15 Check the gas pressure switch settings min 14 Cvlinder sensor DHW temperature sensor or lead faultv Check sensor and lead faultv 15 Outside temperature The outside temperature sensor or cable is 1 Check lead sensor faultv faultv Check the outside temperature sensor 16 Return sensor faultv The return temperature sensor or lead is Check lead faultv Replace the return sensor 20 Fault gas valve 1 A flame is detected for 15 s after burner Replace the gas combination valve operation even though gas valve 1 has received a shutdown command 21 Fault gas valve 2 1 A flame is det
27. e On the right side a clearance of at least 500 mm is required to enable the burner removal and installation An adequate amount of space must also be provided in front of the boiler to enable cleaning and service 2 boilers inthe installation room back t back 3062880_201305 11 WI F Transportation into the installation room To ease the transportation into the boiler room lifting slings are supplied with the boiler Never use sack trucks Levelling the boiler with the adjustable feet At the factory the boiler is equipped with four adjustable feet e Level the boiler with the adjustable feet spanner size 13 Dimensions 1355 TI6K 170 210 250 300 Fig Dimensions Total height incl connector MGK 130 250 1460 mm MGK 300 1510 mm 12 Installation information Dimensions Fig Lifting eves for lifting slings Fig Feet MGK 130 MGK 170 210 250 300 1187 Fig Connection dimensions 3062880 201305 WI JEF Dismantling casing Dismantling the casing Fig Dismantling the front and side casing 3062880 201305 WI JEF Boiler svstem pipework Heating svstem flow and return are at the top of the boiler For connections see Fig Alwavs provide shut off valves for the flow and the return Install a check valve downstream of the heating circuit Heating flow Heating return pump s to prevent incorrect circulation For new sy
28. e installation of a MGK with a low loss header Select pumps in accordance with the respective svstem if no low loss header is to be installed Wilo Grundfos 130 Stratos 25 1 8 Magna 25 80 screwed 11 2 screwed 172 170 Stratos 30 1 10 Magna 32 80 screwed 2 screwed 2 210 Stratos 30 1 12 Magna 32 100 screwed 2 screwed 2 250 Stratos 32 1 12 Magna 32 120 F flanged flanged 300 Stratos 32 1 12 Magna 32 120 F flanged flanged 3062880_201305 WI F Ventilation air flue gas routing Engineering information combustion air flue gas routing t t 14 Nt t FN 4 A U A 1 L a l LI C33 4 LI OO je i t l C53 lt z C53 B23 FI FI EI 9 gi EHH i l C83 lt B23 C33 C43 B33 Ed EJ Ed E E EE H H H Connection types Boiler Gas boiler Categorv Operating mode Can be connected to tvpe tvpe 1 Germany Open flue Balanced Moisture Room Room Building Moisture flue resistant sealed sealed Regulation resistant flue chimney balanced balanced approved flue flue Flue B23 B33 C33 l 2 Ves Ves C83 C43 C33 C53 C53 C63 B23 C53 C83 C43 C53 ce3 1 jU C63 C83 1 For type B23 the combustion air is drawn from the installation room open flue combustion equipment For type C the combustion air is drawn through a seal
29. e gas connections must only be carried out by a licensed gas fitter Remove all residues from the heating pipework and the gas line prior to connecting the condensing boiler particularly in older systems Prior to commissioning test all pipe and gas connections for leaks Inappropriate installation or Using unsuitable components or assemblies may lead to gas escaping which results in a risk of poisoning and explosion Install a gas ball valve with fire protection in the gas supply line upstream of the Wolf condensing boiler Otherwise explosions mav occur during a fire Size the gas supplv line in accordance with local regulations Check the gas line for tightness without the boiler Never release the test pressure via the gas valve Gas fittings on the appliance mav be pressure tested to 150 mbar Higher pressure mav damage the gas train resulting in a risk of explosion asphvxiation 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 easilv accessible place Prior to installation ensure that the boiler is set to the available gas tvpe At the factorv the boiler is set up for natural gas H 15 0 Ws 11 4 15 2 kWh m3 40 9 54 7 MJ m3 When changing the gas type set the appliance in accordance with chapter Changing the gas tvpe CO settings Only commission the appliance when the rated supply pressure has been reached 3062880_201305 17 WI UF
30. e 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 3062880_201305 Safety instructions Fig Junction box MGK 170 210 250 300 Danger from electrical voltage Fig Ignition transformer high voltage ignition electrode combustion chamber Danger from live electrical components risk of burning through hot components Fig Gas combination valve MGK 170 210 250 300 Danger from electrical voltage Escaping gas may cause poisoning or the risk of explosion WI F Safetv instructions The following regulations and rules have to be adhered to during installation commissioning maintenance and service gt D D gt D P PRP P gt The installation may only be operated in technically perfect condition Pertur bances and damages affecting safety have to be eliminated at once When set
31. ected for 15 s after burner Replace the gas combination valve operation even though gas valve 2 has received a shutdown command 24 Gas fan fault The gas fan does not reach the required Check the gas fan supply cable and the gas pre purging speed fan press the reset button 25 Gas fan fault The gas fan does not reach the ignition Check the gas fan supply cable and the gas speed fan press the reset button 26 Gas fan fault The gas fan does not stop Check the gas fan supply cable and the gas fan press the reset button 30 CRC fault gas The EEPROM record Gas condensing Switch the power supply OFF and ON condensing boiler boiler is invalid If unsuccessful replace the control PCB 31 CRC fault burner The EEPROM record Burner is invalid Switch the power supply OFF and ON If unsuccessful replace the control PCB 32 24 V AC supply 24 V AC supply outside the permissible Check the gas fan faulty range e g short circuit 46 3062880_201305 WI JEF Troubleshooting Fault Fault Cause Remedy code 33 CRC fault default The EEPROM record Master reset is Replace the control PCB values invalid 34 CRC error BCC Parameter plug error Exchange parameter plug 35 BCC missing Parameter plug has been removed Plug in the correct parameter plug 36 CRC error BCC Parameter plug error Exchange parameter plug 37 VVrong BCC The parameter plug is not compatible vvith Plug in the correct parameter plug the cont
32. ed system from the outside balanced flue combustion equipment 3062880_ 201305 37 WI JEF Engineering information combustion air flue gas routing Ventilation air flue gas routing Implementation versions condensing boiler Maximum length 1 MGK DN 130 170 210 250 300 B23 Flue in a duct and combustion air directly via the boiler 160 2 50 m 50 m 47 m 35 m 20 m open flue 200 3 50 m 50 m 50 m 50 m 50 m 7 yx 2 B33 Connection to a moisture resistant chimney with 160 Calculation 1 to EN 13384 1 horizontal connection line 200 3 Combustion air supplv and flue gas routing via the roof 160 2 Calculation 1 to EN 13384 1 C33 in a common pressure range 4 200 3 See also example C33 1 Vertical concentric roof outlet through a pitched or flat oe 15m 15m 13 m 8m 3m C33 roof vertical concentric balanced flue for installation in a 200 duct each balanced flue 300 15m 15m Connection to a moisture resistant balanced flue 160 2 1 R C43 chimnev balanced flue 200 3 Calculation 1 to EN 13384 1 C53 Terminals of the ventilation air and flue are in different 160 2 50 m 50 m 47m 35 m 20 m pressure ranges balanced flue 200 3 50 m 50 m 50 m 50 m 50 m Connection to a flue run on an external wall with a 50 m 50 m 35 m 5m C53 horizontal concentric connection line length 2 5 m 200 balanced flue
33. eing pulled apart If this is not done there is a danger of poisoning caused by escaping flue gas Furthermore boiler damage may result To prevent flue gas escaping a positive A pressure flue cascade is only permitted with a tested flue gas damper part no 2482896 For the MGK 130 this is alreadv integrated 3062880 201305 Engineering information combustion air flue gas routing Connection to a combustion air and flue svstem tvpe C63 that has not been tested together with the gas combustion equipment Original Wolfcomponents have been optimised over many years and are matched to the use with Wolf condensing boilers When using third party equipment that is only CE designated the installer will be responsible for the correct sizing and perfectfunction of such systems Faults material losses and injuries resulting from incorrect pipe lengths excessive pressure drop premature wear with escaping flue gas and condensate or incorrect function e g through components working themselves loose are excluded from our warranty if non CE approved third party equipment is used Ifthe combustion air is taken froma duct the coonduit has to be free of contaminations Connection to the ventilation air system and the flue The unobstructed cross section of flues must be able to be inspected Therefore install an inspection and or test aperture inside the boiler room agree suitable arrangements with your local flue gas inspector
34. er again Connection digital Wolf control accessories Oniv connect control units from the Wolf accessorv range Each accessorv is supplied with its own connection diagram Use a two core cable cross section gt 0 5 mm as the connecting cable between the control unit accessorv and the condensing boiler Fig Digital Wolf control accessories connection eBUS interface Connection outside temperature sensor The outside temperature sensor for digital control accessories may be connected to the terminal strip of the AF boiler connection or the terminal strip of the control accessories Fig Connection outside temperature sensor 22 3062880 201305 WI F Filling the system filling the siphon Fill the system and vent it correctly in line with the details in the chapter Water treatment to ensure the perfect function of the condensing boiler see page 30 Before connecting the gas condensing boiler 2 69 flush the heating svstem to remove residues a gt a such as welding pearls hemp putty etc from the pipework ON OFF switch Reset button Thermometer The gas tap must be shut Open the air vent valves Fig Control unit overview e Open all heating circuits Open all radiator or mixer valves e Slowly fill the entire heating system and boiler when cold for example via the BDF valve at the return t
35. er damage e Instruct the customer about energy saving options e Check thatall flue gas accessories have been correctly installed e Refer your customer to section Information j for energy efficient operation in the operating Open the shut off valves in flow and return instructions Open the gas shut off valve Switch the power supply live Switch ON the system ON OFF switch on the control unit e Check the ignition and the regular flame structure of the burner If the system water pressure falls below 1 5 bar top up with water until a pressure of 2 0 to max 5 5 bar ON OFF Reset button Thermometer has been achieved switch Illuminated ring Theilluminated ring shows a green colour if the boiler Fig Control unit overview Setting the BUS address for multiple heating appliances When operating several heating appliances set the BUS address in conjunction with a KM control unit in accordance with the table Hold down the reset button after 5 seconds the corresponding flashing code will be displaved see table Select the corresponding address with the DHW temperature rotarv selector then release the reset button again BUS address Rotarv selector position lluminated ring indication DHW 1 1 flashing red 2 2 flashing vellow gg U flashing yellowed 4 4 flashing yellow green 5 5 flashing green red 0 6 flashing green factory setting 3062880_201305 25 WI F Mod
36. etting the BUS 4 55 25 Displaying modifying control 5 26 Limiting the maximum OUtpUt 55 27 Changing the gas type CO settings 28 30 Testing the combustion 5 31 Commissioning Tepr ii 32 Technical information water treatment 33 34 Systemlogr standen cele nede eee 35 Engineering data sissa jk a e Aksdal 36 Engineering information combustion air flue gas routing 37 43 Wiring diagram MGK 130 2422231006304660 EE EE 44 Wiring diagram MGK 170 300 iiic 45 Troubleshootingse i pig fin een ee nee 46 47 Resistance table mime dreit ekk wita few ek Im je d abri RAN d kke BR LA pE R nie 48 NOUCO 122200 tA A era sen 49 51 EC declaration of conformity 52 2 3062880 201305 WI F The following svmbols and references are used in conjunction with these important instructions concerning personal safetv as well as operational reliabilitv Safety instructions are instructions with A which you must comply exactly to prevent risks and injuries to individuals and material losses on the boiler A Danger from live electrical components NB Switch OFF the ON OFF switch befor
37. filling in the calculation Untreated potable water can then be used for topping up later Vireated Ax Vsystem V supplement In the case of large systems in stage 4 the supplementary water may not be included in the calculation for the initial filling V treated Ax Vsystem 34 Technical information water treatment Example System power 170 KW System volume Vsystem 4000 I Volume of the supplementary water Vsuppiement 1000 Total hardness of the potable water Chot water 18 5 dH Maximum permissible total hardness Cmax 8 4 dH System power 170 KW System volume Vsystem 4 000 I Volume of the supplementary water V supplement 1 000 Vsys specific 4000 I 170 KW 23 53 I KW Total hardness of the potable water Chot water 18 5 dH Maximum permissible total hardness Cmax 8 4 dH Proportion of the filling water to be treated A 100 8 4 0 1 18 5 0 1 x 100 54 9 54 9 of the filling and supplementary water must be desalted Vireated 54 9 x 4 000 I 1 000 I 2 746 When filling the system 2 745 deionised water must be filled Subsequently the system can be topped up to Vmax with potable water When topping up it must be checked regularly that the maximum permissible total hardness is not exceeded 3062880_ 201305 WI F Svstem log
38. ial enough to carry its weight The boiler must be level level with adjustable feet The boiler must only be installed in a room that is protected from frost Drain the boiler and the entire heating system if there is a risk of frost when the system has been shut down to prevent pipes from bursting Boilers should not be installed in areas subject to aggressive vapours very dusty or highly Boiler in the installation room humid conditions workshops laundry rooms hobby rooms etc This prevents the optimum burner function from being achieved The combustion air supplied to the boiler must A be free from halogenated hvdrocarbons e g as contained in spravs solvents cleaning fluids paints and adhesives Under the most unfavourable conditions these mav lead to pitting of the boiler and even the flue gas svstem 2 4 boilers in the installation room side by side Never store or use combustible material or liquids near the boiler The ventilation air supply must be ensured and comply with local regulations or those relating to gas installations When there is an insufficient supplv of ventilation air flue gas can escape leading to a risk to life poisoning asphvxiation PP Prior to commissioning ensure with the appropriate authorities whether a neutralising svstem for condensate is required Recommended minimum wall clearances The boiler can be positioned close to the wall both at its back and its left sid
39. ifications must oniv be carried out bv arecognised heating contractor or bv Wolf customer service Incorrect operation can lead to svstem 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 Displaving modifving control parameters A heating system damage 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 The control parameters can be modified or displayed via control accessories with eBUS capability For procedures check the operating instructions of the relevant accessories Factorv Parameter Setting range setting Ind setting Column 1 Column 2 GB01 HG01 Flow temperature hysteresis 5 to 30 K 8K HGO2 Lower fan speed 20 to 100 20 HGO3 Higher fan speed DHW 20 to 10096 10096 GB04 HG04 Higher fan speed central heating 20 to 100 100 GB05 A09 Frost protection limit 10 to 10 C 2 C With connected outside temperature sensor and insufficient temperature pump ON GB06 HG06 Pump operating mode 0 to 1 0 0 Pump ON in winter mode 1 Pump ON with burner operation GBO7 HGO7 Boiler circuit pumps run on time 1 t
40. nd 5 minutes OFF Output A1 is constantly cycled in 5 minute intervals when no accessory controller is installed 3 DHW circulation pump 20 Output Af is switched by control accessories BM in cycles if DHW circulation has been enabled 2 minutes ON and 8 minutes OFF Output A1 cycles constantly when no accessory controller is installed 4 Alarm output Output A1 is switched after a fault and after expiry of 4 minutes 5 Flame detector Output A1 is switched after a flame has been detected 6 3 way valve Output A1 is switched during cylinder heating 7 Ventilation damper Output A1 is switched first prior to each burner start The burner will however only be enabled after input E1 has been closed gt N H ia EH 2 50 En 3 o0 Important In any case input E1 must also be programmed as Ventilation damper lt Dd lz The feedback to input E1 must be made with a floating contact Otherwise use an on site relay for potential separation 8 External ventilation Output A1 is switched inverse to the gas combination valve Switching OFF external ventilation e g extractor fan during burner operation is only required if the boiler is operated as an open flue system 9 External gas valve Output A1 is switched in parallel to the gas combination valve 3062880_201305 21 WI JEF Electrical connection Connection input E1 24 V Connect the connecting cable for input 1 at terminals E1 in accordance with the wiring diagram first remove
41. ng the svstem must be thoroughiv cleaned flushed through and a sludge filter 5 um e g Wolf accessories installed in the return and in direct proximitv to the boiler The filling and supplementarv water mav be treated only by means of a desalting procedure The necessary degree of water treatment can be taken from the table Maximum permissible total hardness The total degree of hardness of the svstem water mav not fall below 2 dH this corresponds to a conductance of 60 uS cm The max permissible total degree of hardness and the corresponding max conductance are svstem specific and must be calculated see also the table Maximum permissible total hardness To this end the saline free water conductance lt 30 uS cm must be mixed with untreated potable water The addition of chemical agents as well as lime elimination via single stage ion exchangers is not permissible since otherwise device damage can occur leading to the escape of water We recommend regular emptving of the sludge filter and the maintenance of a svstem logbook Permissible methods Deionisation via mixed bed cartridges These are multi stage ion exchangers We recommend cartridges from the Grunbeck or Judo companies for the initial filling and later if required Deionisation by reverse osmosis Topping up with distilled water Technical information water treatment Treatment of the heating water based on VDI 2035 We recommend a pH value of
42. o approx 2 bar pressure Inhibitors are not permissible Open the flow valves on the condensing boiler e Fillthe heating system to 2 bar pressure In operation the pressure gauge must indicate between 1 5 and 5 5 bar Check the entire system for water leaks e Remove the siphon Fill the siphon with water e Refit the siphon Start the condensing boiler set the heating water BDF valve Water pressure switch selector to position 2 pump running illuminated status indicator ring constantly green Fig BDF valve Vent the heating circuit for this switch the gas condensing boiler ON and OFF again several times Top up with water when the system pressure falls substantially Open the gas ball valve Press the reset button Note In constant mode the heating circuit is automatically vented via the air vent valve accessory The condensate hose attached to the siphon must not form a loop or roll up otherwise the operation might be impaired Fig Siphon 3062880_201305 23 WOM Checking the gas supply pressure Checking the gas supply pressure Gas flow pressure Work on gas components must only be A performed by a licensed gas fitter Work which is carried out incorrectly may lead to gas escaping resulting in a risk of explosion asphvxiation or poisoning Set the ON OFF switch to Open the gas shut off valve Release the plug at test nipple and vent the gas supply
43. o 30 min 1 min GB08 HGO8 Maximum limit boiler circuit TV max 2 A or HG22 applies to heating mode 55 57 GBO9 HG09 Burner cycle block 1 to 30 min 7 min Applies to heating mode HG10 eBUS address display only 0 to 5 0 Heat source BUS address GB13 HG13 Programmable input E1 0105 5 Various functions can be assigned input E1 See chapter Connection input E1 GB14 HG14 Programmable output A1 0 to 15 7 Various functions can be assigned to output A1 See chapter Connection output A1 GB15 HG15 Cylinder hysteresis 1 to 30 K 5K Switching differential for cylinder re heating HG21 Minimum boiler temperature TK min 20 to 90 C 20 C Column 1 Control accessories ART DWT DWTM DWTK Column 2 Control accessories WRS Wolf control system 26 3062880_ 201305 WI JEF Limiting the maximum output MGK 130 MGK 170 MGK 210 MGK 250 MGK 300 Output setting parameter GB04 The output setting can be modified with Wolf control accessories with eBUS capabilitv The heating output will be determined by the gas fan speed By reducing the gas fan speed in accordance with the table the maximum output will be matched at 80 60 C to natural gas H Output kw 23 31 38 46 53 61 68 76 83 91 99 1061 1141 121 Display value MGK 170 Output kW 27 40 50 60 70 80 90 100 110 1201 1301 1401 1501 1601 output ew T r 40 55 170 Tas 100 15 130 145 160 175 190 200 Dis
44. o 85 C and may be adjusted to 90 C if required Generally the flow temperature is 80 C for DHW operation There is noneed for a minimum throughput at maximum flow temperatures below 85 C Heating water General requirements There is a danger of damage to the wall A mounted boiler leading to the escape of water poorer heat transmission or corrosion Theheating system is to be flushed through before the connection of the wall mounted gas condensing boiler in order to remove residues from the pipework such as welding sputter hemp puttv sludge deposits etc Installation of a sieve dirt trap in the return and regular maintenance of the sieve dirt trap see Wolf accessories 5 um The automatic vent of the appliance must be open during operation Potable water or saline free potable water is to be used as filling and supplementary water The hardness of the system water may not fall below 2 dH The system specific filling and supplementary water qualities are to be taken from the section Water treatment planning notes A hydraulic separator must be provided for if the entry of oxygen cannot be excluded The pH value of the heating water must lie between 8 2 and 8 5 In general filling and supplementary water must be submitted to a desalization softening via a single stage ion exchanger is not permissible The permissible methods and limit values are to be taken from the section entitled Water treatment planning no
45. oiler has not been isolated from the power supply Risk to life 3062880_201305 Electrical connection Power supply Programmable 230 V output AC 50 Hz 230 V AC 50Hz Povver suppiy heating circuit pump 230 V AC 50 Hz max 400 VA Programmablej Outside input floating temperature sensor BUS Controller radio clock AF vvith radio clock receiver outside radio sensor Rast5 plug Strain relief x Fuse 5 A fast Fig Junction box Fig Terminal box cover open WI JEF Electrical connection Heating circuit pump connection 230 V AC max EIE DEKI Insert the cable glands into the terminal box Insert LIIN 11 and secure the cable through the cable entry Connect the heating circuit pump 230 V AC to terminals L1 N and T Fig Connection heating circuit pump Wiring diagram ventilation air damper not for MGK 130 Note The contractor parameter HG13 GB13 input 1 must be set to 5 factorv setting for supplv air damper and HG14 GB14 input 1 must be set to 7 factorv setting for supplv air damper With the contact open the burne
46. ort After the test has been completed remove the test probe and close the test port again Ensure the screws are seated firmly Return the temperature selector into its original position 3062880_ 201305 31 WI F Commissioning report Commissioning steps Test value or confirmation 1 Gas tvpe Net flue gas temperature Carbon dioxide content CO3 or oxygen content O3 Carbon monoxide content CO Natural gas H U LPG O Wobbe index kWh m Calorific value heating kWh m 2 Gas supply pressure checked q 3 Gas leak test carried out 4 Balanced flue system checked q 5 Water connections checked for leaks q 6 Siphon filled q 7 System flushed 8 System filled and vvater treatment carried out according to Water treatment planning notes pH value adjusted pH value Total degree of hardness adjusted 4 9 Has the system been filled in acc with the technical information regarding water treatment 10 Boiler and system vented o 11 System pressure 1 5 2 5 bar gO 12 Entered gas type and output onto label 13 Function test carried out o 14 Flue gas test Gross flue gas temperature ta C Inlet air temperature ta C ta t PC ppm 15 Casing fitted q 16 System user trained documentation handed over q 17 Confirm commissioning gO 32 3062880_ 201305 WI F Before commissioni
47. p 9 Top up water Viop up 10 Check Water volume V gt Vmax LI Yes O No If the water volume V is greater than Vinax top up with desalinated water 3062880_201305 35 WI F Heating water pressure drop Max spread Max flow rate Pump sizing MGK 130 170 210 250 300 36 Pressure drop on the heating water side mbar Engineering data 540 s _ T JE E 5 1 me pose eee ei es swo JA nu m DUNO a on ee 1 a EE ee Ee 1 OE 26 E 25 0 AT EH HE en n ee so Ie 180 160 140 120 100 7 4 60 Z 4o OA 20 0 0 1 2 3 4 5 6 F 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Throughput m h A cast section protection function is integrated in the MGK This prevents stresses in the material by limiting the maximum temperature differential between the flow and return As of 28 K the output is reduced If 38 K is nevertheless reached the burner shuts down briefly without a fault message This characteristic must be taken into account when selecting the components e g pumps heat exchanger and cylinder Excessive flow velocities may lead to erosion Maximum flow rate at Qmax MGK 130 9 4 m h MGK 170 13 6 m h MGK 210 16 4 m h MGK 250 19 1 m h MGK 300 21 9 m3 h The following 230V pumps represent recommendations in conjunction with th
48. panv VDE standards and local regulations of the En ergv Supplv Companv have to be adhered to Terminal box The control regulating and safetv equipment are fullv wired and tested You only need to connect the power supply and the external accessories Power supplv Create a permanent connection for the power supply Provide the power supplv via a main isolator heating system emergency stop switch that ensures at least 3 mm contact separation for all poles Power cable flexible 3 x 1 0 mm or rigid up to 3 x 1 5 mm Installation information electrical connection mains Isolate the system from the power supply before opening Open the terminal box Insert the strain relief into the holes provided Strip approx 70 mm insulation off the power cable Push the cable through the strain relief and secure the strain relief Pull off the Rast5 plug Terminate the appropriate cores at the Rast5 plug Leave the cores for the earth conductor gr ye approx 10 mm longer than those for L and N Push the inserts back into the terminal box casing Push the Rast5 plugs back into their correct positions Changing a fuse Isolate the gas condensing boiler from A the power supply before changing a fuse The ON OFF switch on the boiler does not provide separation from the power supply Danger through live electrical components Never touch electrical components or contacts as long as the gas condensing b
49. play value wm 20 23 30 37 Tas 52 66 73 95 109 Output kw 40 55 70 85 1001 115 1301 145 1601 1751 190 205 220 240 Display value 20 26 32 38 44 50 56 62 68 74 80 86 92 100 Output kw 45 62 79 97 114 131 148 165 182 200 217 234 2511 275 Display value 20 27 34 41 47 154 61 68 75 82 89 96 1021 100 Table Output setting Limiting the maximum output relative to a flow return temperature of 80 60 C 280 _ LT T L i Lo ao iii T IX 220 200 180 160 140 120 100 80 60 40 20 Maximum output in kW 20 28 34 40 46 52 58 64 70 76 82 88 94 100 Settings for parameter GB04 with eBUS enabled Wolf connection accessories in 3062880_201305 27 WI F Adjusting the gas air connection Carrv out the adjustments in the following sequence Atthe 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 Converting the MGK 130 to LPG P A separate conversion kit with gas restrictor gas combination valve and boiler coding card is required for this conversion Observe the information in the conversion instructions supplied Conversion MGK 170 210 250 300 to P A separate conversion kit with boiler coding card is required for this conversion Ob
50. r remains blocked for DHW and central heating even Ei rs s n A d for emissions test and frost protection Terminal box MGK Supply air damper with servomotor NB Limit svvitch for supply air damper must be floating Othervvise the MGK control unit vvill be destroyed Power supplv 230 V AC L Limit switch 20 3062880 201305 WI JEF Electrical connection Connection output A1 230 V AC 200 VA Insert the cable glands into the terminal box Insert and secure the connecting cable through the cable gland LIPPE Terminate the connecting cable at terminals L1 N and The parameters for output A1 are described in the table LYN LE C Fig Connection output A1 The functions of output A1 can be scanned and adjusted with eBUS enabled Wolf control accessories The following functions can be allocated to output A1 Code Explanation 0 No function Output A1 is not switched 1 DHW circulation pump 100 Output A1 is switched by control accessory BM if DHW circulation has been enabled Output A1 is constantly activated when no accessory controller is installed 2 DHW circulation pump 50 Output A1 is switched by control accessories BM in cycles if DHW circulation has been enabled 5 minutes ON a
51. rn sensor flow sensor header sensor Temp C Resist O Temp C Resist O Temp C Resist O Temp C Resist O 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 26189 26 4786 61 1200 96 382 8 24816 27 4582 62 1158 97 371 7 23523 28 4388 63 1117 98 360 6 22305 29 4204 64 1078 99 349 5 21157 30 4028 65 1041 100 339 4 20075 31 3860 66 1005 101 330 3 19054 32 3701 67 971 102 320 2 18091 33 3549 68 938 103 311 1 17183 34 3403 69 906 104 302 0 16325 35 3265 70 876 105 294 1 15515 36 3133 71 846 106 285 2 14750 37 3007 72 818 107 277 3 14027 38 2887 73 791 108 270 4 13344 39 2772 74 765 109 262 5 12697 40 2662 75 740 110 255 6 12086 41 2558 76 716 111 248 7 11508 42 2458 77 693 112 241 8 10961 43 2362 78 670 113 235 9 10442 44 2271 79 670 114 228 10 9952 45 2183 80 628 115 222 11 9487 46 2100 81 608 116 216 12 9046 47 2020 82 589 117 211 13 8629 48 1944 83 570 118 205 48 3062880 201305 WI F 3062880 201305 Notice WI JEF Notice 50 3062880
52. rol board 38 BCC no invalid Parameter plug error Exchange parameter plug 39 BCC system error Parameter plug error Parameterstecker vvechseln 41 Flovv monitoring Return temperature gt Flow 25 K Vent the heating system check the system pressure Check the heating circuit pump 43 Burner starts Flow rate through the heat exchanger too Check the flow rate gt 20 per hour low or in case of cascade measuring point 1 Header sensor must measure the common of the header temperature unsuitable or feed temperature of the cascade power consumption of the calorifier charging too low 50 Activation of the The parameter plug is still to be activated Press the reset button twice parameter plug 52 Activation of the The parameter plug is still to be activated Press the reset button twice parameter plug 60 lonisation current The siphon is blocked or the flue gas Clean siphon check flue gas system check fluctuates system is blocked severe storm ventilation air check monitoring electrode 61 lonisation current Poor gas quality monitoring electrode faulty Check monitoring electrode and lead fails severe storm LED constantly red lonisation cable shorted out or ionisation Check ionisation cable and position of electrode earthed casing electrode to burner Press the reset button 3062880_201305 47 WI JEF Resistance table NTC Boiler sensor cvlinder sensor solar cvlinder sensor outside temperature Sensor resistances sensor retu
53. s after 15 minutes or when the maximum flow temperature has been exceeded To reactivate turn the heating vvater temperature selector anti clockvvise and then back into position Thermometer The current heating flovv temperature is displayed Anti seizing pump protection n summer mode any connected circulation pump operates for approx 30 seconds after a maximum idle period of 24 hours The number of times the condensing boiler can be started in heating mode is limited electronically This limit can be bypassed by pressing the reset button Then the boiler starts immediately as soon as a heat demand has been issued WOLF Delivered condition Connections Delivered condition The standard delivery includes Gas condensing boiler fully wired Technical guide and installation instructions Operating instructions Lifting slings Ma Connections Power cable inlet 230 V Heating flow Heating return Cable inlet 24V Gas connection Grommet Condensate hose Combustion air supply 160 Flue outlet with integral test nipple 0160 0200 Condensate drain connection Condensate drain connection optional Connection for balanced flue operation with ventilation air adaptor accessorv 10 3062880 201305 WI JEF Installation instructions General tips regarding location MGK 130 The boiler should be installed on a level surface which Dim B 1 MGK 170 210 250 300 1355 mm is substant
54. se of multi boiler svstems it is recommended to put all boilers into operation at the same time so that the total amount of lime cannot concentrate on the heat transfer surface of an individual boiler To submit pipework to a leak test A 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 safetv valve accessorv will open at 3 bar The device has alreadv been tested for leaks at 6 bar in the factorv If there are leaks there is a danger of escape of water leading to damage to propertv With a specific system volume of 250 I KW the total degree of hardness must be adjusted to 2 3 dH using a desalting process WI JEF Installation Condensate connection Fill the siphon with water prior to commissioning Otherwise there is a risk of flue gas escaping When routing condensate into the public sewer svstem observe local regulations If condensate is directly routed to the public sewer ensure ventilation so that the public sewer cannot affect the condensing boiler Use only plastic for all condensate drain pipes Fig Siphon Neutralising system accessory The neutralising system can be connected directly to the appliance Consumption approx 10 30 g kW p a Observe the associated instructions Trim the connection hoses so that the condensate can drain fully backup loops are prevented a perfect seal is ensured Fig
55. serve the information in the conversion instructions supplied Conversion kits MGK LPG Type Part no conversion kit MGK 130 87 51 351 MGK 170 and MGK 250 87 51 293 MGK 210 87 51 295 MGK 300 87 51 298 Overview boiler coding cards MGK Type Part no Part no boiler coding card 1 boiler coding card for natural gas for LPG P MGK 130 127 44 358 27 44 356 MGK 170 12744 238 27 44 354 MGK 210 27 44 237 27 44 355 MGK 250 127 44 170 27 44 354 MGK 300 127 44 359 27 44 357 28 Changing the gas type CO settings A standard adjustment at the GCV is alwavs required for a change of gas tvpe to be effective Make the standard settings at the gas combination valve in accordance with the table Otherwise there is a risk of damage to the appliance Carefully turn the screw fully home and then undo as follows Standard setting for different gas tvpes Turn anti clockwise Natural gas H Tvpe Zero point adjusting screw MGK 130 1 32 turns Gas restrictor 1000 Natural gas H Type Zero point adjusting screw Throughput adjusting screw MGK 170 2 turns 1 1 2 turns MGK 210 1 1 2 turns 1 3 4 turns MGK 250 1 1 2 turns 1 3 4 turns MGK 300 1 3 4 turns 2 turns For other standard settings relating to the gas type see the conversion instructions 3062880_201305 WI F A CO setting at the upper lo
56. stems we recommend the installation of a blow down tank alternatively a dirt filter into the return For older systems this installation is compulsory Install a safety assembly comprising a safety AN valve with a response pressure of 6 bar a pressure gauge and an automatic air ventvalve The line between the boiler and the safetv valve must not be able to be shut off Severely excessive boiler pressure due to excessive boiler water temperatures can burst the boiler bodv or the boiler pipework which would lead to a sudden escape of hot water risk of scalding Provide svstem separation bv means ofa heat exchanger when using pipes which are not impermeable to oxvgen This boiler is only suitable for heating systems with pumped heating circuits If no heating circuit pump has been installed sufficient circulation through the radiators cannot be ensured so that the room heating cannot be guaranteed Fig Heating connections The MGK is supplied without circulation pump The pump rate of the pump to be installed on site must be determined subject to the svstem and boiler pressure drop Switching via the MGK see electrical connections 14 3062880 201305 WI F Note Provide a drain 4 fill valve at the lowest svstem point Safetv equipment The minimum svstem pressure is 1 0 bar The gas condensing boilers are approved exclusivelv for sealed unvented systems up to 6 bar The maximum flow temperature is factory set t
57. tal room thermostat or a weather compensated controller The temperature will then be selected at the controller accessorv Heating water temperature selection Settings 2 8 correspond when factory set to a heating water temperature of 20 85 C The heating water thermostat setting becomes ineffective when the svstem is combined with a digital room thermostat or a weather compensated controller 3062880 201305 WI F Settings Note 3062880 201305 Control Function Operation Winter mode position 2 to 8 In winter mode the boiler heats the heating water to the temperature selected at the heating water controller According to the pump operating mode the circulation pump operates constantiv factorv setting or onlv in parallel with the burner activation run on period Summer mode Winter mode is disabled bv rotating the heating water temperature selector into position hi In other words the boiler will then operate in summer mode Summer mode heating OFF means only DHW heating Frost protection for the heating svstem and pump anti seizing protection however remain enabled Emissions test mode The emissions test mode is activated bv rotating the heating water temperature selector into position m The indicator ring flashes yellovv After the emissions test mode has been activated the boiler will heat with the set maximum output Any previous cvcle block will be cancelled The emissions test mode terminate
58. tes ATTENTION the limit values are plant specific Inhibitors and anti freeze are not approved A system logbook is to be maintained see Water treatment planning notes 3062880_201305 Installation After proper filling of the system the system must be heated to the maximum and the total hardness and pH value measured again and adjusted These values must be checked again and adjusted after 6 8 weeks Additional requirements for operation without low loss header Systems with only one MGK Sludge separator in the device return of the MGK Desalization of the heating water to 2 3 dH Control of the calorifier charging only via the MM module configurations 1 and 10 Calorifier charge pump atleast DN 25 with a lifting height of at least 6 m The max inlet temperature must be set to 75 C with the parameter HG08 The water treatment planning notes must A be observed as otherwise damage to the svstem mav occur leading to the escape of water The manufacturer cannot accept anv liabilitv for damage to the heat exchanger resulting from oxvgen diffusion into the heating water In the case that oxvgen can penetrate into the svstem we recommend a hvdraulic separator bv installing an intermediate heat exchanger Note from VDI 2035 Limescale formation can be influenced above all through the tvpe and method of commissioning Heat up the svstem at the lowest power with an even and sufficient flow rate In the ca
59. throughput adjusting screw under cover Allen screw 3 mm for the MGK 170 MGK 300 Slotted screw for the MGK 130 Fig Gas combination valve 30 3062880_201305 WI JEF Testing the combustion parameters Test the combustion parameters with the boiler closed Testing the combustion air Hold the test probe into the combustion air supply and calibrate the tester or for balanced flue operation insert the test probe into the ventilation air adaptor Start the gas condensing boiler and turn the heating water temperature selector to the emissions test svmbol The status displav ring flashes vellow Check the temperature and enter it in the commissioning report After the test has been completed svvitch the boiler OFF remove the test probe and close the test port Ensure the screvvs are seated firmly Return the temperature selector into its original position Test port Inlet air flue gas test port D o 04 reg ON OFF switch Temperature selector 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 Remove the screw from the flue gas test port Start the gas condensing boiler and turn the temperature selector to the emissions test symbol chimney sweep The indicator ring flashes yellow Insert the test probe Read off flue gas values and enter them in the commissioning rep
60. ting the sanitary hot water temperature above 60 C or when acti vating the anti legionello function with a temperature exceeding 60 C it has to provided a corresponding fresh water admixture risk of scalding The perfect function of the electrical equipment has to be checked periodically Perturbances and damages may only be eliminated by expert technicians Damaged components may only be replaced by genuine Wolf spare parts Prescripted electrical fuse values have to be adhered to see technical data Any damage resulting from technical modifications to Wolf control units is ex cluded from our liability The appropriate European and electrical safety regulations as well as the cor responding regulations of the Energy Supply Company have to be adhered to during the installation and execution of electrical works It is not allowed to remove shunt or invalidate safety and monitoring facilities 3062880_201305 WI F Obtain the permission of vour mains gas supplier and flue gas inspector prior to the installation of Wolf gas fired boilers where appropriate Wolf gas fired boilers must only be installed by a recognised heating contractor This heating contractor will also be responsible for the proper installation and commissioning of the heating svstem The following regulations rules and guidelines must be observed during installation VDE 0722 EN50165 Electrical equipment of heat generators with non electrical he

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