COB Planungsunterlage-und-Montageanleitung

Installation instructions and
technical guide
Oil condensing boiler
COB
COB-TS
Boiler for heating

Boiler with stratification cylinder
Wolf GmbH Postfach 1380 D-84048 Mainburg Tel. +49-8751/74-0 Fax +49-8751/741600 Internet: www.wolf-heiztechnik.de
Document no.: 3062547_201408
Subject to modifications
GB
Index
Index ...................................................................................................................Page
1. Safety instructions....................................................................................................3
2. COB/COB-TS installation/standard delivery.............................................................4
3. Specification..........................................................................................................5-7
4. Layout/description of components............................................................................8
5. System examples.....................................................................................................9
6. Standards and regulations..................................................................................... 10
7. Installation instructions............................................................................................11
Installation............................................................................................................. 12-21

8. General notes......................................................................................... 12-13
9. Installation accessories................................................................................14
10. Boiler/TS cylinder.......................................................................................15
11. Installation examples..................................................................................16
12. Oil connection in a single-line system........................................................17
13. Siphon/neutralisation/condensate pump....................................................18
14. Installation of a balanced flue system........................................................19
15. Filling the heating system...........................................................................20
16. Electrical connection..................................................................................21
Control unit ........................................................................................................... 22-31

17. Control unit........................................................................................... 22-23
18. Displaying/modifying control parameters/Settings report.......................... 24
19. Contractor level parameters................................................................. 25-31
Cascade operation................................................................................................ 32-39

20. Control/specification/notes.........................................................................32
21. Flue system design....................................................................................33
22. Flue gas header version.............................................................................34
23. Flue gas header version / notes.......................................................... 35-36
24. Flue gas damper installation.................................................................... 37
25. Flue gas damper installation / wiring diagram.......................................... 38
26. Flue gas damper tightness test.................................................................39
Commissioning......................................................................................................40-44

27. Commissioning with Wolf control accessories (BM)............................ 40-41
28. Commissioning without Wolf control accessories (BM)...................... 42-43
29. Commissioning report................................................................................44
30. Maintenance and design data..............................................................45-46
31. Design information - balanced flue system..........................................47-55
32. Wiring diagram..........................................................................................56
33. Reset.........................................................................................................57
34. Troubleshooting.................................................................................... 58-59
EC Declaration of Conformity.....................................................................................60
2
3062547_201408
1. Safety instructions
The following symbols are used in conjunction with
these important instructions concerning personal
safety, as well as operational reliability.
"Safety instructions" are instructions with
which you must comply exactly, to prevent risks
and injuries to individuals and materiallosses.
Danger through 'live' electrical components!
NB: Switch OFF the ON/OFF switch before
removing the casing.
Never touch electrical components or contacts
when the ON/OFF switch is in the ON position!
This results in a risk of electrocution that may
lead to injury or death.
The terminals are 'live' even when the ON/OFF
switch is in the OFF position.
NB
This indicates technical instructions which

you must observe to prevent damage and
malfunctions.
Diagram: Danger from electrical voltage and hot components
Diagram: Terminal box: Danger from electrical voltage
Maintenance
NB - only a heating contractor has the

necessary knowledge and expertise!
- According to paragraph 10(3) EnEV the user is required to

have the system serviced regularly to ensure the reliable
and safe function of the oil condensing boiler.
- The boiler should be serviced annually.
- Maintenance is explicitly detailed in the installation and
maintenance instructions.
- Isolate the boiler from the power supply before any
maintenance work is carried out.
- After a service and before the oil condensing boiler is
restarted, check that all components that were removed for
maintenance have been refitted correctly.
- We recommend you arrange a maintenance contract with
an approved heating contractor.
3062547_201408
COB-15/20/29: 1290
COB-15/20/29: 1290
COB-40: 1490
2. COB/COB-TS installation/
standard delivery
605
605
1132
COB-15/20/29/40 oil condensing boiler

for heating with connection option for
DHW cylinder e.g. SE-2, SEM-1, BSP
COB-15/20/29 oil condensing boiler

with TS stratification cylinder,
on the right, floorstanding
COB-15/20/29: 1290
COB-15/20/29: 1290
566
1132
605
566
121

on the left, floorstanding

at the back, floorstanding
COB standard delivery
COB-TS standard delivery (not with COB-40)

Connection adaptor for flue gas with test nipple
Siphon with hose
Stainless steel cleaning brush
Maintenance tool with setting gauge
Protective cap for maintenance
COB/TS installation instructions
COB/TS operating instructions
COB/TS maintenance instructions
Oil filter insert 40 m

Stratification cylinder
Connection adaptor for flue gas with test nipple
Siphon with hose
Stainless steel cleaning brush
Maintenance tool with setting gauge
Protective cap for maintenance
COB/TS installation instructions
COB/TS operating instructions
COB/TS maintenance instructions
Oil filter insert 40 m
The appliance is fully assembled with the casing fitted, and the control unit is fully wired.
4
3062547_201408
3. Specification
462
Recesses for
individual piping
203 of the heating
connections
Balanced flue
connection
605
566
Opening the casing
Entries for oil

hoses (optional)
COB-15/20: 919
COB-29: 930
COB-40: 1209
Return
Optional fixing point
for oil filter
260
426
122
603
1084
COB-15/20/29: 1290
COB-40: 1490
Flow
Condensate
drain level
194
516
Closing the casing
Type plate
3062547_201408
3. Specification
kW
Rated output at 80/60C, stage 1/2
kW
Rated load, stage 1/2
kW
Oil throughput, stage 1/2
kg/h
Ltr
Rated capacity TS (equivalent)
Constant cylinder output TS
kW/Ltr/h
Performance factor TS
NL60
DHW output TS
l/10min
Standby input TS
kWh/24h
Max, permissible cold water supply pressure TS
bar
Minimum anode current, protective magnesium anode
mA
G
External diameter, heating flow
External diameter, heating return
G
Condensate connection
Oil connection, flow/return hoses
G
Cold water inlet
G
DHW connection
G
DHW circulation connection
G
mm
Height
Width
mm
Depth
mm
Boiler weight
kg
Cylinder weight
kg
mm
Balanced flue connection
Balanced flue routing
type
Fuel oil
Nozzle*
Fuel oil filter
CO2 setting stage 1 and stage 2
Pump pressure stage 1
Maximum negative pressure in oil lines
Flow temperature, factory setting
Max, flow temperature
Heating water pressure drop at T=20K
Max, permissible boiler pressure
Heating surface, heating water heat exchanger
Heat exchanger water content
Seasonal efficiency [to DIN] at 40/30C (Hi / Hs)
Efficiency at rated load at 80/60C (Hi / Hs)
Efficiency at 30% partial load and TR=30C (Hi / Hs)
Boiler standby loss qB at 70C (EnEv)
SEDBUK
SAP 2009 annual efficiency
Rated heat input (stage 2):
Flue gas mass flow rate
Flue gas temperature 50/30 - 80/60C
Available fan draught
Lowest heat input (stage 1):
Electrical connection
Integral fuse (medium slow)
Power consumption, stage 1 / stage 2
Protection
Condensate volume at 40/30C
%
bar
bar
bar
C
C
mbar
mbar
bar
m
Ltr,
%
%
%
%
%
band
%
COB-15
COB-15/TS
COB-20
COB-20/TS
9,0 / 14,4
9,0 / 14,4
13,1 / 19,0
13,1 / 19,0
9,5 / 15,1
9,5 / 15,1
13,9 / 20,0
13,9 / 20,0
9,2 / 14,7
9,2 / 14,7
13,5 / 19,6
13,5 / 19,6
0,86 / 1,38
0,86 / 1,38
1,15 / 1,66
1,15 / 1,66
160 (200)
160 (240)
15 / 370
20 / 490
3,5
4,5
250
280
1,47
1,47
10
10
> 0,3
> 0,3
1"
1"
1"
1"
1"
1"
1"
1"
1"
1"
1"
1"
3/8"
3/8"
3/8"
3/8"
3/4"
3/4"
3/4"
3/4"
3/4"
3/4"
1290
1290
1290
1290
566
1132
566
1132
605
605
605
605
92
92
92
92
76
76
80/125
80/125
80/125
80/125
B23, B33, C33(x), C43(x), C53(x), C63(x), C83(x), C93(x)
Fuel oil EL, low sulphur, bio-oil B10 or fuel oil EL standard
Danfoss
Danfoss
0,30 / 80S
0,40 / 80S LE
Siku max, 40 m
13,5 0,3
13,5 0,3
13,5 0,3
13,5 0,3
5,0 1,0
5,0 1,0
8,5 1
8,5 1
12,0 2,5
12,0 2,5
16,8 2,5
16,8 2,5
-0,3
-0,3
-0,3
-0,3
80
80
80
80
85
85
85
85
3,6
3,6
6
6
12
12
21
21
3
3
3
3
2,55
2,55
2,55
2,55
7,5
7,5
7,5
7,5
105 / 99
105 / 99
105 / 99
105 / 99
100 / 95
100 / 95
101 / 96
101 / 96
97 / 92
97 / 92
97 / 92
97 / 92
103 / 97
103 / 97
103 / 97
103 / 97
0,75
0,75
0,75
0,75
A
A
A
A
91.4
91.4
91.4
91.4
g/s
C
Pa
6,45
40 - 63
65
6,45
40 - 63
65
9,06
49 - 69
65
9,06
49 - 69
65
g/s
C
Pa
V~/Hz
A
W
4,04
35 - 55
32
230/50
5A
86/128
IP20
1,2
4,04
35 - 55
32
230/50
5A
86/128
IP20
1,2
6,28
40 - 61
45
230/50
5A
99/139
IP20
1,6
6,28
40 - 61
45
230/50
5A
99/139
IP20
1,6
Ltr,/h
* These nozzles comply with the emission requirements according to RAL-UZ 46 and ensure reliable operation. No other nozzles are permissible!
6
3062547_201408
3. Specification
kW
kW
Rated load, stage 1/2
kW
Oil throughput, stage 1/2
kg/h
Ltr
Rated capacity TS (equivalent)
Constant cylinder output TS
kW/Ltr/h
Performance factor TS
NL60
DHW output TS
l/10min
Standby input TS
kWh/24h
Max. permissible cold water supply pressure TS
bar
Minimum anode current, protective magnesium anode
mA
G
External diameter, heating flow
External diameter, heating return
G
Condensate connection
Oil connection, flow/return hoses
G
Cold water inlet
G
DHW connection
G
DHW circulation connection
G
mm
Height
Width
mm
Depth
mm
Boiler weight
kg
Cylinder weight
kg
mm
Balanced flue connection
Type
Fuel oil
Nozzle*
Fuel oil filter
%
CO2 setting stage 1 and stage 2
bar
bar
Maximum negative pressure in oil lines
bar
Flow temperature, factory setting
C
Max. flow temperature
C
mbar
mbar
Max. permissible boiler pressure
bar
Heating surface, heating water heat exchanger
m
Heat exchanger water content
Ltr.
%
%
%
Efficiency at rated load at 80/60C (Hi / Hs)
%
Efficiency at 30% partial load and TR=30C (Hi / Hs)
Boiler standby loss qB at 70C (EnEV)
%
band
SEDBUK
%
SAP 2009 annual efficiency
Rated heat input (stage 2):
g/s
C
Pa
Lowest heat input (stage 1):
g/s
C
Pa
V~/Hz
Electrical connection
Integral fuse (medium slow)
A
Power consumption, stage 1 / stage 2
W
Protection
Ltr./h
Condensate volume at 40/30C
Condensate pH value
COB-29
COB-29/TS
COB-40
18,5 / 28,2
18,5 / 28,2
25,3 / 38,0
19,6 / 29,6
19,6 / 29,6
26,8 / 40,0
19,0 / 29,0
19,0 / 29,0
26,0 / 38,8
1,60 / 2,45
1,60 / 2,45
2,44 / 3,64
160 (260)
29 / 710
5,0
300
1,47
10
> 0,3
1"
1"
1"
1"
1"
1"
1"
1"
1"
3/8"
3/8"
3/8"
3/4"
3/4"
3/4"
1290
1290
1490
566
1132
566
605
605
605
99
99
122
76
80/125
80/125
110/160
B23, B33, C33(x), C43(x), C53(x), C63(x), C83(x), C93(x)
Fuel oil EL, low sulphur, bio-oil B10 or fuel oil EL standard
Danfoss 0,55 / 80 S LE
Siku max, 40 m
13,5 0,3
13,5 0,3
13,5 0,3
8,5 1
8,5 1
11,0 1,0
16,8 2,5
16,8 2,5
23,5 2,5
-0,3
-0,3
-0,3
80
80
80
85
85
85
17
17
54
55
55
205
3
3
3
3,05
3,05
3,85
9,0
9,0
11,5
105 / 99
105 / 99
104 / 98
101 / 96
101 / 96
98 / 93
97 / 92
97 / 92
98 / 93
103 / 97
103 / 97
103 / 97
0,55
0,55
0,45
A
A
A
91.4
91.4
91.4
13,33
55 - 76
105
13,33
55 - 76
105
17,51
56 - 83
150
9,05
40 - 64
55
230/50
5A
129 / 178
IP20
2,2
approx, 3
9,05
40 - 64
55
230/50
5A
129 / 178
IP20
2,2
approx, 3
10,91
43 - 68
72
230/50
5A
126 / 205
IP20
2,8
approx, 3
* These nozzles comply with the emission requirements according to RAL-UZ 46 and ensure reliable operation. No other nozzles are permissible!
3062547_201408
4. Layout of components
COB-TS oil condensing boiler with stratification cylinder
1 Cylinder heating from above with deflector and divider
2 DHW draw-off at the highest point

3 Cold water supply with control and
distribution appliance
4 Cold water draw-off for cylinder heating
5 DHW circulation line
6 Protective magnesium anode
7 Sensor well for cylinder temperature sensor
8 Drain (in standard delivery)
9 Siphon
10 Neutralising system (accessory)
11 Condensate pump (accessory)
Stratification cylinder
DHW circulation
Cold water
DHW
9
4
10
NB
11
TS stratification cylinder cannot be installed with COB-40
3062547_201408
5. Description of components
COB component description
Automatic air vent

High limit safety cut-out
Blast tube
connection
Oil pump motor
Two-stage oil pump
Boiler
sensor
Ignition
transformer
Flame monitor
Fan
Flue gas temperature
limiter
Water pressure switch
Drain valve
TS component description
Heating flow 1"

Heating return 1"
Hot water connection "
Regulated
stratification pump
Plate-type heat exchanger
Immersion pipe,
cylinder sensor
Stratification sensor
Cylinder primary pump
Cold water connection

" (optional accessory)
Expansion vessel 8l
(accessory)
DHW circulation
(accessory)
Protective anode
(under cover)
Drain
3062547_201408
6. Standards and regulations

COB / COB-TS oil condensing boiler
- DIN 1988
Two-stage oil condensing boiler with electronic ignition and

electronic flue gas monitoring, for low temperature heating
and DHW heating in heating systems with flow temperatures
of up to 85C and a permissible operating pressure of 3bar.
- DIN EN 12831 Procedure for calculating the standard

heating load
The COB complies with the following regulations:

EC Directives:
- 92/42/EEC Efficiency Directive
- 2004/108/EC EMC Directive
- 2006/95/EC Low Voltage Directive
DIN / EN Standards:
EN 230, EN 303, EN 304, EN 15034, EN 15035, EN 12828,
EN 61000-3-2, EN 61000-3-3, EN 61000-4-3, EN 55014-1,
EN 60335-1, EN 60335-2-102, EN 60529
Stratification cylinder type TS made of steel S235JR with
connections to the on-site pipework.
Corrosion protection through enamel coating on the inside
of the cylinder as per DIN 4753 and additional corrosion
protection through a protective magnesium anode.
Open flue oil condensing boilers must only be

installed in a room which complies with the
appropriate ventilation requirements. Otherwise
there is a risk of asphyxiation or poisoning.
Read these installation and maintenance
instructions before installing the boiler. Also
take the technical guide into consideration.
Note:
- EN 12828
Heating systems in buildings
Designing DHW heating systems
- DIN 4701

Rules for calculating the heat demand of

buildings
- DIN 4751 Part 3 Safety equipment for heating systems with flow

temperatures of up to 95C
- DIN 18160
Flue gas systems
- DIN EN 1717

Protection of DHW against contamination in

DHW installations
- ATV-A-251

Materials for drain pipes for condensate from

condensing boilers
- VDI 2035

Avoiding damage in DHW heating systems

Scaling in general water and DHW heating
systems
Local regulations from building and
industry regulatory agencies (mainly covered
by the local flue gas inspector)
- DIN VDE 0100 Regulations regarding the installation of

high-voltage systems with rated voltages up

to 1000V
- VDE 0105

Operation of high-voltage systems, general

considerations
- DIN EN 60529 Protection through casings
The DHW temperature should be limited to a

maximum of 55C if the hardness of the hot
water is more than 2.86mmol/l. A reduced DHW
temperature prevents excessive scaling. This
cuts the level of maintenance and energy input.
Any damage or loss resulting from technical

modifications to the control unit or to the control
components are excluded from our liability.
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.
To save energy and protect against scaling

if the total hardness is greater than 15dH
(2.5mol/m), the DHW temperature may be set
to a maximum of 50C.
If the total hardness is greater than 20dH
(3.58mol/m), we recommend using a water
treatment facility in the cold water supply line
for DHW heating, to prolong the maintenance
interval (descaling DHW heat exchanger).
Obtain the permission of your local flue gas inspector and

the lower water authority prior to the installation of Wolf
oil condensing boilers.
Wolf oil condensing boilers must only be installed by a
recognised heating contractor. This heating contractor
will also be responsible for the proper installation and the
commissioning of the heating system. The DVGW Code of
Practice G676, boiler room guidelines or Building Regulations
relating to the construction and installation of central boiler
rooms and fuel storage facilities apply.
Technical rules for DHW installations
The following regulations, rules and guidelines must be

observed during installation:
- Energy Savings Act (EnEG) and related directives
- EnEV Energy Savings Order
- Technical regulations for oil installations IWO-TRL 2006
in the currently applicable version
10
3062547_201408
7. Installation instructions
Transport
Boiler/stratification cylinder
- The boiler and the stratification cylinder are transported, fully packaged, on a pallet
- A sack truck is a suitable means of transportation
- Position the sack truck behind the boiler or stratification cylinder, secure with a strap
and transport to the installation location
- Remove strap and packaging
- Remove the four fixing screws on the pallet
- Lift the boiler and/or stratification cylinder off the pallet
- Install the boiler or boiler plus DHW cylinder on a level

surface which is substantial enough to carry its weight.
Installation information
- Level the boiler and stratification cylinder horizontally using

adjustable feet.
Adjustable feet
- The boiler must only be installed in a room that is protected from frost.
Drain the boiler, stratification cylinder and heating system if there is a risk
of frost when the system has been shut down.
NB
- Boilers should not be installed in a room that is subject to aggressive vapours

orin very dusty or highly humid conditions (workshops, washrooms, hobby
rooms, etc.).
NB
- The combustion air must be free from halogenated hydrocarbons.
NB
- A surface temperature of 40 C is not exceeded in the case of COB if

operated as intended. The respective national fire regulations are to be
observed in the case of installation in oil storage rooms.
Recommended minimum
wall clearance
The COB and TS are installed adjacent to the wall, which means that a clearance of
70cm only needs to be observed at the front. When installing the boiler, you should
observe the recommended wall clearances in order to simplify assembly, maintenance
and servicing.
COB with
TS behind
3062547_201408
70 cm
COB-40
minimum
room height
70 cm
70 cm
190 cm
70 cm
COB with
TS right
or left
70 cm
COB
11
8. Installation - general notes
Safety equipment
The COB has not been fitted with an expansion vessel at
the factory. This must be fitted externally (available from the
Wolf accessories range). The expansion vessel must be in
accordance with DIN 4807.
There should not be a shut-off valve between the
expansion vessel and the oil condensing boiler,
because otherwise the pressure build-up would
permanently damage the boiler during heating.
There is a risk of system components rupturing,
giving rise to a risk of scalding.
Exceptions are cap valves upstream of the expansion vessel.
The safety assembly from the Wolf accessories range includes
an integral 3bar safety valve. Route the blow-off line into a
drain outlet.
The minimum system pressure is 1.0bar.
The oil condensing boiler is permitted exclusively for sealed
systems of up to 3bar. The maximum flow temperature is
factory-set to 80C and may be adjusted to 90C if required.
Generally, the maximum flow temperature is 80C for DHW
operation.
There is no need for a minimum throughput at flow
temperatures below 80C.
Heating water
The return line to the appliance should have a dirt trap.
Deposits in the heat exchanger may lead to boiling noise, a
drop in performance or faults in the appliance.
Domestic hot water may be used as fill water and top-up water.
The addition of chemicals or de-scaling using single-stage ion
exchangers is not permissible.
In the case of high-volume systems or those where large topup water volumes (e.g. due to water losses) are required, the
following values must be observed.
0.3m3
Total hardness in dH
Note:
Provide a fill and drain valve at the lowest point in the
system.
Water treatment
necessary
Water treatment not

necessary
System volume in m3
If the limit curve is exceeded, an appropriate portion of the

system water must be treated.
Example:
Total hardness of the domestic hot water: 19dH
System volume: 1m
This means at least 0.3m = 300 l must be desalinated.
Permissible methods:
- Desalination using mixed-bed cartridges. These are
multi-stage ion exchangers. We recommend, for
example, using the "Megafill Alu" cartridges from
Taconova for the first fill, and later as and when required.
- Topping up with distilled water.
We recommend a heating water pH value of between
pH 6.5 and pH 8.5.
Wolf does not assume liability for any damage to the heat
exchanger caused by oxygen diffusion in the heating water. In
the event of oxygen penetrating the system, we recommend
a system separation through the interconnection of a heat
exchanger.
Inhibitors (substances to prevent corrosion
and limescale deposits) and antifreeze are
not permitted. There is a risk of damage to
the boiler resulting from poor heat transfer or
corrosion.
12
3062547_201408
8. Installation - general notes

Information from VDI 2035
The method of commissioning in particular can affect scaling.
Heat the system with burner stage 1 with an even and adequate
throughput.
Before commissioning, all hydraulic pipes must undergo a
tightness test:
Test pressure on heating water side max. 4bar
Prior to testing, close the shut-off valves in the heating circuit for
the appliance, because otherwise, the safety valve (accessory)
opens at 3bar. The appliance has already been tested at the
factory for tightness at 4.5bar.
If the appliance is not watertight, there is a risk of leaks and
resulting material losses.
The maximum flow rate must not exceed 6000l/h (100l/min).
We highly recommend that you use low sulphur fuel oil

to protect the environment.
Information on the use of bio-oil blends:
1. Permissible bio-oil percentages
The COB (from date of manufacture May 2010) can be
operated with fuel oil with up to 10 % alternative constituents
B10- to DIN V 51603-6.
2. Bio-oil quality
The bio-oil must comply with EN 14213 when the customer
tank is filled.
3. Oil storage tanks
The customer must obtain written confirmation from the
manufacturer or supplier regarding the suitability of the tank
for the use of bio-oils, giving the maximum permitted FAME
percentage. It must be ensured that the tank fittings, gaskets,
filters and oil pipes are also suitable for bio oil.
4. Cleaning the tank
FAME acts as a solvent, removing all deposits and residues in
the tank and the oil lines. Wolf therefore always recommends
cleaning the tank before filling it with bio-oil.
5. Storing bio-oils
Bio-oil is a natural product with a lower shelf life than fuel
oil EL. Bio-oil must therefore be stored at low temperatures
(ambient temperature between 5C and 20C) and protected
from exposure to direct sunlight (in the case of plastic tanks
in particular).
Up-to-date information indicates that bio-oil should not be stored
for longer than one year, but the mineral oil industry is currently
searching for suitable additives to increase the shelf life.
3062547_201408
13
9. Installation - accessories
We recommend making the connection to the heating system with the following parts from the Wolf accessories range.
COB connection set adjacent to the wall comprising:
2 cross pieces, each with one connection
2 clips
1 corrugated stainless steel pipe 1", length 1300mm
1 silicon grease tube
COB connection set with TS adjacent to the wall comprising:
2 cross pieces, each with two connections
4 clips
2 corrugated stainless steel pipes ", length 800mm
1 trimming set "
COB connection set adjacent to the wall for a freestanding
cylinder up to SEM-1-750 and SE-2-750 comprising:
2 cross pieces, each with two connections
4 clips
6 flat packings 1"
1 pipe bend
2 flat packings 1" EPDM
1 pump
1 adaptor fitting G1" (fem.)
2 double nipples G 1" (male) - G 1" on G1" (male)
1 elbow with air vent
TS accessory set for cold water comprising:
1 expansion vessel 8 l
1 cold water connection pipe to the expansion vessel
2 double nipples "
1 trimming set "
TS DHW circulation pump accessory set comprising:
1 analogue DHW circulation pump
1 corrugated stainless steel pipe "
1 trimming set "
Pipe assembly comprising:
1 circulation pump
2 thermometers in flow and return
2 ball valves in flow and return
- Incl. / excl. mixer
- With manifold for 2 or 3 pipe assemblies
Neutralisation box, incl. plinth comprising:
1 granulate fill
1 installation accessories set
(for standard fuel oil EL (sulphur content > 50ppm),
neutralisation of the condensate is required).
Condensate lifting system with a zero-volt alarm output

comprising:
1 condensate lifting pump with a zero volt alarm output
1 condensate tank with cover and wall mounting bracket
1 PVC hose, 10 mm (6 m long)
1 non-return valve
1 condensate inlet adaptor
For further accessories, such as a safety assembly 1" or wall mounting bracket for pipe assembly, etc., see
"Heating systems" pricelist
14
3062547_201408
10. Installation - boiler/TS cylinder

Example: COB-15/20/29 oil condensing boiler with TS stratification cylinder on the right,
floorstanding (when looking at front of boiler). The pipework for the heating
flow and heating return, as well as the heating water flow and heating water
return, are connected to the stratification cylinder with corrugated stainless
steel pipes (accessories) (see chapter 9 "Installation - accessories").
Cold water connection
We recommend the installation of a maintenance valve into the cold water supply line. A
tested and certified pressure reducer must be installed if the cold water supply pressure
is above the maximum permissible operating pressure of 10bar.
Provide a centralised pressure reducer if mixer taps are used.
Observe the regulations of DIN 1988 as well as those of your local water supply utility
when connecting cold water and DHW. Your warranty rights may be lost if the installation
does not comply with the illustration shown.
When selecting the installation material for the system, it is important to

observe the technical rules and any possible electrochemical processes
(mixed installation).
Safety valve
(individually tested)
Note:
Boiler flow
Shut-off
valve
Pressure gauge port
Non-return valve
(individually tested)
Pressure reducing
valve
Drain
DHW filter
Shut-off valve
Cold water inlet
Above top edge of the cylinder
Boiler return
Drain
Diagram: Cold water connection to DIN 1988
3062547_201408
15
11. Installation examples
Pipe assembly for three heating

circuits with manifold for safety
assembly installation
Pipe assembly for two heating circuits

with manifold for safety assembly
installation
Pipe assembly for one heating circuit

for safety assembly installation
Safety assembly for fixing to the

corrugated stainless steel pipes of
heating flow and return
The safety assembly and the required pipe
assembly can be installed on the left, on
the right or at the back of the boiler on a
wall or attached to the side of the boiler
casing.
Note: The pipe assembly for three heating
circuits should always be wall mounted.
16
3062547_201408
12. Oil connection in a single line system

Oil filter
Secure the oil filter with the holder in the positions provided on the outside of the
boiler casing. It can also be secured on the inside of the boiler. In this case, the oil
hose can be up to 90cm outside the casing when fed in from the top (to the back).
Notes:
Only use filter inserts made of sintered plastic with 25 - 40m.
The temperature must not fall below +5C. External tanks must have
supplementary heating facilities.
Contaminants can lead to system damage. The oil line must be flushed
prior to commissioning.
The system must be connected as a single line system. A filter/air vent valve
combination from the Wolf product range must be installed. Older two-line
systems must be converted to single line systems.
Two-line systems lead to accelerated oil ageing and the penetration of air into
the oil. They are no longer in line with the latest technology.
In order to prevent damage to the oil pump, the fuel oil must be supplied to the
filter using a suitable manual pump.
Single line system
Assumptions:
Kinematic viscosity 6mm/s at 20C, oil temperature = 10C
Additional pressure drops: 4 elbows 90, 1 non-return valve, 1 shut-off valve
In view of possible outgassing of the oil, an inlet height of more than 4m should be
avoided.
Maximum line lengths

in single line systems
Output
Anti-lift valve
Oil pump,
burner
Throughput
Internal
line
kg/h
mm
-1
-2
-3
77
68
58
49
40
31
22
13
100
100
100
100
100
100
87
64
39
34
29
25
20
16
11
100
100
100
100
100
79
56
32
COB-15
COB-20
COB-29
to 2.5
COB-40
2.5 to 5.0
Inlet height H (m)
Floating air
extraction
Oil lines that are too large may lead to operating faults caused by trapped air.
The oil line must therefore have the smallest possible diameter.
Single line system with pump lower than tank Only materials that are suitable for oil lines should be used. In the case of copper pipes,
only metallic compression fitting olives with support sleeves are permissible. They are
a reliable means of preventing air intake.
The oil lines must be installed while the system is isolated from the electrical
supply in order to avoid leaks.
Oil pump,
burner
Floating air
extraction
With negative pressure controlled anti-lift valves, the negative pressure on the inlet side is
increased considerably. It is often difficult to adhere to the maximum permissible negative
pressure of 0.3bar in the oil line. We therefore recommend using electromagnetically
controlled anti-lift valves.
The electrical anti-lift devices can be connected to the COB in two ways:
1. The anti-lift valve is connected at output A1. For this, output A1 must be programmed
to 9 (oil shut-off valve), see HG14.
2. If output A1 is already being used (e.g. for a DHW circulation pump), an adaptor
plug can be used. The plug (mat. no. 1718768761) is inserted between the motor of
the oil pump.
When connecting a feed pump in the supply line, the negative pressure must not exceed
0.5bar.
Single line system with pump higher than tank

3062547_201408
17
13. Siphon/neutralisation/condensate pump

Condensate drain without neutralisation
If low sulphur fuel oil EL (sulphur content < 50mg/kg) is used,
it may be possible to forego neutralisation of the condensate
after consultation with the lower water authority.
The condensate may be discharged into drainage pipes only in
accordance with ATV DVGW worksheet A251. Nevertheless,
neutralisation is required if a sufficient quantity of domestic
wastewater (at least 20 times the volume of the expected
amount of condensate) is not added to the condensate.
Connect the siphon supplied to the connectors on the
combustion chamber pan.
NB
Drain hose, siphon
Siphon
Remove the sealing plug on the siphon plug

before installing the siphon.
With a flexible siphon drain hose, form a connection to the on-site

drain (condensate drain level from siphon 260mm).
When using a condensate pump, route the flexible siphon drain
hose into the condensate pump and form a connection from
there to the on-site drain.
Note: The siphon must be filled with water prior to
commissioning.
If the appliance is operated with an empty siphon,
there is a danger of poisoning caused by escaping
flue gases. For this reason, the siphon must be filled
with water prior to commissioning. Undo, remove
and fill the siphon until water runs out of the side
drain. Refit the siphon and make sure the gasket is
perfectly seated.
If condensate is directly routed to the on-site drain, ventilation
must be provided so that the drain pipe cannot affect the boiler.
Condensate drain with neutralisation

For standard fuel oil EL (sulphur content > 50ppm),
neutralisation of the condensate is required.
Note: The siphon and the neutralisation box must be filled
with water prior to commissioning.
Condensate pump
18
Siphon
NB
Observe the neutralisation box installation

instructions.
3062547_201408
14. Installation of a balanced flue system

Installation of the balanced flue system
NB
For flues and concentric balanced flue systems,

use only original Wolf components.
Please observe the technical information
regarding balanced flue systems prior
to installing the flue or the balanced flue
connection.
As regulations in the individual Federal States
[Germany] differ, we recommend consulting the
relevant authorities and local flue gas inspector
prior to installation.
NB
In the case of COB-15/20/29 the enclosed flue

gas measuring nipple must be mounted on the
air/flue gas connecting piece of the boiler.
Alternatively, the flue gas measuring nipple
can be mounted immediately behind that in a
horizontal position directly on the 87 elbow
fitted to the boiler. When doing this, however,
care must be taken that the air/flue gas duct is
installed above the appliance in such a way that
it is possible to remove the displacer (minimum
distance above COB-15/20/29 is 30 cm; in the
case of the COB-40 this is 40 cm).
C93x
Diagram: Example of a C93x balanced flue system

NB
The local flue gas inspector must have clear

access to the flue gas test nipples.
Flue connections are created using couplings and gaskets.

Always arrange couplings against the condensate flow
direction.
The balanced flue should be installed with
a slope of at least 3 (6cm/m) to the oil
condensing boiler. Spacer brackets should be
fitted to secure the equipment in position.
In the worst case scenario, a smaller slope
for the balanced flue may lead to corrosion or
operating faults.
NB
Generally bevel or deburr trimmed flues to ensure

a gas tight installation of pipe joints. Ensure that
gaskets are properly fitted. Remove all contamination
prior to installation - never fit faulty parts.
Between the flue terminal and the roof surface, there must be
a distance of at least 0.4m.
3062547_201408
Achtung Bei COB-15/-20/-29 muss der beiliegende

Abgas-Messstutzen auf dem Luft-/
Abgasstutzen des Kessels montiert werden.
Alternativ darf der Abgas-Messstutzen
auch unmittelbar nach dem dann direkt
auf dem Kessel aufgesteckten 87-Bogen
waagrecht montiert werden. Hierbei ist aber
zu beachten, dass die Luft-/Abgasfhrung
so ber dem Gert zu verlegen ist, dass ein
Ausbau der Verdrnger gewhrleistet ist
(Mindestabstand ber COB-15/-20/-29 ist
30cm; bei COB-40 ist dieser 40cm).
19
15. Filling the heating system

Filling the heating system
Fill the system and vent it properly to ensure

perfect boiler function.
NB
Air vent valve
Before connecting the boiler, flush the heating

system to remove residues such as welding
pearls, hemp, putty, etc. from the pipework.
- Open the cap on the vent in the boiler by one revolution.

- Open all radiator valves.
- Fill the system via the return line at 2bar (1.5 to 2.5bar).
- With the entire heating system and boiler in a cold
condition, fill slowly via the inspection/fill & drain valve at
the return until 2bar pressure is indicated.
- Check the entire system for water leaks.
- Start the boiler, set the heating water temperature to
position "2" (pump running, illuminated signal ring as
status indicator constantly green).
- Vent the pump; for this, briefly open and then retighten the
air vent screw.
- Vent the heating circuit completely, switching the boiler
ON for 5 seconds and OFF for 5 seconds at the ON/OFF
switch, five times in succession.
- When the system pressure drops below 1.5bar, top up the
water.
Diagram: Venting the COB
Checking the position of the displacement device

The displacement device may have slipped during
transport.
To ensure perfect combustion, check the
displacement device is correctly positioned before
commissioning the appliance.
Unplug the
central connector
- Unplug the central connector.

- Loosen the three 6mm Allen screws on the burner flange
(do not unscrew them completely).
- Rotate the burner unit approx. 1cm to the right
(clockwise).
Burner in the
maintenance position
- Lift the burner unit upwards out of the combustion

chamber lid and hang in place in the maintenance
position, as shown in the figure.
- Undo the wing screws on the combustion chamber lid.
- Lift off the combustion chamber lid and place to one side.
- Measure the distance between the upper edge of the top
displacement device and the upper end of the ridged profile,
then compare with the table below.
Displacement
device distance to
ridged profile (mm)
COB-15 COB-20 COB-29 COB-40

98-103
98-103 123-128 123-125
- Assembly is carried out in reverse order.
Displacement device
distance
Diagram: View of COB displacement device

20
3062547_201408
16. Electrical connection

General notes
The installation must be carried out by a

licensed electrical contractor. Observe VDE
regulations as well as all local regulations by
your power supply utility.
Terminal box
The power supply terminals are 'live' even when

the ON/OFF switch has been switched OFF.
Isolate the boiler from the power supply
before changing the 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 boiler
has not been isolated from the power supply.
Danger to life.
Terminal box
The terminal box is supplied fitted to the back panel of the

boiler.
If necessary, the terminal box can be mounted on the wall to
the right, to the left or above the boiler.
The control, regulating and safety equipment are fully wired
and tested.
Power supply
In the case of a permanent connection, provide the power
supply via a mains isolator (e.g. fuse, heating system
emergency stop), which ensures at least 3mm contact
separation for all poles. Connecting cable, flexible, 3 x 1.0mm
or rigid, max. 3 x 1.5mm.
The maximum current carrying capacity of the outputs is 2A,
but a total of 5A must not be exceeded.
Fuse
M 5A
Replacement
fuse
Power supply
230V / 50Hz
Heating
circuit
pump
Cylinder
primary
pump
Cylinder
sensor
Outside
temperature
sensor
Installation information, electrical connection

Isolate the system from the power supply before opening the
casing.
Unclip the terminal box from the holder.
Open the terminal box.
Insert the strain relief into the holes provided.
Strip approx. 70mm off the power cable insulation.
Push the cable through the strain relief and secure the strain
relief.
Terminate the appropriate cores at the Rast-5 plug.
Push the inserts back into the terminal box casing.
Insert the Rast-5 plug.
Fit the cover.
Two-wire eBUS
connection
Programmable input E1 (24V),

zero-volt
Remove jumper a/b when making
the connection
Stratification pump
Control signal,
stratification pump
Cylinder sensor
Output A1 to DHW circulation
3062547_201408
Programmable
output A1
(230VAC; 200VA)
Power plug,
condensate pump
Alarm switch,
TS stratification pump
condensate pump
Control signal,
Stratification
stratification pump sensor
21
17. Control unit
0
I
60
40
20
0
ON/OFF switch
Illuminated Reset button

signal ring
DHW
temperature
selector
Heating water
temperature
selector
80
100
C 120
Thermometer
ON/OFF switch
The condensing boiler is OFF in position 0.
Reset
A fault is reset by pressing the reset button which will also restart the system. If the boiler
is in a cycle block, this is reset by pressing the button (2 seconds)
Illuminated signal ring as status indicator

Display
Explanation
Flashing green
Stand by (ON/OFF switch ON, no heat demand,

pump OFF)
Constant green light
Heat demand: Pump running; burner OFF
Flashing yellow
Emissions test mode
Constant yellow light
Burner ON; flame steady
Flashing red
Fault
DHW temperature selector

When oil condensing boilers are combined with a DHW cylinder, setting 1-9 corresponds
to a cylinder temperature of 15-65C. DHW temperatures of over 60C are not
permissible in conjunction with a TS stratification cylinder. In combination with
a BM programming module, adjustment at the DHW temperature selector is disabled.
The temperature is set at the BM programming module.
Heating water temperature selector

Settings 2-8 correspond, when factory-set, to a heating water temperature of
20-80C. Combined with a BM programming module, the adjustment at the heating
water temperature selector is disabled.
22
3062547_201408
17. Control unit

Setting
Winter mode (settings 2 to 8)

In winter mode, the boiler heats the flow temperature to the value set on the thermostat.
According to the pump operating mode, the circulation pump operates constantly (factory
setting) or only in parallel with the burner activation / run-on period.
Summer mode
Winter mode is disabled by rotating the heating water temperature selector into position.

The boiler then operates in summer mode. Summer mode (heating OFF) means

only DHW heating. Frost protection for the heating system and pump anti-seizing
protection, however, remain enabled.
Emissions test mode

The emissions test mode is activated by rotating the heating water temperature selector

into position. The illuminated signal ring flashes yellow. After the emissions test

mode has been activated, the boiler will heat with the selected maximum output. Any
previous cycle block will be cancelled. The emissions test mode terminates after 15 minutes
or when the maximum flow temperature has been exceeded. To reactivate, turn the heating
water temperature selector anti-clockwise and then back into position
.
Anti-seizing pump
protection
In summer mode, the circulation pump operates for approx. 30 seconds after a maximum
idle period of 24 hours.
Control unit with BM programming module
0
I
60
40
20
0
ON/OFF switch
3062547_201408
Illuminated
signal ring
Reset button
BM programming
module
80
100
C 120
Thermometer
23
18. Displaying / modifying control parameters

The control parameters can only be modified or displayed via Wolf control accessories with eBUS capability. For installation
and procedures, check the operating instructions of the relevant accessories.
BM programming module
L.h. rotary selector program selection
R.h. rotary selector temperature selection
Display
NB
Modifications must only the carried out by a

recognised heating contractor or by the Wolf
customer service.
To prevent damage to the heating system, cancel
night setback when outside temperatures fall
below -12C. If this rule is not observed, ice
may build up on the flue outlet which may cause
injury or material losses.
Info key
Single cylinder
heating key
Heating key
Setback key
Parameter overview / settings report

(settings and functions on the following pages)
Parameter
A09
Frost protection limit
A10
Parallel DHW operation
A14
Maximum DHW temperature
A: - System parameters
HG: - Boiler parameters
Setting range
Factory setting
-20 to +10C
+2C
0/1
60 to 80C
65C
HG00
Matching the pipe length
HG01
Burner switching differential
1 to 5
1 to 20K
10K
HG06
Pump operating mode
0 to 3
HG07
Boiler circuit pump run-on time
0 to 30min
4 min
HG08
Maximum limit, boiler circuit TV-max.
40 to 90C
75C
HG09
Burner cycle block
1 to 30min
10min
HG13
Programmable input E1
1 to 11
HG14
Programmable output A1
HG15
Cylinder hysteresis
HG16
N/A
HG17
N/A
HG19
Cylinder primary pump run-on time
HG20
Maximum cylinder heating time
HG21
HG22
HG25
Boiler overtemperature during DHW cylinder heating
HG28
Burner operating mode
HG31
Blocking time burner stage 2
0 to 14
1 to 30K
5K
0 to 10min
5min
0 to 5h
2h
Minimum boiler water temperature TK-min.
20 to 90C
20C
Maximum boiler water temperature TK-max.
50 to 90C
80C
0 to 40K
10K
1 to 5
0 to 40min
10 min
Individual settings
Pressing the r.h. rotary selector leads to control level 2, where you can select the menu levels shown in the overview by turning
the rotary selector clockwise.
Pressing the Info key takes you back to the standard display, irrespective of which submenu is currently displayed.
The system automatically also returns to the standard display when no adjustment is made for more than one minute.
All available set and actual temperatures, burner starts and hours run as well as other system values can be displayed. This scan
is identical to that initiated via the Info key.
24
3062547_201408
19. Contractor level parameters

Contractor level
Heating
contractor
Code scan
Press the r.h. rotary selector to change to control level 2. Turn the r.h. rotary selector
clockwise to select the contractor level and confirm the selection by pressing the r.h.
rotary selector again.
The display shows the code scan.
The correct code is set by pressing (display indication flashes) and then turning the r.h.
rotary selector from 0 to 1. After changing the code from 0 to 1, pressing the r.h. rotary
selector again confirms the setting; you are then at the contractor level.
code NO
---Factory setting: 1
Frost protection limit

Parameter A09
A09
2.0
The boiler circuit pump operates constantly if the outside temperature stays below
the selected value. The burner starts and heats the boiler to at least 20C if the boiler
water temperature falls below +5C.
Note:
Only change the factory setting if you can ensure that the heating system and its
components will not freeze up at low outside temperatures.

Factory setting: 2C
Setting range: -20 to +10C
Parallel DHW operation

Parameter A10
A10
Factory setting: 0
Setting range: 0 / 1
NB
The heating circuit pump is switched OFF during cylinder heating with DHW priority
(0). The boiler energy will then be used exclusively for DHW heating. The burner
shuts down and the heating circuit pump is started as soon as the cylinder has
reached its set temperature. The calorifier charge pump runs on in summer operating
mode for the period set in parameter HG19 (calorifier charge pump run-on time).
In winter operating mode the calorifier charge pump runs on for 2 min. following
successful calorifier charging.
The heating circuit pump continues to operate in parallel DHW mode (1). Cylinder
heating ends when the cylinder reaches the set water temperature. The calorifier
charge pump runs on in summer operating mode for the period set in parameter
HG19 (calorifier charge pump run-on time).
NB
Maximum DHW temperature

Parameter A14
A14
65
3062547_201408
In parallel DHW mode (1), the heating circuit can temporarily be operated
at a higher temperature.
Parallel operation in conjunction with a stratification cylinder is not recommended.
The maximum DHW temperature is factory-set to 65C. If, for commercial reasons,
a higher DHW temperature is required, a maximum temperature of up to 80C is
enabled.
If pasteurisation has been activated (BM), the DHW cylinder will be heated to the
selected maximum DHW temperature during the first cylinder heating of the day.
NB
Factory setting: 65C

Setting range: 60 to 80C
Incorrect operation can lead to system faults.

Please note when adjusting parameter A09 (frost protection / outside
temperature), that frost protection is no longer safeguarded if you set
temperatures lower than 0C. This can lead to heating system damage.
Take adequate measures to prevent scalding.

Parameter HG22 (maximum boiler water temperature) should be set at
least 5K higher than the selected maximum DHW temperature.
DHW temperatures of over 60C are not permissible in conjunction with
a TS stratification cylinder.
25

Matching the pipe length
Parameter HG00
HG00
This parameter shifts the minimum and maximum fan speed parallel downwards or
upwards.
This enables the CO2 value for burner stages 1 and 2 to be adjusted at the same
time. See also chapter 22 "CO2 adjustment by matching the pipe lengths"
One unit = 120r.p.m
Setting 3 = set value, burner control unit
Factory setting: 3
Setting range: 1 to 5
Burner switching differential

Parameter HG01
HG01
10
The burner switching differential regulates the burner temperature within a set range
by switching the burner ON and OFF.
The switching differential between burner stage 1 and burner stage 2 is always half
the switching differential.
See also parameter HG31 diagram.
Factory setting: 10K

Setting range: 1 to 20K
Pump operating mode

Parameter HG06
HG06
Factory setting: 0
Setting range: 0 / 1 / 2
Pump operating mode 0:

Heating circuit pump for heating systems without cascade control and without
low loss header
The heating circuit pump runs constantly when there is a heat demand. The heating
circuit pump will be switched OFF during cylinder heating if DHW priority has been
selected.
Feed pump for heating systems with cascade control and / or low loss header
Heating circuit pump becomes the feed pump.
The header sensor affects the heating operation as well as cylinder heating. The feed
pump runs only when there is a burner demand. Pump run-on in accordance with
parameter HG07.
Hydraulic scheme:
MM
MKP
SAF
ZUP
SPL
SF
SAF
KF
MKP
M
MM
26
=
=
=
=
=
=
=
=
Feed pump
Cylinder sensor
Header sensor
Boiler sensor
Mixer circuit pump
Mixer motor
Mixer module
KF
ZUP
M
Low loss
header or
buffer
SF
Cylinder
SPL
3062547_201408

Buffer primary pump for BSP cylinder
Heating circuit pump become the buffer primary pump.
The manifold sensor (buffer) only affects the heating operation. In case of cylinder
heating, the reference temperature is provided by the internal boiler sensor. In heating
mode, the buffer primary pump runs only when there is a burner demand. Pump run-on
in accordance with parameter HG07.
Hydraulic scheme:
MKP
MM
SPL
PLP
SF
SAF
KF
MKP
M
MM
=
=
=
=
=
=
=
=

Buffer cylinder primary pump
Cylinder sensor
Header sensor
Boiler sensor
Mixer circuit pump
Mixer motor
Mixer module
Buffer cylinder
Wood
boiler
SPL
SF
PLP
SAF
KF
Oil condensing
boiler
Solar thermal system integration
Boiler circuit pump run-on time

Parameter HG07
HG07
Subject to there being no heat demand from the heating circuit, the boiler circuit pump
will run on in accordance with the set time, to prevent a boiler safety shutdown at high
temperatures.
Factory setting: 4min

Setting range: 0 to 30min
Maximum limit boiler circuit TV-max. This function limits the boiler water temperature upwards in heating mode, and the
burner shuts down. This parameter has no function during cylinder heating, and the
Parameter HG08
HG08
75
boiler water temperature may also be higher during this time. "Reheating effects" can
result in the temperature being slightly exceeded.

Burner cycle block

Parameter HG09
HG09
10
Each time the burner is shut down in heating mode, it will be blocked for the duration
of the burner cycle block.
The burner cycle block is reset by switching the ON/OFF switch OFF and ON or by
briefly pressing the reset button.

3062547_201408
27

Programmable input E1
Parameter HG13
HG13
The functions of input E1 can only be scanned and adjusted with Wolf control
accessories with eBUS capability.
The following functions can be allocated to input E1:
Explanation
Room thermostat
Closed contact is a prerequisite for enabling the burner in heating mode.
No function for DHW mode.
No function for emissions test mode and frost protection, no error message.
Open contact blocks the enabling of the heating and the heating circuit pump
(pump run-on).
Maximum thermostat/system pressure switch

Closed contact is a prerequisite for enabling the burner in heating and DHW
mode.
When the contact is opened, the burner switches off and the pump run-on
begins - no error message. Applies to all pumps.
When the mains power is on and the contact is open, there is only a pump
kick, no run-on.
Factory setting: 1
Flue gas/ventilation air damper

Function monitoring of the flue gas/ventilation air damper with zero volt contact.
Closed contact is a prerequisite for enabling the fan and burner in heating,
DHW, cascade and emissions test mode.
Output A1 must be programmed for flue gas/ventilation air damper function.
If output A1 is controlled and does not close input E1 within two minutes, Fault
Code 8 is issued.
If output A1 is not controlled, input E1 must also open within two minutes.
Otherwise FC8 is generated.
With FC8, the fan is controlled with 65% of speed stage 1.
DHW circulation pushbutton

After the DHW circulation pushbutton is activated, output A1 is switched on for
5 minutes, if output A1 is programmed as DHW circulation pump (A1 = 13).
Header sensor
A header sensor (5K-NTC) is connected at E1; observe parameter HG 06.
Burner blocking
Operation without burner.
Closed contact, burner blocked.
Heating circuit pump and cylinder primary pump run in standard mode.
In emissions test mode and frost protection, the burner is enabled.
Open contact enables the burner again.
External burner demand

Closed contact, TKset is set to TKmax -5K.
10
Demand also functions in standby; cycle block active
(control of output A1 when parameter output A1 = 14).
0, 3, 4, 9, 11 are without function.
28
3062547_201408

Parameter HG14
HG14
The functions of output A1 can only be scanned and adjusted with Wolf control
accessories with eBUS capability.
The following functions can be allocated to output A1:
Factory setting: 0
Explanation
1
DHW circulation pump 100%

Output A1 is switched by control accessories (BM) if DHW circulation has
been enabled. Output A1 is constantly enabled when no accessory controller
is installed.

been enabled. 5 minutes ON and 5 minutes OFF. Output A1 constantly cycled
in 5 minute cycles when no accessory controller is installed.

been enabled. 2 minutes ON and 8 minutes OFF. Output A1 cycles constantly
when no accessory controller is installed.
Alarm output
Output A1 is controlled after a fault and expiry of 4 minutes.
Flame detector
Output A1 is controlled after a flame has been recognised.
Flue gas/ventilation air damper

Output A1 is always controlled before the fan starts. The feedback is checked via
input E1. If input E1 does not close, the fan and burner will not start, and after two
minutes FC8 will be generated. The flue gas/ventilation air damper is controlled until
the fan starts. If input E1 is interrupted during burner operation, the burner shuts
down. In case of a fault, e.g. pressure switch, flame failure during operation etc., the
flue gas damper is closed after the flushing time has expired.
Input E1 must be programmed as flue gas/ventilation air damper.
With FC8, the fan is controlled with 65% of speed stage 1.
External ventilation
Output A1 is controlled inverted to the burner. Switching OFF external
ventilation (e.g. extractor fan) during burner operation is only required, if the
boiler is operated as open flue system.
Oil shut-off valve

Output A1 switches simultaneously to the oil pump.
11 External pump
Output A1 switches simultaneously with the heating circuit pump. Use with, for
example, system separation.
12 Diverter valve
Synchronous control with input E1 (E1 = 8, burner blocking).
13 DHW circulation pump
DHW circulation pump ON for 5mins if input E1 (E1 = 6) is programmed as
DHW circulation pushbutton and input E1Key is closed.
14 Pump with external burner demand
Simultaneous control with input E1 (E1 = 10, ext. burner demand).
0, 6, 10, 15 are without function.
3062547_201408
29

Cylinder hysteresis
Parameter HG15
HG15
The cylinder hysteresis regulates the start point for cylinder heating. The higher the
setting, the lower the start point for cylinder heating.
Example:

Set cylinder temperature 60C

Cylinder hysteresis 5K
Cylinder heating commences at 55C and ends at 60C.
Factory setting: 5K

run-on time
Parameter HG19
HG19
After completing cylinder heating in summer operating mode (the cylinder has reached
the set temperature), the cylinder primary pump will run on up to the maximum set run-on
time. The cylinder primary pump will switch OFF prematurely if, during the run-on time,
the boiler water temperature cools down to a differential between boiler and cylinder
water temperature of 5K, to prevent the boiler cooling down too severely.
In winter operating mode the calorifier charge pump runs on for a fixed period of 2 min.
(irrespective of parameter HG 19).

Max. cylinder heating time

Parameter HG20
HG20
Factory setting: 2h
Setting range: 0 to 5h
Minimum boiler water

temperature TK-min.
Parameter HG21
HG21
Cylinder heating commences as soon as the cylinder temperature sensor demands

heat. The heating circuit pumps would be constantly switched off if the boiler was
undersized, the cylinder was scaled-up or if DHW was constantly drawn off during
DHW priority mode. The accommodation cools down significantly. One option
enables a max. cylinder heating time to be specified to limit this effect. If the set
maximum cylinder heating time has expired, error message FC52 appears on the BM
module. The control unit reverts to heating mode and cycles in the selected rhythm
(HG20) between heating and cylinder heating mode, irrespective of whether the
cylinder has reached its set temperature or not. This function remains enabled even
in parallel mode (parameter A10 set to 1). It is only disabled if it is set to 0.
Set this parameter to 0 in heating systems with a high DHW consumption, e.g. hotels,
sports facilities, etc.
The control unit is equipped with an electronic boiler thermostat, with an adjustable
minimum switch-ON temperature. 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 TKmin. is also not necessarily achieved when there is no heat demand.
20

30
3062547_201408

Maximum boiler water
temperature TK-max.
Parameter HG22
HG22
80
The control unit is equipped with an electronic boiler thermostat which has an adjustable
maximum shutdown temperature (maximum boiler water temperature). The burner is
switched off if this temperature is exceeded. The burner will be started again when the
boiler water temperature has fallen by as much as the burner switching differential.
If the boiler water temperature exceeds 95C (possible effect of reheating), the boiler
circuit pump and cylinder primary pump (if installed) will also be started in "summer
mode". These pumps are stopped again when the boiler water temperature falls
below 92C. This prevents the boiler overheating.

Boiler overtemperature during

cylinder heating
Parameter HG25
HG25
10
The excess temperature differential between the cylinder temperature and the boiler
water temperature during cylinder heating is selected with parameter HG25. The boiler
water temperature continues to be limited by the maximum boiler water temperature
(parameter HG22). This ensures that, even in spring and autumn, the boiler water
temperature is higher than the cylinder temperature, thereby ensuring short heating
times.
Factory setting: 10K

HG28
2
Factory setting: 2
Blocking time burner stage 2

Parameter HG31
HG31
10
You can select any burner operating mode. Control unit is set at the factory for
two-stage burner operation.
Setting "1":
single stage burner operation, stage 1
Setting "2":
two-stage burner operation, stages 1 + 2
Setting "3":

Setting 4:

Setting 5:

single stage burner operation during cylinder heating

two-stage burner operation in heating mode
Burner single-stage in heating mode
Burner 2-stage during calorifier charging
Burner 2-stage in heating mode, anti-short cycle in accordance
with parameter HG09
Burner 2-stage during calorifier charging. The burner is
blocked for 4 minutes after every burner stop, during calorifier
charging mode. This setting ensures an optimized burner
running period and prevents a restart after the
subsequent ventilation period with low calorifer capacity.
Burner stage 2 is started when there is stage 2 demand and after the blocking period
has expired (factory setting 4min). It is stopped once a temperature of approx. 5K
above the set value has been reached. Once the stage 2 has been enabled, it will be
started as soon as the set temperature has been reached or is no longer achieved.
Enabling is removed when burner stage 1 is shut down.
During cylinder heating and emissions test mode, this parameter is disabled.
Boiler
temperatureC
Burner operating mode

Parameter HG28
Set value
Burner
OFF
Burner stage 1
Burner stage 2
Burner
stage 2
Burner
stage 1
Burner
OFF
Demand
stage 2
Blocking period, factory setting 10min
3062547_201408
Burner
stage 1
Time
31
20. Cascade operation

Control / specification / notes
General
These oil condensing boilers have control PCBs with functions that are optimally
matched to the digital controller type KM for cascade control. Up to four COB-29
or COB-40 oil condensing boilers (with the same output) with an output range of
18.5kW to 112.8kW (cascade COB-29) or 25.3kW to 152.0kW (cascade COB-40)
can be linked together to form a single cascade. Subject to load, this digital cascade
controller KM can control the header flow, a mixer circuit and a DHW cylinder circuit.
The digital controller type MM from the WOLF range of control accessories can be
connected to regulate an additional mixer circuit and radiator circuit. Furthermore, a
BM can be used in each case as a remote control.
For a detailed description, see also the installation instructions for the individual modules.
Setting the eBUS address for

cascade mode
(see installation instructions for
KM module)
The eBUS address is set by pressing the reset button for at least 5 seconds after
the appliance has been switched on. After 5 seconds, the corresponding flashing
code appears (in accordance with the table) at the illuminated signal ring. Select the
corresponding eBUS address with the DHW temperature rotary selector. Your selection
of the required eBUS address is saved by releasing the reset button. No address can
be allocated more than once.
Boiler in cascade
operation
eBUS
address
Rotary selector,
DHW temperature
selection
Illuminated signal
ring indication
Boiler 1
1*
1*
flashing red
Boiler 2
flashing yellow
Boiler 3
flashing yellow/red
Boiler 4
flashing yellow/green
*Factory setting (individual boiler without cascade mode)
DHW cylinder
A DHW cylinder is generally connected downstream of the system separation (e.g. via
a low loss header).
Cylinder heating is controlled via the cascade controller type KM, to which a cylinder
primary pump and the electronic cylinder sensor are connected.
Heating circuit
To ensure the heating water flow rate through every condensing boiler is as even as
possible, the following connection types are recommended:
1. For precise hydraulic balancing, a line regulating valve can be fitted in the supply
line to every appliance.
2. Design the flow and return lines with the same length for the flow and return according
to the Tichelmann system, to ensure the pressure drop in every line is equally high.
Low loss header
It must not be possible for the on-site heating circuit pumps or primary pumps to influence
the function of the condensing boilers. A low loss header should therefore be installed
upstream of the heating water circuit or DHW cylinder circuit. Furthermore, ensure that
the heating water flow rate through the condensing boilers is set lower than that through
the subsequent heating circuit. The flow rate should therefore be set upstream of the low
loss header via a line regulating valve or butterfly valve.
System separation
Instead of the low loss header, a heat exchanger can be installed. If pipes are used which
are not impermeable to oxygen, this is a requirement in any case.
Specification
Cascade type
Rated output at 80/60C
Rated output at 50/30C
Rated heat input
Lowest output at 80/60C Stage 1
Lowest output at 50/30C Stage 1
Lowest output
32
kW
kW
kW
kW
kW
kW
2x
COB-29
56.4
59.2
58.0
3x
COB-29
84.6
88.8
87.0
18.5
19.6
19.0
4x
2x
3x
4x
112.8
76.0
114.0
152.0
118.4
80.0
120.0
160.0
116.0
77.6
116.4
155.2
25.3
26.8
26.0
3062547_201408

Flue system design
Oil condensing boilers with a separate, concentric, balanced flue outlet (DN 80/125
or DN 110/160) above the roof, type C33x, may only be installed in attics, or in rooms
where the ceiling also forms the roof, or where only the roof construction is located
above the ceiling.
If the pipework for the combustion air supply and flue gas routing crosses different
floors in the building, route the pipes outside the boiler room inside a duct with a fire
resistance of at least 90 minutes, and in living spaces of low height with a resistance
of at least 30 minutes.
To prevent flue gas being drawn back through adjacent roof outlets where
several flue outlets are arranged next to each other, arrange the outlets at
approximately the same height and with at least 600mm between them.
The maximum permissible straight length for concentric balanced flue routing must
not exceed 16m with an internal diameter DN 80/125, or 21m with DN 110/160. The
calculated length of the balanced flue routing comprises the straight pipe length and
the length of the pipe bends. In this calculation, an 87 bend is calculated as being
1.5m and a 45 bend as being 1m.
min. 600
min. 600
min. 600
KM module
Cascade control with separate, vertical, concentric balanced flue routing, type C33x.
3062547_201408
33

Flue gas header design
Flue cascade
Flue cascades are only suitable in balanced flue operation. They must be designed to
EN 13984-1.

To prevent flue gas escaping, a flue cascade is only permitted with a tested
flue gas damper.
Flue gas routing with header
Oil condensing boilers with common flue routing - open flue operation in installation
type B23.
For open flue operation, there must be an aperture in the boiler room that opens to
the outside and has a clear cross-section of at least 150cm.
Where necessary, adapt the installation examples to the relevant Building Regulations
and requirements of your country/region. Discuss any questions relating to the
installation, particularly of inspection covers and ventilation apertures (ventilation
generally required above 50kW output) with your local heating engineer.
Number
Installation
Flue internal diameter
Total flue gas mass flow rate
Max. flue gas temperature
Max. effective building height
g/s
C
m
2x
COB-29
2x
COB-29
3x
COB-29
DN110
26.6
DN160
26.6
DN160
40.0
76
4x
COB-29
Art B23
DN160
53.3
30
2x
COB-40
3x
COB-40
4x
COB-40
DN160
35.0
DN160
52.5
83
DN160
70.0
The effective heights specified are only valid on the condition that the length of the flue between the individual appliances and
downstream of the last appliance does not exceed 2 m. 325 m was assumed as the geodetic height. If the conditions at the
installation site are different, an individual calculation is required.
Ceiling height at least 2500 mm
min. 600
max. 1000
min. 600
max. 1000
min. 600
max. 1000
min. 605
max. 2000
DWTK
KM module
Cascade control with header

34
3062547_201408

Flue gas header design / notes
The maximum horizontal length of the flue gas header is 1.5m between the
appliances and 1.5m downstream of the last appliance. In addition to the boiler
connection bend, a maximum of two 87 diverters may be installed.
Pipe length calculation:
The calculated length of the flue comprises the straight pipe length and the length of
the pipe bends.
Installation in an existing
chimney/duct
Component
Calculated length
87 bend
1.5m
45 bend
1m
87 tee with inspection aperture
2m
Straight pipe
Subject to length
Minimum cross-section of the duct: With a round duct, the clear distance from the flue
to the duct wall must be at least 3cm and with an angular duct, at least 2cm.
The flues must be installed in ducts and channels in such a way that it is possible
to inspect and, if necessary, clean the ventilated cross-section. Close cleaning
apertures in ducts with chimney cleaning covers which have been assigned a test
mark.
The distance from the cleaning and inspection aperture in the duct/channel to the
front edge of the flue can be twice the diameter of the flue, up to a maximum of
35cm, as long as cleaning and inspection do not take place at the outlet.
Flues in ducts should be designed at the outlet in such a way that no precipitation
can enter the space between the flue and duct, and the secondary ventilation can
escape freely.
Removable covers must be able to be removed without tools and be secured to
prevent them falling.
Retaining straps and spacers must be designed in such a way that it is possible to
inspect and, if necessary, clean the free duct cross-section.
Provide sufficient cleaning and inspection apertures.
3062547_201408
35

Flue gas header design / notes
Installing the flue
In the vertical part of the flue, a cleaning and inspection aperture is required
immediately above or below the flue diverter if the distance from the centre of the
cleaning and inspection aperture in the horizontal part of the flue to the vertical axis
of the flue is greater than 30cm.
The distance can be up to 1m if the inspection aperture in the horizontal part of the
flue is arranged on the front and if there are no diverters in the flue from this cleaning
and inspection aperture to the vertical part.
In the upper part of the flue arranged inside the building (< 5m), a cleaning and
inspection aperture is required if cleaning or inspection cannot be carried out from the
roof.
Before commissioning the combustion system, have the safe usability of the flue
system confirmed by the local flue gas inspector [in Germany; check local regulations].
1 Oil condensing boiler
36 Siphon
2 Connection adaptor with test nipple

for air and flue gas (included in COB standard delivery)
37 PP header
38 End piece with inspection aperture and condensate
drain
16 Rose
23 Support rail
24 87 support bend
25 Spacer
26 PP pipe
27 Cowl
33 PP outlet
34 Electrical flue gas damper
27
35 Extension (where required)
33
26
16
38
37
37
37
37
26
25
24
23
36
32
32
32
32
26
26
26
26
35
35
35
35
34
34
34
34
Secondary
ventilation
Example of an open flue cascade design according to type B23
36
3062547_201408

Flue gas damper installation
information
Flue gas damper
- Push flue gas damper as far as it will go onto connection

adaptor (with test nipple) on the boiler.
- Push the flue as far as it will go onto the flue gas damper.
- Correctly route the limit switch cable and motor cable from
the flue gas damper to the terminal box and to the cable
(programmable output A1).
COB
Electrical connection installation

information
Terminal box
In the delivered condition, the terminal box is fitted to the

back panel of the boiler.
If required, the terminal box can be mounted on the wall to
the right or left of the boiler, or above it.
The control, regulating and safety equipment are fully wired
and tested.
Installation information regarding electrical connection of

input E1 and output A1 for the flue gas damper
-
-
-
-
-
-
-

-

-
Isolate the system from the power supply before opening.

Unclip the terminal box from the holder.
Open the terminal box.
Insert the strain relief into the holes provided.
Strip approx. 70 mm off the power cable from the limit switch.
Push the cable through the strain relief and secure the strain
relief.
Connect the wires from the limit switch to input E1
(see chapter 25 "Wiring diagram cascade operation").
Connect motor cable from the flue gas damper via an onsite junction box with programmable output A1
(see chapter 25 "Wiring diagram cascade operation").
Fit the cover.
Proceed with chapter 26 "Flue gas damper tightness test"

and "Commissioning".
Programmable
output A1
(230VAC; 200VA)
COB back view
3062547_201408
37

Flue gas damper installation / wiring diagram
Flue gas damper wiring diagram
COB terminal box
Netz KKP
LP
N L1 N L1
L1
E1 eBUS AF
a b + - 1 2
1 2
L1 N
1 2
1 2
1 2
L1 N
L1
SF
1 2
Note:
Contractor parameter HG13
(input E1) must be set to 5 and
HG14 (output A1) must be set
to 7.
Flue gas damper with

servomotor
Power supply (230 VAC; 200 VA)
M
230 V ~
Limit switch
NB:
Flue gas damper limit switch
must be zero volt. Otherwise
the COB control unit will be
destroyed.
COB-15/20/29/40
Junction box
on site
(230VAC; 200VA)
38
3062547_201408

Flue gas damper tightness test
Testing adjacent
appliances for
tightness
As part of the annual boiler test, the cascade damper in overpressure boiler systems
must be tested for tightness to ensure no CO2 can escape into the boiler room; risk of
poisoning or suffocation.
The check must be carried out with the appliance closed.
We recommend proceeding as follows:
Testing adjacent appliances for tightness
- Set the program selector (l.h. rotary selector) to Standby on the BM programming module.
- Then turn the first COB to position 1 Emissions test by means of the heating
water temperature selector COB starts.
- Operate the first COB for at least 5 minutes.
- On all other appliances, check the CO2 contents at the air connector:
- If the CO2 value exceeds 0.2% within 15 minutes, the leak must be found and
remedied.
- Subsequently close all test apertures again. When doing so, ensure the caps are
seated firmly.
Testing the first COB for tightness
- Turn the temperature selector for heating water on the first COB to its centre position COB shuts down.
- Turn the second COP to position 1 Emissions test by means of the heating water
temperature selector COB starts.
- Operate the second COB for at least 5 minutes.
- Carry out the CO2 test on the first COB.
- If the CO2 value exceeds 0.2% within 15 minutes, the leak must be found and
remedied.
- Subsequently close all test apertures again. When doing so, ensure the caps are
seated firmly.
1. ON
2. OFF
3062547_201408
OFF
ON
OFF
OFF
OFF
OFF
39
27. Commissioning with

Wolf control accessories (BM)
If no control accessory is installed, see chapter 28 "Commissioning without Wolf
control accessories (BM)".
Commissioning
"Inlet air"
test port
Only qualified personnel must carry out the commissioning and

operation of the boiler, as well as instruct the user.
"Flue gas"
test port
- Check the boiler and system for leaks. Normal operating pressure
when system is cold 1.5 - 2.0bar. Prevent water leaks.
- Check location and seating of the installation. (e.g. displacement device

position)
- Check the fuel level in the oil tank and water level in the siphon or
neutralisation box.
- Check all connections, including those between components, for leaks.
- If tightness cannot be ensured then there is a danger of water damage.
- Fit casing.
- Check that all flue gas accessories have been correctly installed.
- Open the shut-off valves on flow and return.
- Open oil shut-off valves (tank, oil line, filter).
- Switch ON the heating system emergency stop switch.
- Switch ON the system ON/OFF switch on the control unit.
- Remove cap from r.h. test port (inlet air).
- Insert test probe 2cm.
- Turn the program selector switch on BM module to "Emissions test"
(Illuminated signal ring flashes yellow)

0
I
60
40
20
0
80
100
C 120
- After a pre-purge time of approx. 25 seconds, the pump starts up and opens the
solenoid valve. The supplied fuel oil reaches the nozzle and a flame is established.
- The burner enters a fault state if, during commissioning, the oil pump does not supply
sufficient oil during the pre-purge time. Repeat the burner start by pressing "Reset".
ON/OFF switch Program selector switch
- Measure temperature and CO2 in the inlet air and enter the values in the commissioning
report in chapter 29.
- The flue is not gas tight if the CO2 content > 0.2%; rectify the leak.
- Terminate the emissions test mode by turning the program selector switch on the
programming module to the required operating mode.
- If emissions test mode is not reset manually, the appliance switches back to the
original operating mode automatically after 15 minutes.
- Remove the test probe and close the test port. Ensure the cap is seated firmly.
40
3062547_201408
27. CO2 check/adjustment by matching

the pipe lengths
CO2 adjustment by
matching the pipe
lengths
With contractor parameter HG 00 (see chapter 19 "Contractor level parameters"),

the appliances can be matched to the flue gas system by changing the speed
for both stages.
- The casing must be closed for this setting.
- Remove the cap from the l.h. "flue gas" test port.
Adjusting the CO2 value in the

upper load range (stage 2)
(emissions test mode)
CO2 set value, boiler closed stage 2
13.5 0.3%
- Insert the test probe of the CO2 measuring instrument into the "flue gas" test port
(approx. 70mm).
- Turn the program selector switch on BM module to "Emissions test". (Illuminated
signal ring as status indicator
flashes yellow.)
- Measure the CO2 content and compare it against the values given in the Stage 2
table adjacent.
- If required, alter the CO2 content with parameter HG00.
HG 00
CO2 settings
Factory setting: 3
1
2
5

Higher
CO value
CO2 check in the lower load

(stage 1)
CO2 set value, boiler closed stage 1
13.5 0.3%
4
Lower CO2 value
- Measure the flue gas, CO2 content, flue gas temperature and soot value and enter
them in the commissioning report (chapter 29).
- Modifying the parameter HG00 has also adjusted the speed for stage 1. For checking
purposes, the boiler must be set to stage 1.
- Switch HG28 burner operating mode from 2 (two-stage) to 1 (single stage).
- Measure the CO2 content and compare it against the values given in the stage 1
table adjacent.
- If the value is outside the set value, the CO2 value must be adjusted via the pump
pressure (see chapter 28 "Commissioning without Wolf control accessories").
- Reset HG28 burner operating mode from 1 to 2.
- Terminate the emissions test mode by turning the program selector switch on the
BM programming module to the required operating mode. If emissions test mode
is not reset manually, the appliance switches back to the original operating mode
automatically after 15 minutes.
- Remove the test probe and close the test port.
Completing the adjustments
- Check the control parameters and match them to the system if necessary.
- Check the condensate drain.
- Instruct the customer in the operation of the boiler, with the aid of the operating
instructions.
- Complete the commissioning report (chapter 29) and hand over the instructions to
the customer.
- Instruct the customer about the need for annual servicing.
- Instruct the customer about energy saving options.
- Refer your customer to section "Information regarding energy efficient operation" in
the operating instructions.
3062547_201408
41
28. Commissioning without Wolf control

accessories (BM)
Commissioning
Only qualified personnel must carry out the commissioning and

operation of the boiler, as well as instruct the user.
- Check the boiler and system for leaks. Normal operating pressure
when system is cold 1.5 - 2.0bar. Prevent water leaks.
- Check location and seating of the installation.
- Check the fuel level in the oil tank.
- Check all connections and component links for leaks.
- If tightness cannot be ensured then there is a danger of water damage.
NB
"Flue gas"
test port
"Inlet air"
test port
- Fit casing.
- Check that all flue gas accessories have been correctly installed.
- Open the shut-off valves on flow and return.
- Open oil shut-off valves (tank, oil line, filter).
- Switch ON the heating system emergency stop switch.
- Switch ON the system ON/OFF switch on the control unit.
- Remove cap from r.h. test port (inlet air).
- Insert test probe 2cm.
- Turn DHW temperature selector to 1.
- Turn heating water temperature selector to "Emissions test"
(illuminated signal ring flashes yellow).
- After a pre-purge time of approx. 25 seconds, the pump starts up and opens the
solenoid valve. The supplied fuel oil reaches the nozzle and a flame is established.
- The burner enters a fault state if, during commissioning, the oil pump does not supply
sufficient oil during the pre-purge time. Repeat the burner start by pressing reset.
0
I
60
40
80
20
0
100
C 120
- Measure temperature and CO2 in the inlet air and enter the values in the commissioning
report in chapter 24.
- The flue is not gas tight if the CO2 content > 0.2%; rectify the leak.
ON/OFF
switch
- Terminate the emissions test mode by turning the temperature selector back to its
original position.
DHW
Heating water - If emissions test mode is not reset manually, the appliance switches back to the
temperature temperature
original operating mode automatically after 15 minutes.
selector
selector
- Remove the test probe and close the test port. Ensure the cap is seated firmly.
CO2 settings via

pump pressure
If no control accessory is connected to the appliance or the CO2 set value is not
achieved by matching the pipe lengths, the setting is made via pump pressure
control:
Adjusting the CO2 value in the

upper load range (stage 2)
(emissions test mode)
- Remove front and top casing.
Pump Danfoss
- Pivot the control unit downwards.

- Insert the oil pressure gauge into the pump's pressure gauge test port.
- Remove the cap from the l.h. "flue gas" test port.
Pressure regulating - Insert the test probe of the CO2 measuring instrument into the "flue gas" test port.
screw, stage 2
Oil pressure
test connection
Vacuum test
connection
Pump Suntec
(approx. 70mm).
- Turn the heating water temperature selector to "Emissions test"

(illuminated signal ring as status indicator flashes yellow.)
- Measure the CO2 content and compare it against the values given in the stage 2
table adjacent.
- If required, set the CO2 content with the stage 2 pressure regulating screw using a
4mm Allen key in accordance with the table.
Vacuum test

connection

Oil pressure
test connection
Pressure regulating
screw, stage 2
42
Turn clockwise - higher CO2 value

Turn anti-clockwise - lower CO2 value
3062547_201408
28. CO2 check/adjustment via pump

pressure
Adjust the CO2 value in the
lower load (stage 1)
Pump Danfoss
Pressure
regulating
screw, stage 1
- Check whether the pump pressure is still within the tolerance range.
If not, then check the nozzle and mixer head.
- Terminate the emissions test mode by turning the DHW temperature selector back
to its original position.
- Press the reset button.
- Set the heating water temperature selector to 8.
- Approx. 60 seconds after the burner start, check the CO2 content with the CO2
measuring instrument.
- If required, alter the CO2 content with the stage 1 pressure regulating screw using a
4mm Allen key.
Testing must be carried out within 240 seconds of the burner start. If necessary, repeat
the start phase for setting procedures by turning back the heating water temperature
selector and pressing the reset button.
Turn clockwise - higher CO2 value
Turn anti-clockwise - lower CO2 value
Appliance open
Pressure
regulating
screw, stage 1
COB-15
COB-20
COB-29
COB-40
Stage 2
CO2 set value
13.2 0.3%
13.2 0.3%
12.7 0.3%
12.7 0.3%
Stage 1
CO2 set value
13.2 0.3%
13.2 0.3%
12.7 0.3%
12.7 0.3%
COB-15
COB-20
COB-29
COB-40
Appliance open
Stage 2 Pump pressure 12.0 2.5 bar 16.8 2.5 bar 16.8 2.5 bar 23.5 2.5 bar
Stage 1 Pump pressure
Pump Suntec
5.0 1.0 bar 8.5 1.0 bar 8.5 1.0 bar 11.0 1.0 bar
The pump pressure in stage 2 must always be greater than that in stage 1
- Check whether the pump pressure is still within the tolerance range. If not, then check
the nozzle and mixer head.
- Terminate boiler operation by turning the heating water temperature selector back
to its original position.
- Remove the oil pressure gauge and close the aperture again.
Checking the CO2 adjustment
- After completing the work, refit the casing lid and check the CO2 value with the
boiler closed.
Observe the CO emissions whilst making CO2 adjustments. The CO
value should be < 50ppm if the CO2 value is correct.
- The condensing boiler is correctly adjusted when the CO2 values correspond to
those in the adjacent table.
- If the CO2 value increases too greatly, the balanced flue must be checked.
- Enter the flue gas values of CO2, flue gas temperature and soot value in the
commissioning report in chapter 29.
Appliance closed
Completing the adjustments
COB-15
COB-20
COB-29
Stage 2
CO2 set value
13.5 0.3%
Stage 1
CO2 set value
13.5 0.3%
COB-40
- Shut down the boiler and close the test ports again.
- Check the control parameters and match them to the system if necessary.
- Check the condensate drain.
- Instruct the customer in the operation of the boiler, with the aid of the operating
instructions.
- Complete the commissioning report (chapter 29) and hand over the instructions to
the customer.
- Instruct the customer about the need for annual servicing.
- Instruct the customer about energy saving options.
- Refer your customer to section "Information regarding energy efficient operation" in
the operating instructions.
3062547_201408
43
29. Commissioning report

Commissioning steps
Test value or confirmation
1.) Fuel oil

Standard EL
Low sulphur EL
Bio-oil B10
2.) Oil leak test carried out?
3.) Balanced flue system checked?
4.) Water connections checked for leaks?
5.) Siphon filled?
6.) Boiler and system vented?
7.) Function test carried out?
8.) Function test carried out?
9.) Flue gas test:
Flue gas temperature gross
Inlet air temperature
Flue gas temperature net
Carbon dioxide content (CO2) or oxygen content (O2)
Carbon monoxide content (CO)
__________________
tA [C]
__________________
tL [C]
__________________
(tA - tL ) [C]
__________________
__________________
ppm
10.) Casing fitted?

11.) Control parameters checked?
12.) System user trained, documentation handed over?
13.)
Confirm commissioning?
Date: ____________________________
Signature: ________________________
44
3062547_201408
30. Maintenance and design data

NTC sensor resistances
Temp.C
-21
-20
-19
-18
-17
-16
-15
-14
-13
-12
-11
-10
-9
-8
-7
-6
-5
-4
-3
-2
-1
0
1
2
3
4
5
6
7
8
9
10
11
12
13
Boiler sensor, cylinder sensor,

outside temperature sensor,
header sensor, DHW heating
sensor
Pressure drop on the heating

water side COB-15
Resist.
51393
48487
45762
43207
40810
38560
36447
34463
32599
30846
29198
27648
26189
24816
23523
22305
21157
20075
19054
18091
17183
16325
15515
14750
14027
13344
12697
12086
11508
10961
10442
9952
9487
9046
8629
Temp.C
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
Resist.
8233
7857
7501
7162
6841
6536
6247
5972
5710
5461
5225
5000
4786
4582
4388
4204
4028
3860
3701
3549
3403
3265
3133
3007
2887
2772
2662
2558
2458
2362
2271
2183
2100
2020
1944
Temp.C
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
Resist.
1870
1800
1733
1669
1608
1549
1493
1438
1387
1337
1289
1244
1200
1158
1117
1078
1041
1005
971
938
906
876
846
818
791
765
740
716
693
670
670
628
608
589
570
Temp.C
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
Resist.
552
535
519
503
487
472
458
444
431
418
406
393
382
371
360
349
339
330
320
311
302
294
285
277
270
262
255
248
241
235
228
222
216
211
205
30
Pressure drop (mbar)
25
COB-15
10K-spread
20
15
COB-15
20K-spread
10
0
0
200
400
600
800
1000
1200
1400
1600
1800
2000
Water volume (l/h)
3062547_201408
45
30. Maintenance and design data

water side COB-20
30
COB-20
10K-spread
25
20
15
COB-20
20K-spread
10
0
0
200
400
600
800
1000
1200
1400
1600
1800
2000
Water volume (l/h)

water side COB-29
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
COB-29
10K-spread
COB-29
20K-spread
200
400
600
800
1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000
Water volume (l/h)

water side COB-40
210
200
190
180
170
160
150
140
130
120
110
100
90
80
70
60
50
40
30
20
10
0
COB-40
10K-spread
COB-40
20K-spread
400
800 1200 1600 2000 2400 2800 3200 3600 4000 4400 4800 5200 5600 6000
Water volume (l/h)

46
3062547_201408
31. Design information
B23
B33
IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII
I
I
I
I
IIII
IIII
IIII
IIII
C33x
C33x
C53x
IIII
II
IIIIIIII
IIIIIIIIII
C93x
C53
C83x
C93x
C43x
C33x
C83x
B33
Connection types
Boiler
type
Appliance type
COB15/20/
29/40
B23, B33, C53,

C33x, C43x,
C53x, C63x,
C83x, C93x
1), 2)
Operating mode
Can be connected to
Open flue Balanced Moisture-resistant Balanced flue Balanced flue
Certified
flue
chimney
chimney
balanced flue
Yes
Yes
B33, C53, C83x
C43x
C33x, C53x,
C63x
C93x
Moistureresistant flue
B23, C53x,
C83x
1)
Marking "x" indicates that all components of the flue are surrounded by combustion air and meet increased requirements for gas
tightness.
2)
For types B23 and B33, the combustion air is drawn from the installation room (open flue combustion equipment).
For type C, the combustion air is drawn through a sealed system from the outside (balanced flue combustion equipment).
The following balanced flue or flues with CE-0036-CPD-9169003 certification may be used:
Flue DN 80
Concentric balanced flue DN 80/125
Flue DN 110
Concentric balanced flue (on an external wall) DN 80/125
Flue (flexible) DN83, DN110
Concentric balanced flue (on an external wall) DN 110/160
Flue DN 160 (for cascade)
The necessary type plates and certificates are included with the relevant Wolf accessories.
Observe all additional installation instructions included with accessories.
3062547_201408
47

Versions as condensing boilers
Max. length, vertical 1)

B23
Flue in a duct and combustion air directly via the boiler (open flue)
30
30
30
30
B33
Flue in a duct with horizontal, concentric connection line (open flue)
30
30
30
30
B33
Connection to a moisture-resistant flue gas chimney with

a horizontal concentric connection line (open flue)
Calculation to DIN EN 13384

(balanced flue manufacturer)
C33x Vertical concentric roof outlet through a pitched or flat roof, vertical concentric
balanced flue for installation in a duct, (balanced flue)
20
C43x Connection to a moisture-resistant balanced flue chimney,

maximum pipe length from centre of boiler bend to connection 2m
(balanced flue)
20
16
21

C53 Connection to the flue in a duct and

ventilation air line through an external wall (balanced flue)
30
30
30
30
C53x Connection to a flue on an external wall (balanced flue)
30
30
30
30
C83x Connection to the flue in a duct and

ventilation air through an external wall (balanced flue)
30
30
30
14
C83x Concentric connection to a moisture-resistant flue gas chimney and

combustion air through an external wall (balanced flue)
C93x Vertical flue for installation in a duct,
flexible and rigid with horizontal concentric connection line

rigid
flexible
27
19
27
19
22
16
20
2)
1)
Available fan draught: COB-15: 32-65 Pa / COB-20: 45-65 Pa / COB-29: 55-105 Pa / COB-40: 70-150 Pa
(the maximum length corresponds to the total length from the appliance to the flue terminal)
2)
Vertical flue for installation in a duct, flexible and rigid with horizontal concentric connection line Calculation to DIN EN 13384
Note:
Systems C 33x and C 83x are also suitable for installation in garages.
Where necessary, adapt the installation examples to the relevant Building Regulations and requirements of your country/region.
Discuss any questions relating to the installation, particularly regarding the inspection components and ventilation apertures, prior
to installation with your local flue gas inspector.
The length dimensions refer to concentric balanced flue and flues, and only to original Wolf components.
Calculating the balanced flue length
Component
Calculated length
87 bend
1.5m
45 bend
1m
Tee 87 with inspection

aperture
2m
Inspection tee 87 = 2m
Straight pipe
Subject to length
2 x 45 bends = 2 x 1m
Table: Pipe length calculation
The calculated length of the balanced flue system or the flue

is derived from the straight pipe length and the length of the
pipe bends.
Example:
Length of straight balanced flue 1.5m
L = 1.5m + 1 x 2m + 2 x 1m
L = 5.5 m
48
3062547_201408

Minimum duct sizes
for balanced flue operation C93x
Flue DN80 (COB-15/20/29), DN110 (COB-40)

32
30
Assumptions: In the installation room,

2 x tee, 1 x 87 bend + 1.5m horizontal
with 87 support bend
COB-15/-20
Max. vertical length (m)
28
26
COB-29
24
22
COB-40
20
18
16
14
12
10
8
110
120
130
140
150
160
Square duct a x a (mm)
Flue DN80 (COB-15/20/29), DN110 (COB-40)

32
30
C93x
COB-15/-20
Max. vertical length (m)
28
C93x balanced flue
26
24
COB-29
22
20
COB-40
18
16
14
12
10
8
120
130
140
150
160
170
180
Round duct (mm)
Minimum duct sizes for open flue operation B23, B33 and
balanced flue operation C53(x), C83(x)
Balanced flue routing, rigid and flexible in a duct
Minimum duct sizes
Required secondary ventilation to DIN 18160
Round
Square
DN80
150 mm
130 mm
DN110
190 mm
170 mm
B23, B33 open flue

in a DN80 duct
3062547_201408
C93x
B23/B33 open flue

in a DN80 duct
49

Concentric balanced flue C33x, C83x, C93x and flue on an external wall C53x
(examples) DN 80/125 and DN 110/160
2

20
Connection adaptor with test

nipple for air and flue gas
(included in COB standard
delivery)
20
18
27
18
33
19
4 Balanced flue

500mm
1000mm
2000mm
27
33
18
18
5
10
16
16 17
26
17
5 Spacer clip
7 Balanced flue, vertical
(roof outlet for
flat or pitched roofs)
8 Separator
(slide coupling), if required
4
5
Flue on an external wall
S
S
10
16
16
10 Inspection tee 87
11 87 bend
26
25
11
24
23
23
16 Rose
17
External wall connection
with smooth ends on
both sides of the air pipe
approx.1500mm
18 Air inlet, external wall

19 Balanced flue, external wall
20 Wall outlet, external wall
C53x
C33x, C93x
21 Twin coupling
23 Support rail
24 Support bend 87
25 Spacer
26 PP flue
500mm
1000mm
2000mm
27
33
16
16 29
28
10
16
26
25
24
23
27 Cowl
28 Air pipe
29 Air inlet pipe

33 PP outlet
C83x
Install the horizontal flue with approx. 3 fall (6cm/m) towards the boiler. Route the
horizontal air supply with a 3 fall towards the outside install the air inlet with wind
protection; permissible wind pressure at the air inlet 90 Pa. The burner will not operate
with higher wind pressure. In a duct, after the support bend (24), a rigid or flexible flue
in DN80 can be connected.
50
3062547_201408

Vertical concentric balanced flue C33x (examples) system DN 80/125 and DN 110/160

for air and flue gas (included in COB
standard delivery)
3 Balanced flue incl. inspection aperture

(250mm long)
12
4 Balanced flue DN 80/125

500mm
1000mm
2000mm
13
6
14
5 Spacer clip
3
6 Mounting bracket
for roof outlet
7 Balanced flue, vertical
(roof outlet for flat
or pitched roofs)
9
4
8 Separator

(slide coupling), if required
9 45 bend
10 Inspection tee, 87
11 87 bend
12 Universal tile for
pitched roof 25 - 45
13 "Klber" adaptor 20 - 50
S
8
14 Flat roof collar
8
10
3
C33x
C33x
4 5
11
C33x
Please note: Install the horizontal flue with approx. 3 fall (6cm/m) towards
the boiler. During installation, slide the separator (8) fully
into the coupling. Push the next balanced flue (4) 50mm
(dim. "S") into the coupling of the separator, and secure in
this location, e.g. with pipe clips DN125 (5) or a fixing screw
on the air side.

Lubricate the pipe ends and gaskets for easier installation
(use only grease without silicone).

3062547_201408
NB
Determine the required inspection piece (3) (10) with your

local flue gas inspector prior to installation.
51

Eccentric balanced flue
(examples) DN 80 and DN 110
Install the balanced flue distributor eccentrically (29) for
separate balanced flue on the oil condensing boiler.
Install the horizontal flue with approx. 3 fall (6cm/m) towards
the boiler. Route the horizontal air supply with a 3 fall towards
the outside install the air inlet with a cowl; permissible wind
pressure at the air inlet 90 Pa. The burner will not operate with
higher wind pressure.
27
33
26
16
16
30
31
32
26
16
24
23
33
29
2
Secondary
ventilation
C53
Balanced flue routing, open flue B33 and B23

(examples) DN 80/125 and DN 110/160
27

for air and flue gas (included in COB standard delivery)
33
26
4 Balanced flue

500mm
1000mm
2000mm
10
22
16
25
24
23
2
5 Spacer clip (only if required)

10 Inspection tee 87
16 Rose
22 Connection to

flue gas chimney B33

length 250mm with air aperture
23 Support rail
approx.1500mm
1
Secondary
ventilation
B33
24 87 support bend
25 Spacer
26 PP flue
500mm
1000mm
2000mm
27
33
26
27 Cowl
32
29 Balanced flue distributor

80/80mm
26
16
25
24
23
30 Air inlet pipe

31 87 bend
32 Tee 87 with
inspection aperture
33 PP outlet
Secondary
ventilation
B23
52
3062547_201408

Supplementary installation instructions for balanced flue DN 80/125
Flat roof:
Affix the ceiling outlet approx. 130mm (14) in the roof

cover.
Pitched roof: At (12), observe the installation instructions on the
cowl regarding roof pitches.
During installation, slide the separator (8) fully into the coupling.
Push the next balanced flue (4) 50mm (dim. "S") into the coupling
of the separator, and secure in this location, e.g. with pipe clips
DN125 (5) or a fixing screw on the air side.
Insert the roof outlet (7) from above through the roof and secure
vertically with (6) to a rafter or brickwork.
Install the roof outlet only in its original condition. Modifications
are not permissible.
4
5
650
1250
550-1050
1750-2300
S
S
8
7
4
If an inspection aperture is required for the balanced flue, insert a

balanced flue with inspection aperture (3) (250mm long).
Fit connection adaptor with test nipple (2) to the oil condensing
boiler connection.
ce
Separate the flue via a slide coupling (8)

For inspection purposes, undo and move the inspection piece clamp.
Undo and remove the inspection pipe cover.
n
ta
is
Offset
Bends
Offset
87
min. 204mm
45
min. 93mm
Distance A
11
11
Distance A
Inspection piece (3)

Connection adaptor
Slide coupling
with test nipple (2) (isolating appliance) (8)
10
11
Determine distance A. Length of balanced flue (4) always approx.

100mm longer than distance A. Always trim the flue on the smooth
side, never on the coupling side.
Chamfer the flue after trimming.
NB
Wet or lubricate all air/flue gas joints prior to installation, e.g. using a grease without silicone.
3062547_201408
53

General notes
Particularly for safety reasons, use only original Wolf
components for flues and concentric balanced flue
systems.
Where necessary, adapt the installation examples to the
relevant Building Regulations and requirements of your
country/region. Discuss any questions relating to the
installation of inspection covers and ventilation apertures with
your local flue gas inspector.

At low outside temperatures, the water 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. Prevent ice from
falling through on-site measures, e.g. the installation
of a snow catcher grille.
A clearance between the concentric balanced flue and

combustible materials or components is not required, as
temperatures are limited to 85C at the rated boiler output.
If only a flue is installed, maintain the clearances specified
by DVGW/TRGI 86/96 [or local regulations].

NB
NB
If the balanced flue crosses different floors, route

the pipes outside the installation room inside a duct
with a fire resistance of at least 90min, and in low
residential buildings with a resistance of at least
30min. Fire may spread if these instructions are not
observed.

Balanced flues without ducts must not be routed

through other installation rooms, as there is a risk
of fire spreading, and mechanical protection is
not ensured.
Condensing boilers with a balanced flue outlet above

the roof may only be installed in attics, or in rooms
where the ceiling also forms the roof, or where only
the roof construction is located above the ceiling.
The combustion air must not be drawn from chimneys

that used to carry flue gases from oil or solid fuel
boilers.
Ducts which were previously connected to an oil
or solid fuel boiler must be thoroughly cleaned
by the flue gas inspector. There must be no dust,
sulphur or soot residues left on the inner surface of
the chimney. If this is not possible, use a separate
ventilation supply. If the combustion air is drawn in
via the cleaned duct, the prior use can cause odours
in the boiler room.
Secure the balanced flue or flue outside ducts

with spacer brackets with a minimum clearance of
50cm from the flue outlet or upstream/downstream
of diverters to prevent the pipe joints being pulled
apart. If this is not observed, there is a danger of
poisoning caused by escaping flue gas. Furthermore,
equipment damage may result.
Connection to the balanced flue

The following applies to boilers with a balanced flue above
the roof, where only the roof structure lies above the ceiling:

If fire resistance is required for the ceiling, the pipes

for combustion air supply and flue gas exhaustion
running between the top edge of the ceiling and the
roof skin must be run inside a liner that provides
the same fire resistance and is constructed from
non-combustible materials. There is a risk of fire
spreading if these requirements are ignored.
The clear 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.
Flue cascade
Flue cascades are only suitable in balanced flue operation.
They must be designed to EN 13984-1.

54
If fire resistance is not required, route the pipes

for combustion air supply and flue gas exhaustion
between the top edge of the ceiling and the roof
skin inside a duct made from non-combustible,
rigid materials or inside a protective metal pipe
(mechanical protection). There is a risk of fire
spreading if these requirements are ignored.
To prevent flue gas escaping, a flue cascade is only

permitted with a tested flue gas damper.
Flue gas temperature limiter
The electronic flue gas temperature limiter switches the oil

condensing boiler off when the flue gas temperature exceeds
120C.
The boiler restarts when the reset button is pressed.
3062547_201408

Connection to a moisture-resistant balanced flue
chimney type C43x
Connection to a moisture-resistant flue type C53, C83x

for balanced flue operation
Straight balanced flues must be no longer than 3m when

connecting the system to a balanced flue chimney. In addition
to the boiler connection tee, up to two 90 diverters may be
installed.
The balanced flue chimney must be CE-designated.
The straight, horizontal flue must be no longer than 3m.

For horizontal air supply pipes, a maximum length of 3m is
recommended. Observe special requirements for flues that are
not surrounded by combustion air in accordance with locally
applicable combustion regulations.
Connection to a moisture-resistant flue gas chimney or a

flue system type B33 for open flue operation
Straight balanced flues must be no longer than 3m when
connecting the system to a flue gas chimney. In addition to the
boiler connection tee, up to two 90 diverters may be installed.
The flue gas chimney must be CE-designated.
If necessary, the flue outlet should be obtained from the
chimney manufacturer.
The air apertures to the boiler room must be completely free
from obstruction.
Connection to a moisture-resistant flue type B23 for open

flue operation
The straight, horizontal flue must be no longer than 3m. In
addition to the boiler connection tee, up to two 90 diverters
may be installed in the horizontal flue.
The flue gas chimney must be CE-designated.
Connection to a combustion air and flue system type

C63x that is not tested together with the oil combustion
equipment
Original Wolf components are designed for long-term use and
are matched for use with Wolf oil condensing boilers. When
using CE-designated third party equipment, the installer is
responsible for the correct sizing and perfect function 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-approved third party
equipment is used.
Straight balanced flues must be no longer than 3m, when
connecting the system to a combustion air supply and a
separate flue.
In addition to the boiler connection tee, up to two 90 diverters
may be installed.
The chimney must be free from contamination if the combustion
air is drawn from the chimney.
1000
Connection to moisture-insensitive flue gas line on double or multiple-flue chimneys (shaft)

Shaft cover from
the Wolf scope
of supply
Fully stainless steel

shaft cover from the Wolf
scope of supply
Chimney
System made of polypropylene,
Chimney
System made of polypropylene,
T400
up to 120 C, CE-approved
T400
up to 120 C, CE-approved
Room air-dependent and room air-independent operating modes
Room air-dependent operating mode only
The requirements according to DIN 18160-1 supplementary sheet 3 apply.
The responsible local chimney sweeper is to be informed before the installation.
3062547_201408
55
F1
bn
br
MT
5A
rtrd
bu
bl
gn/ye
gn/ge
wh
ws
bk
sw
L1 N
L1
L N PE
ye
ge
bk
sw
og
or
vt
vio
bn
br
gn
gn
1 2
1 2
1 2
E1 eBUS AF
a b + - 1 2
o o o o o o
L N PE
1 2
SF
1 2
o o o o
rtrd
bu
bl
Terminal box:
Mains 230VAC 50Hz
LP
External primary pump

230VAC
E1
Programmable input
eBUS BUS connection for external

control accessories
KKP
Heating circuit pump
AF
Outside temperature sensor
SF
Cylinder sensor
L1 N
Mains
Netz
KKP
LP
N L1 N
L1
L1
PE
X10 (earth
conductor
terminal)
L N
bl
bl
L N
1 2 3
bn
br
X1
Accessories
M1 (stratification pump)
PE
rd
rt
Output A1
bl
bl
PWM
br
bn
Stratification pump
NN-Klemme
terminal
X2
X7
NN N L L
bl
bl
sw
rd
gn/ye
gn/ge
sw
bk
bn
br
Primary pump
Output A1
Heating circuit pump
Burner
X
X
5
6
bl
bl
S4
N L
S2
(TW flue gas)
N N L
A2
A1
X3
3
2 1
M4 (fan)
3 2 1
bl gn/ge
gn/ye
bn
br
bl
S4
(water pressure switch)
gn/ge
gn/ye
br
bn
bl
bn
br
Mains
rt
rd
Oil pump
bn
br
Valve 1
Valve 2
L valves
blbl
Fan
bl
bk
sw
br
Oil preheater
gn
gn
ye
ge
rd
rt
GND
GND
rtrd
Ignition
bn
br
>
X4
+ - ~~+ - + -
eBUS
bn
br
gn
gn
ye
ge
wh
ws
S1
(TW flow)
X8
X6
+- + - ++ -~ ~+ -
>
B1
(flow sensor)
X5
+ - ~~~ ~+- ++ -
eBUS plug
br
bn
gn
gn
ge
ye
wh
ws
rtrd br
bn
gn
gn
1 2
TW flue gas
E1 (ignition transformer)
Speed
bn
Input E1
1 2 3 4 5
gn
gn
bn
br
gn
gn
bn
br
gn
gn
bn
br
wh
ws
ye
ge
rtrd
gn
gn
bn
br
TW flow
Flow sensor
eBUS
+
GND
12V
B3 (IRD)
Cylinder sensor
wh
ws
gn
gn
M3 (oil pump)
eBUS
R680
X9 boiler coding
card
GND
GND
5V
5V
0.5..4.5V
0,5..4,5V
GND
GND
Y2 (valve 2)
PWM stratification pump
or
og
vt
vio
bk
sw
ye
ge
bn
br
gn
gn
bl
bl
rd
rt
Outside temperature sensor
wh
ws
gn
ge
External boiler monitoring
bn
br
ge
ye
-
56
>
Y1 (valve 1)
Jumper
Stratification
sensor
gn
gn
wh
ws
ge
ye
bn
br
PWM stratification
pump
grau
grey
Fault message,
condensate pump
32. Wiring diagram
3062547_201408
33. Reset
Reset
Observe the following steps to implement a reset:
0
I
60
40
20
0
Reset button
ON/OFF switch
3062547_201408
80
100
C 120
-
-

-

The ON/OFF switch must be set to O (OFF).

Press and hold down the reset button on the standard control unit whilst setting
the ON/OFF switch to I (ON).
Hold down the reset button again for at least 2 seconds after switching on the
system.
All parameters (individual settings) are returned to their factory settings by a reset.
57
34. Troubleshooting
Any faults will be displayed as fault code by Wolf control accessories with eBUS capability. The cause and remedy for a fault can
be established using the following table. This table is designed to allow your local heating contractor to trace the fault more easily.
Fault
code
1
58
Fault
Cause
Remedy
Excess temperature
(high limit safety
cut-out)
The flow temperature has exceeded 110C
Test heating circuit pump, vent system,

press reset, clean heat exchanger
No flame
established
No flame at burner start

Inspection window for flame monitor/mixer head
contaminated
Faulty flame monitor
Air in oil line
Negative pressure at oil pump too high, max. 0.3bar
Overpressure at oil pump too high, max. 0.5bar
Boiler dirty
Check oil line, if necessary check fuel

level, check ignition electrode and
ignition transformer, press reset
Check inspection window for flame
monitor/mixer head
Check flame monitor and lead
Siphon backpressure
Check free condensate drainage
Maintenance necessary
Flame failure during

operation
Negative pressure at oil pump too high, max.

0.3bar, flue gas recirculation (flue gas in the
ventilation air)
Boiler dirty
Check CO2 values, check flame monitor

and lead, press reset, check flue system
for leaks
TW excess temperature The flow has exceeded the limit of the

temperature limiter (100C)
Vent the system, check the heating

circuit pump
Flue gas sensor excess

temperature
The flue gas temperature has exceeded 120C
Clean heat exchanger, check whether

all displacement devices are installed
Check the flow through the boiler
Check boiler flow / boiler return
press reset
Flue gas/ventilation air

damper does not move
Flue gas/ventilation air damper contact (E1)

fails to close or open when there is a demand
Check flue gas/ventilation air damper

and wiring
11
Flame pretence
A flame is recognised before the burner starts
Press the reset

Check solenoid valve for oil pump
12
Faulty boiler sensor
Faulty boiler sensor or lead
Check sensor and lead
14
Faulty cylinder sensor

SF
Faulty cylinder sensor or lead
15
Faulty outside
temperature sensor
Faulty outside temperature sensor or lead
25
Fan fault
The fan does not reach the set speed

Boiler dirty
Check power cable to fan and check

fan;
Check that the condensate can drain off
freely from the balanced flue system
press reset
26
Fan fault
The fan does not stop
Check power cable to fan and check

fan; press reset
27
Faulty stratification
sensor
Faulty stratification cylinder sensor or lead
3062547_201408
34. Troubleshooting
Fault
code
40
Fault
Cause
Remedy
Insufficient water
pressure
The pressure switch does not switch on, water

pressure is too low (< 0.8bar)
Check system pressure >1.5bar

Check water pressure switch, check lead,
press reset
42
Condensate pump is
not pumping anything
out
Faulty condensate pump, drain line blocked, no

power supply to pump
Check pump, check drain line, check

mains plug and fuse
52
Max. cylinder heating

time exceeded
Set cylinder temperature is not being reached,

insufficient flow
Vent cylinder, increase cylinder heating

time (HG20), check cylinder sensor
assembly
78
Header sensor fault
Faulty header sensor or lead
Insufficient heating
system heating,
frequent cycling
Air in the heating or cylinder system
Vent radiators, vent cylinder primary

circuit, vent heating circuit pumps, vent
boiler
No DHW heating
Sensor is not detected by the boiler
Switch boiler off and on; sensor will be

detected on restarting
3062547_201408
59
DECLARATION OF CONFORMITY
(to DIN EN ISO/IEC 17050-1)
Number:
3062547
Issued by:
Wolf GmbH
Adress:
Industriestrae 1, D-84048 Mainburg
Product:
COB/COB-TS
The product described above conforms to the requirements specified in the following documents:
6, 1. BImSchV, 26.01.2010
DIN EN 230, 10/2005
DIN EN 267, 11/1999
DIN EN 303, 12/2003
DIN EN 304, 01/2004
DIN EN 15034, 01/2007
DIN EN 15035, 05/2007
DIN EN 12828, 06/2003
DIN EN 61000-3-2, 03/2010
DIN EN 61000-3-3, 06/2009
DIN EN 61000-4-3, 06/2008
DIN EN 55014-1, 02/2010
DIN EN 60335-1, 02/2007
DIN EN 60335-2-102, 04/2007
DIN EN 60529, 09/2000
In accordance with the following Directives
92/42/EWG (Efficiency Directive)
2004/108/EG (EMC Directive)
2006/95/EG (Low Voltage Directive)
this product is identified as follows:
0085

Mainburg, 21 April 2010
Gerdewan Jacobs
Technical Management
Klaus Grabmaier
Product approval
Wolf GmbH Postfach 1380 D-84048 Mainburg Tel. +49-8751/74-0 Fax +49-8751/741600 Internet: www.wolf-heiztechnik.de

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Installation instructions and

Boiler for heating

8. General notes......................................................................................... 12-13

10. Boiler/TS cylinder.......................................................................................15

11. Installation examples..................................................................................16

12. Oil connection in a single-line system........................................................17

13. Siphon/neutralisation/condensate pump....................................................18

14. Installation of a balanced flue system........................................................19

15. Filling the heating system...........................................................................20

16. Electrical connection..................................................................................21

Control unit ........................................................................................................... 22-31

17. Control unit........................................................................................... 22-23

18. Displaying/modifying control parameters/Settings report.......................... 24

19. Contractor level parameters................................................................. 25-31

Cascade operation................................................................................................ 32-39

21. Flue system design....................................................................................33

22. Flue gas header version.............................................................................34

23. Flue gas header version / notes.......................................................... 35-36

24. Flue gas damper installation.................................................................... 37

25. Flue gas damper installation / wiring diagram.......................................... 38

26. Flue gas damper tightness test.................................................................39

27. Commissioning with Wolf control accessories (BM)............................ 40-41

28. Commissioning without Wolf control accessories (BM)...................... 42-43

29. Commissioning report................................................................................44

30. Maintenance and design data..............................................................45-46

31. Design information - balanced flue system..........................................47-55

32. Wiring diagram..........................................................................................56

34. Troubleshooting.................................................................................... 58-59

This indicates technical instructions which

Diagram: Terminal box: Danger from electrical voltage

NB - only a heating contractor has the

- According to paragraph 10(3) EnEV the user is required to

COB-15/20/29/40 oil condensing boiler

COB-15/20/29 oil condensing boiler

COB-15/20/29 oil condensing boiler

COB-15/20/29 oil condensing boiler

COB standard delivery

COB-TS standard delivery (not with COB-40)

Oil condensing boiler

Oil condensing boiler

Opening the casing

Entries for oil

Closing the casing

2 DHW draw-off at the highest point

Oil condensing boiler

Automatic air vent

Heating flow 1"

Cold water connection

6. Standards and regulations

Two-stage oil condensing boiler with electronic ignition and

- DIN EN 12831 Procedure for calculating the standard

The COB complies with the following regulations:

Open flue oil condensing boilers must only be

Heating systems in buildings

Designing DHW heating systems

Rules for calculating the heat demand of

Flue gas systems

Protection of DHW against contamination in

Materials for drain pipes for condensate from

Avoiding damage in DHW heating systems

- DIN VDE 0100 Regulations regarding the installation of

Operation of high-voltage systems, general

- DIN EN 60529 Protection through casings