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Viessmann Vitobloc 200 EM-50/81 Operating Instructions Manual

Block-type thermal power plant module for natural gas operation
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Operating instructions
for specialists
VITOBLOC 200
block-type thermal power plant module for natural gas operation
model EM-50/81
model EM-70/115
model EM-140/207
6130329 GB
04/2019
model EM-199/263
model EM-238/363
model EM-260/390
model EM-401/549
model EM-530/660
To be kept carefully!

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Summary of Contents for Viessmann Vitobloc 200 EM-50/81

  • Page 1 Operating instructions for specialists VITOBLOC 200 block-type thermal power plant module for natural gas operation model EM-50/81 model EM-199/263 model EM-401/549 model EM-70/115 model EM-238/363 model EM-530/660 model EM-140/207 model EM-260/390 To be kept carefully! 6130329 GB 04/2019...
  • Page 2 Legal notice This equipment satisfies the basic require- ments of the appropriate standards and di- rectives. Its conformity has been demon- strated. These documents and the original conformity declaration are stored on the premises of the manufacturer. NOTE The Vitobloc 200 cogeneration module is not suited to 60 Hz operation which means that it is in particular not available to the American and Canadian market.

  • Page 3: Table Of Contents

    Table of Contents Instructions for operating the CHP ..........4 Qualification of the personnel ..................4 Introduction into the unit’s functions and operation ..........4 Hazard warnings pursuant to the Machinery Directive ..........4 Residual dangers from operating a combined heat and power plant ......6 Requirements concerning the technical room ............

  • Page 4: Instructions For Operating The Chp

    Instructions for operating the CHP Instructions for operating the CHP Qualification of the personnel Introduction into the unit’s func- tions and operation The combined heat and power plant (CHP) has been designed and built according to the state-of-the-art The manufacturer shall familiarize the plant operator and on the basis of the latest safety regulations.
  • Page 5 Instructions for operating the CHP Article § 5(1)1a of the Equipment & Product Safety Act (GPSG): What risks may arise during usual or reasonably predictable operations? source of danger: dangerous activity: consequence: switchgear: feeder circuit-breaker removal of covers alternator contactor reaching under the covers life-endangering electric shock power cable...

  • Page 6: Residual Dangers From Operating A Combined Heat And Power Plant

    Instructions for operating the CHP Residual dangers from operating a combined heat and power plant What active risks are the operating personnel ex- The following table makes reference to potential re- posed to from CHP module operations? sidual dangers which may still arise from the opera- tion of a combined heat and power plant, even if the Irrespective of the actual conditions where a com- relevant safety measures have been taken.
  • Page 7 Instructions for operating the CHP Thermal risks Risks from breakage during operation The combustion engine in the CHP module as well as Exercise particular care and attention when lifting the the heat extraction components and the exhaust gas CHP modules on a crane hook or on their lifting eyes. piping downstream may get very hot for operational In the event of a breakage, thermally overloaded reasons and develop temperatures of some hundred...

  • Page 8: Requirements Concerning The Technical Room

    Instructions for operating the CHP Requirements concerning the technical room CAUTION CAUTION Smoking and open fire are not permit- Only a specialist firm with personnel ted. Flammable materials or liquids specifically trained in these fields of re- must not be stored or used close to the sponsibility by the CHP module manu- CHP module.

  • Page 9: Regulations For The Prevention Of Accidents Causing Personal Injury

    Instructions for operating the CHP Regulations for the prevention of accidents causing personal injury When installing the CHP module and before the commissioning: ● ● No persons must stay under loads suspended from Open the coolant circuit only after the engine has a crane hook.

  • Page 10: Preparations

    Preparations Preparations LIABILITY Inform the warranty office in writing be- fore commissioning the plant, when us- ing the specified or approved operating supplies (see assembly instructions in the chapter „Notification about the plant’s readiness for commissioning“), as this is the prerequisite for having any warranty claims acknowledged.
  • Page 11 Preparations Gas quality Fuel values to be observed WARNING Natural gas and the combustion air parameter value must not contain any phosphorus, ar- calorific value H > 5 kWh/Nm senic, heavy metals or dust, and halo- gens only in quantities up to the limits methane number >...
  • Page 12 Preparations 2.1.2 Engine lubrication oil Principles The use of lubrication oil that the CHP module manu- The contaminants contained in special types of gas, facturer specifies for the relevant type of gas is a such as dumpsite gas and biogas, can considerably prerequisite for the safe and wear-resistant operation reduce the service life of the lubrication oil.
  • Page 13 BHKW manufacturer required, demonstrated by means of oil analyses at Viessmann Kraft-Wärme-Kopplung GmbH are own responsibility. Other engine lubricants All other engine lubricants can be used at own re-...
  • Page 14 Preparations 2.1.3 Coolants Mandatory components How to handle anti-freeze concentrate The cooling system must be filled with a mixture of WARNING drinkable tap water and an anti-freeze agent contain- ing a corrosion-preventive additive for engine cooling When handling anti-freeze concentrate systems.
  • Page 15 Preparations Approved anti-freeze agents approval granted to product designation Agip Deutschland AG Agip Antifreeze Plus Agip Schmiertechnik Agip/Autol Langzeitfrostschutz Aral AG Aral Kühlerfrostschutz A Aral Kühlerschutz Extra Aral Kühlerschutz D Avia-Mineralöl AG Avia Frostschutz Avia Frostschutz APN BASF AG Glysantin G 03 Glysantin G 48 Glysantin mit Protect Plus BASF/USA...
  • Page 16 Preparations 2.1.4 Heating water Quality regulations for hot water in conformity CAUTION with VDI Guideline 2035 You can calculate the specific plant vol- ume in several heat generators with the The current edition of the manufacturer’s data and smallest single heat performance (see VDI Guideline 2035 (Guidelines for Preventing Dam- VDI 2035 for greater detail).

  • Page 17: Filling Fuels

    Preparations Filling Fuels 2.2.1 Disassembling/Assembling the Sound Hood CAUTION Only ever use the supplied original cab- inet spanner to avoid damage to the locks. Always remember the following when opening and closing the locks: Closing: Opening: Raise the sound hood plate and press against the Raise the sound hood plate and press against the corresponding frame.
  • Page 18 Preparations 2.2.2 Filling and venting the engine cooling system Coolant with anti-freeze Mixing coolant Fill the cooling system with a mixture of potable tap CAUTION water and anti-freeze containing a corrosion- preventive additive for engine cooling systems. Do not use containers designated for drinking water or foodstuffs.
  • Page 19 Preparations Filling the cooling system • Connect the pressure hose of an electric pump or of a hand pump with the intake (Fig. 1, item 1). • Open the stop cock (Fig. 1, item 2) and fill in the coolant slowly up to approx. 1 bar. •...
  • Page 20 Preparations 2.2.3 Filling in engine lubrication oil Fill in fresh engine lubrication oil ● into the engine and ● into the additional tank for fresh oil (reserve for operating the automatic lubrication oil system). WARNING Use only engine oil for gas-fuelled en- gines that has been approved in the CHP module manufacturer’s operating instructions (see sub-section 2.1.2...
  • Page 21 Preparations Filling in engine lubrication oil directly ● Fill in the engine lubrication oil into the cylinder head at the intake (Fig. 3, item 1). Filling quantities pursuant to the “Technical descrip- tion of the CHP module“. Fig. 3 Lubrication oil intake at the cover of the cylinder head and dipstick ●...
  • Page 22 Preparations • Remove the top front sound-insulation cover (Fig. 5, item 1). • Fill in the lubrication oil reserve into the addition- al tank at the intake (Fig. 5, item 2). Put the refill cock at the oil tank in its “OPEN“ position (Fig.
  • Page 23 Preparations 2.2.5 Filling the battery system Unfilled charged starter batteries are ready for opera- Maintenance tions after being filled without any further charging. ● Keep the surface of the battery clean and dry. When filling the batteries, both the battery and the Clean it with a wet cloth only.

  • Page 24: Commissioning

    Commissioning Commissioning Authorized personnel NOTE ● Only suitably qualified personnel are authorized to The commissioning which is to be car- check the installation and to carry out the commis- ried out by the factory service centre sioning. must be applied for with the relevant ●...

  • Page 25: Measuring And Setting Points For The Commissioning

    Commissioning Measuring and setting points for the commissioning WARNING The marking on the assemblies and the cables of the The position of the measuring and set- actually delivered modules as well as the order- ting points is only roughly indicated in related switching and assembly diagrams are binding.
  • Page 26 Commissioning 3.2.2 Measuring and setting points at the CHP module Fig. 7 Schematic diagram of the measuring and setting points in the CHP module Vitobloc 200 item 1: emergency stop button (in the door of the item 18: lubrication oil pressure sensor (oil pressure module control panel) sensor) operator’s and indicator unit of the module...
  • Page 27 Commissioning 3.2.3 Measuring and setting points at the CHP module (cont.) Fig. 8 Schematic diagram of the measuring and setting points in the CHP module Vitobloc 200 item 1: emergency stop button (in the door of the item 18: lubrication oil pressure sensor (oil pressure module control panel) transducer) operator’s and indicator unit of the module...

  • Page 28: Commissioning Instructions For The Chp Module

    Commissioning Commissioning instructions for the CHP module WARNING INSTRUCTION The information about the relevant work The following documents are required in during the commissioning is merely addition to these operating instructions: meant to be a memory aid especially for – a separate protocol about the com- the authorized specialists who have missioning been trained by the CHP module manu-...
  • Page 29 Commissioning 10. Check the connection of the emergency shut- - switching diagram, sheet 18 down. - module control panel: internal or external overtemperature protector switch, external gas detector, fire alarm etc. to -X1/22.23, if not existing bridge to -X1/22.23. 11. Check the connection for general faults. - switching diagram, sheet 19 - module control panel: general breakdown to -X1/26.27, if not existing bridge to -...
  • Page 30 Commissioning • functional test pursuant to the plant configuration 28. Check, whether the external auxiliary drives, the heating water pump and the return flow boost are switched on. 29. Test the internal auxiliary drives. - cooling for the water pump - fan (direction of rotation, setting of the motor current) 30.
  • Page 31 Commissioning WARNING The proper functioning of the system-tie circuit breaker and its feedback messages must be tested manually by the control before the au- tomatic switching connections are activated. • In order to simulate stand-by operations, switch off fuse - 1F3 (network measurement) in the module control panel.

  • Page 32: Programming

    Programming Programming Operator’s and indicator unit of the CHP module Operator’s and indicator unit of the CHP module Fig. 9 item 1: Display of the module control: Key F6: Level display of the basic configuration (change operator level) (screenshot) or display of von menu Only after password has been entered.
  • Page 33 Programming Basic display of the operator’s and indicator unit Fig. 10 of the CHP module item 1: operating mode - AUTO(MATIC MODE) - HAND (= MANUAL MODE) - OFF item 2: external request: - heat - current - power stand-by - off item 3: voltage (per phase)

  • Page 34: Chp Module Control Level 1: Display & Change Operating Values

    Programming CHP module control level 1: Display & change operating values 4.2.1 Display of engine values ● display of the menu with function key F2 (for infor- mation only. example: Fig. 11) ● 2 x F2 – further temperatures ● return to the basic configuration with key C Fig.
  • Page 35 Programming 4.2.3 Display & change of the date and the time of the day ● display the selection menu with function key F5; field selection underlined once (Fig. 13) ● select a field: shift the underscore with arrow keys 4 or 6 to the desired position (e.g. date) (Fig. 14) ●...

  • Page 36: Chp Module Control Level 2: Manual Mode

    Programming CHP module control level 2: Manual mode 4.3.1 Entry of a password for level 2 ● display the selection menu with function key F5 (screenshot of the menu: see Fig. 14) ● select a field: shift (underscore) with arrow keys 4 or 6 to the field “Password”...
  • Page 37 Programming Special functions of the numerical keys in the manual mode key 1 = alternator switch OFF ( )/ON (x) key 2 = idling speed lower (when Geno OFF) alter- nator capacity lower (when Geno ON) key 3 = display the maximum/minimum engine values since the old values have been erased most recently with function key F8 (Reset)

  • Page 38: Chp Module Control Level 3: Display & Change Of Parameters

    Programming CHP module control level 3: Display & change of parameters 4.4.1 Entry of a password for level 3 ● display the selection menu with function key F5 (screenshot of the menu: see Fig. 21). ● select a field: shift the underscore with arrow keys 4 or 6 to the field “Password”...
  • Page 39 Programming Cancel value selection ● NOTE: cancel a value selection (value change) with key C ● select a value again as described above; change All passwords will be erased automati- the field selection cally, if no key has been pressed within 60 min.
  • Page 40 Programming 4.4.4 Parameter list level 3: Parameter Left value/Function Right value/Function set value for the output set value for the output for gas set value for the output for gas type A type B (e.g. 125 kW) (e.g. 120 kW) activated by digital input 28 warm-up limit ------------------------------------------ warm-up limit, the machine will run with 50 %...
  • Page 41 Programming Parameter Left value/Function Right value/Function maximum exhaust gas time delay (e.g. 0 sec) maximum limit (e.g. 700 °C) temperature A if the limit set at this temperature sensor is exceeded by the set time delay, the machine will trip minimum exhaust gas waiting time (e.g.
  • Page 42 Programming Parameter Left value/Function Right value/Function alternator load imbal- time delay (e.g. 3 sec) maximum limit ance if the set limit set is exceeded by the set time delay, the machine will trip alternator time delay (e.g. 3 sec) minimum limit undervoltage if the set limit set falls short by the set time delay, the machine will trip...

  • Page 43: Usage And Operations

    Usage and operations Usage and operations Duties of the plant operator ● check leakages CAUTION When the smell of gas is detected or in the case of other risks, see section 1.3. “Hazard warnings“ and section 5.4 “Emergency“. CAUTION Fig. 23 Basic configuration for checking the automatic mode Immediately request the maintenance...

  • Page 44: Remote Monitoring With Telecontrol Lan

    CHP unit and provides the operating immediately. After commissioning, you should contact data via the LAN/internet. the CHP Service department at Viessmann Landsberg (Tel. +49 (0)08191 / 9279-60) to check whether the data The only requirement is a network connection with free from the corresponding CHP unit is being received at access to the internet at the system.

  • Page 45: Operations Log For Chp Modules

    Usage and operations Operations log for CHP modules password of the plant module type manufacturer number plant address phone: daily checks date operating hours starts (total number) output (electric) Lambda probe voltage oil pressure exhaust gas temperature °C °C °C °C °C °C...

  • Page 46: Requirements For Optimal Operation

    Usage and operations Requirements for optimal operation ● Your operational safety will be boosted if you comply Follow the assembly instructions for the exhaust gas with the items below. Malfunctions or consequential systems for Vitobloc 200. damage due to unacceptable operating conditions are ●...

  • Page 47: Emergency

    Usage and operations Emergency Central emergency stop What to do in the case of fire ● ● at the operator’s side/front side of the CHP mod- Call the fire brigade. ● Help injured persons immediately and call a first ● if possible, close the gas shut-off valve on the aider, if necessary.

  • Page 48: Cleaning

    Cleaning Cleaning Removing dust with cloths Contamination caused by engine oil ● ● generally inside the module caused by the separation of oil in the air filter, runs out from the hose into the drip pan under the en- ● particular attention to be given to: gine unit the alternator’s inlet air and extract air grilles...

  • Page 49: Trouble-Shooting

    Trouble-shooting Trouble-shooting The error message will be displayed in plain text (Fig. 26, item 1) and the red LED „Fault“ (Fig. 26, item 2) will indicate such a fault. PLEASE NOTE If a menu is displayed when an error message is received, press function key F7 to display the error message on the screen in plain text.

  • Page 50: Fault Messages From The Chp Module That Cannot Be Acknowledged

    Trouble-shooting Fault messages from the CHP module that cannot be acknowledged error message fault clearance possible cause of the fault emergency stop ● ● release emergency stop button at the emergency stop button has been pressed door of the module control panel with ●...
  • Page 51 Trouble-shooting error message fault clearance possible cause of the fault cooling water tem- ● ● let the engine cool down temperature of the engine cooling water too perature high, no heat reduction on site ● acknowledge fault with function key F8; call customer service if error message is repeated maximum exhaust...
  • Page 52 Trouble-shooting error message fault clearance possible cause of the fault feeder circuit-breaker ● ● switch on the feeder circuit-breaker feeder circuit-breaker has failed due to the thermal monitoring or has tripped as a result ● acknowledge fault with function key F8; of „Faulty alternator contactor“...
  • Page 53 Trouble-shooting error message fault clearance possible cause of the fault tightness test fails ● ● acknowledge fault with function key F8; optional test device for the gas tightness call customer service if error message ● gas valve(s) not right is repeated alternator overvolt- ●...

  • Page 54: Shutdown

    Shutdown Shutdown Temporary shutdown NOTE: 8.1.2 Shutdown for a period of more than 6 months In order to maintain possible warranty claims in the event of a temporary shutdown of the CHP module, the plant The following additional measures will become nec- operator shall protect the module by essary in the event of shutting down the CHP module suitable preservation measures.

  • Page 55: Final Shutdown (Decommissioning)

    Shutdown Final shutdown (decommissioning) ● Before the disassembly, the CHP module must be electrically isolated by a specialist, i.e. the connec- tions with the mains must be physically severed. ● Drain and dispose the heating water, glycol-containing cooling water and starter batteries, while the engine is cold and out of operation.
  • Page 56 Viessmann Werke GmbH&Co KG D-35107 Allendorf phone: +49 6452 70-0 fax: +49 6452 70-2780 www.viessmann.de...

This manual is also suitable for:

Vitobloc 200 em-70/115Vitobloc 200 em-401/549Vitobloc 200 em-199/263Vitobloc 200 em-530/660Vitobloc 200 em-238/363Vitobloc 200 em-260/390 ... Show all

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