Hoval PowerBloc EG Operating And Installation Manual
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Hoval PowerBloc EG Operating And Installation Manual

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Operating and installation manual
Hoval PowerBloc EG (12,15,20)
Hoval PowerBloc FG (12,15,20)
4 218 891 / 00 – 09/20
Subject to modification

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Summary of Contents for Hoval PowerBloc EG

  • Page 1 Operating and installation manual Hoval PowerBloc EG (12,15,20) Hoval PowerBloc FG (12,15,20) 4 218 891 / 00 – 09/20 Subject to modification...

  • Page 2: Table Of Contents

    Table of contents General information ......................5 1.1. The principle of cogeneration ................. 5 Basic information ......................6 2.1. Copyright and reservation of rights ................. 6 2.2. Warranty ......................... 6 2.3. Liability ........................7 2.4. Responsibilities of the owner .................. 7 2.5.
  • Page 3 4.1. Technical documentation ..................26 4.2. Transport and installation ..................28 4.2.1. Safety ..................... 28 4.2.2. Transport ....................29 4.2.3. Storage conditions .................. 29 4.2.4. Installation ....................30 4.3. Assembly and installation ..................31 4.4. Installation and connection conditions ..............37 4.4.1.
  • Page 4 6.4.3. Temperatures (menu structure 1.3.) ............72 6.4.4. Oil change / service interval (menu structure 1.4.) ........73 6.4.5. System information / language (menu structure 1.5.) ......74 6.5. Code / setup (menu structure 2.) ................75 6.6. User level 1 ......................75 6.6.1.

  • Page 5: General Information

    Basic information General information 1.1. The principle of cogeneration Cogeneration plants use an internal combustion engine to drive a generator that generates electrical power. The resulting waste heat is used as heating energy (as shown in Figure 1: Principle of cogeneration). Such cogeneration plants are also referred to as combined heat and power (CHP) plants.

  • Page 6: Basic Information

    Hoval reserves all rights to this document and to the object depicted therein. Without the prior written consent of Hoval, this document may not be reproduced in whole or in part, copied or in any form made accessible to third parties in whole or in part and used outside the purpose for which it was handed over to the recipient.

  • Page 7: Liability

    2.3. Liability Hoval is only liable for direct personal injury and damage to property on the basis of the applicable product liability law if the plant is used for the purpose prescribed in the operating instructions or for the contractually agreed use.

  • Page 8: Standards And Directives

    Basic information 2.5. Standards and directives The plant has been designed and built in accordance with the currently valid technical rules and recognised safety regulations. The basic safety requirements, standards and guidelines were applied in the design of the plant. The safety of the plant is documented by the declaration of conformity.
  • Page 9 Basic information DIN EN 1037 Safety of machinery; Prevention of unexpected start-up DIN EN 1127-1 Explosive atmospheres; Explosion prevention and protection, Part 1: Basic concepts and methodology DIN EN 12828 Heating systems in buildings - Design of hot water systems (replacement for DIN 4751) DIN EN 12831 Heating systems in buildings...

  • Page 10: Notes On The Representation Of Symbols And Signal Words

    Basic information Other basic regulations BGV A8 Safety and health marking at the workplace TRF 1996 Technical rules for liquid gas ATV – Worksheet A251 Introduction of condensation water from gas and oil- operated firing plants in public sewage and small-scale water treatment plants, edition Nov.

  • Page 11: Service Addresses

    2.7. Service addresses  Switzerland Hoval AG General Wille-Strasse 201 8706 Feldmeilen ZH +41 44 925 6111 info@hoval.ch  Austria Hoval Gesellschaft m.b.H. Hovalstrasse 11 4614 Marchtrenk +43 50 365-0 info@hoval.at  Germany Hoval GmbH Humboldtstrasse 30 85609 Aschheim-Dornach +49 89 922 097-0 info.de@hoval.com...

  • Page 12: Safety

    Safety 3. Safety 3.1. Basic safety instructions 3.1.1. Observance of the operating instructions The operating instructions must be read and understood by the personnel and must be observed during all work. For this reason, always keep the operating instructions handy in the immediate vicinity of the plant.

  • Page 13: Safety Markings In This Manual

    Safety 3.3. Safety markings in this manual 3.3.1. DANGER marking DANGER COMPLY WITH THE GENERAL SAFETY INSTRUCTIONS! To avoid hazards and damage, observe:  the safety instructions in chapter 2  the information in the relevant chapters  the information in the associated operating instructions The danger warning must be observed.
  • Page 14 Safety WARNING Warning of flammable substances! In work rooms (e.g. storage rooms) or in the vicinity of storage cabinets with hazardous contents, do not carry out any work that causes the substances to ignite. WARNING During transport with lifting equipment, injuries may result from falling objects. Warning: W a r n u n g v o r h e r a b fa lle n d e n...

  • Page 15: Caution Marking

    Safety 3.3.3. CAUTION marking Caution Caution: Use hand protection! Due to the risk of injury, hand protection must be worn. Read the operating instructions before using the hand protection! The operating instructions describe the right type of protective glove and where it should be used. Caution Caution: Use foot protection! Safety shoes must be worn to protect the feet from foot injuries.

  • Page 16: Waste Disposal

    These substances must be collected, stored, transported and disposed of in suitable containers. The product data sheets are available from Hoval Service (for service address, see chapter 1.7). They must be observed during disposal.

  • Page 17: Possible Misuse

    Any use other than the intended use is not permitted. Possible improper applications include non-compliance with safety equipment, safety regulations and current accident prevention regulations. Hoval is not liable for damage resulting from improper use. The possible consequences are shown below.

  • Page 18: Electrical Hazards

    CHP plant. Before working on the plant, the power supply must be switched off and secured against being switched on again. The electrical installation is only allowed to be carried out by a specialist electrician trained by Hoval. WARNING Risk of electric shock! Electrostatic discharge when touching the machine: The plant and machine parts must be earthed so that potential differences can be compensated.
  • Page 19 For your own safety, please note that installation, adjustment and maintenance of the unit are only allowed to be carried out by Hoval or authorised service partners. This also applies to the inspection and repair of the unit as well as changes to the set gas quantity.
  • Page 20 Safety Tight-sealing windows When installing tight-sealing windows, you must ensure, in consultation with the manufacturer, that there is still a sufficient supply of combustion air to the unit. Explosive or highly inflammable substances Do not use or store explosive or highly inflammable substances (petrol, paint, paper) in the installation room of the unit.

  • Page 21: Special Safety Instructions

    Safety 3.7. Special safety instructions 3.7.1. Fuel variants The CHP plant is a compact plant which is shipped ready for connection. Depending on your requirements, the plant can run on the following gaseous fuels:  Natural gas  Liquid gas ...

  • Page 22: Integrated Network And Plant Protection

    3.7.6. CO sensor (optional) For an additional charge, Hoval offers an emergency shutdown of the CHP plant via a CO monitor. This has a service life of 5 years and covers a measuring range up to 500ppm.

  • Page 23: Generator

    Safety 3.7.10. Generator A water-cooled three-phase asynchronous machine is used in the CHP plant. This three- phase machine functions as a starter for starting up the internal combustion engine. Following start-up, the three-phase machine generates three-phase current. The water is cooled by the heating water.

  • Page 24: Heat Exchanger System

    Safety 3.7.13. Heat exchanger system The heat exchanger system consists of several components which absorb heat at several points in the overall system and dissipate it again elsewhere. The main components are the exhaust gas heat exchanger, plate heat exchanger and the exhaust manifold. The exhaust gas heat exchanger has been specially designed for transmitting heat from the exhaust gases of the gas engine to the heating water circuit.

  • Page 25: Power Factor Correction

    Safety 3.7.14. Power factor correction In order to generate the plant’s electrical power, reactive energy and the necessary reactive current are required. As these boxes are established and dissipated continuously during the alternating voltage cycle, the energy continuously fluctuates between the generator and consumer.

  • Page 26: Technical Documentation

    ATROMATIC control unit, as well as basic and optional control functions. Hoval combined heat and power plants are ready for operation ex-works and are equipped with the following features as standard: ...
  • Page 27 Optionally, all available additional functions in the ATROMATIC control unit can be retrofitted later. The electrical and thermal output levels offered by the Hoval combined heat and power plants can be both manually and automatically adapted to meet individual energy requirements.

  • Page 28: Transport And Installation

    Technical documentation 4.2. Transport and installation 4.2.1. Safety The following safety instructions must be observed when transporting the plant - this will prevent fatal injuries to persons and other damage to property.  The transport work is only allowed to be carried out by qualified persons in compliance with the safety instructions - the following special qualifications are required: specialist personnel for transport, specialist personnel for load securing.

  • Page 29: Transport

    Technical documentation 4.2.2. Transport A lift truck for Euro pallets is best suited for transporting the CHP plant. The base frame is designed in such a way that the lift truck forks fit exactly into the recesses and the CHP plant can be lifted in this way.

  • Page 30: Installation

    4.2.4. Installation The CHP plant can be transported from the unloading point to the installation location along the ground, dismantled or also by means of a load crane. Please contact Hoval regarding disassembly for transport to the installation location. When using a load crane, the CHP plant must be lifted as shown in Fig. 1. M10 threads are provided for the four mounting points of the brackets.

  • Page 31: Assembly And Installation

    Technical documentation 4.3. Assembly and installation 1. Remove the packaging (cardboard box and foil bag) 2. Assembly of the heating circuit pump Please screw the heating circuit pump (1) onto the connection according to the picture with seal (2). (Observe flow direction of the pump!) Subject to modifications 31 of 131...
  • Page 32 Technical documentation 3. Please mount the Wilo heating circuit pump at a 45° angle: (cables are permanently connected) 45° ° 4. Assembly of the heating circuit return connection. Please screw the heating circuit return onto the connection according to the picture with seal: Subject to modifications 32 of 131...
  • Page 33 Technical documentation Please mount the heating circuit return so that it runs parallel to the casing: (Please handle the sensor cable with care, do not expose it to any loading/do not damage it). 5. Assembly of the pre-silencer. For this purpose, please remove the left casing covering and mount the pre-silencer (1) on the lower connection (2) (for easier mounting of the pre- silencer, apply “lubricant for plug-in socket systems”...
  • Page 34 Technical documentation 6. Assembly of the condensate trap. For this purpose, please mount the condensate trap (1) on the pre-silencer (2) (for easier mounting of the condensate trap, apply “lubricant for plug-in socket systems” to the rubber seal (3)). Subject to modifications 34 of 131...
  • Page 35 Technical documentation Please align the condensate trap so that the siphon points to the rear and secure it with 4 countersunk screws M5 x 16 mm. Subject to modifications 35 of 131...
  • Page 36 Technical documentation 7. Assembly for C62 installation (room air independent). For this purpose, please push the corrugated suction hose (1) onto the connection at the condensate trap (2) and secure it with the hose clamp (3). 8. Assembly for B23 installation (room air dependent). No further assembly is required.

  • Page 37: Installation And Connection Conditions

    Technical documentation 4.4. Installation and connection conditions The installation conditions shown here must be complied with. Installation is only allowed to be performed by specialist personnel. 1. Prior to commissioning, the CHP plant must be placed on the sound insulation underlays included in the scope of delivery.
  • Page 38 Technical documentation 2. The outlet of the heating circuit safety valve must be discharged behind the CHP plant into a suitable drain. See Fig. 3 Figure 3 The following particular hazards are to be expected when installing the plant:  Incorrectly placed or improperly fastened plant parts can fall down or overturn.
  • Page 39 Technical documentation WARNING Danger of accidents!  Do not remove guards and covers!  Check protective devices for completeness and proper fastening before each time the plant is switched on.  After completion of installation or maintenance work, all protective devices and covers must be properly reinstalled.

  • Page 40: Installation Conditions Of The Cogeneration Plant

    4.4.3. Extract air The extract air emitted by the plant is technically clean air. The values of CO and CO2 in the exhaust gas of Hoval combined heat and power plants are CO max. = 120 ppm , CO2 = 11,80 %.

  • Page 41: Condensate

    (PPs) in fire category B1 according to DIN 4102. Hoval offers an exhaust system certified for its plants as an accessory. If several modules are connected to a shared exhaust line, each exhaust line must be equipped with an exhaust pressure monitor and a backflow preventer which closes the exhaust line in question if the CHP plant is shut off.

  • Page 42: Gas Connection

    Technical documentation 4.4.5. Gas connection The gas supply line (20 - 65 mbar) must be sized in such a way that a gas pressure of at least 20 mbar is still present at the inlet of the gas control line at a maximum consumption rate of 8,1 m³...
  • Page 43 Technical documentation 4.4.8.2. Diagrams for connection example of an individual plant Figure 4: Individual CHP plant 4.4.8.3. Sample application: CHP cascade plant The integration of the CHP cascade plant into the heating circuit of the building takes place, as in the sample application of the individual plant, via the coupling to the buffer storage tank.
  • Page 44 Shut-off valves (1" female thread) for the CHP plant supply and return lines must be installed on site. The coupling to the unit is carried out by means of flexible hoses, which are supplied by Hoval and can also be installed on site. Subject to modifications...
  • Page 45 Technical documentation NOTICE When operating the CHP plant, it must be ensured that a heating water flow of at least 1.8 m³/h always flows through the CHP plant. This prevents overheating and possible damage to the plant. For filling the CHP plants, an outlet tap with connection to the drinking water network in the unit installation room as well as a wash basin must be provided.

  • Page 46: Dimensions And Weight

    Technical documentation 4.4.9. Dimensions and weight Length x width x height: 1300 mm x 800 mm x 1300 mm (can be brought to site disassembled) Weight approx. 710 kg CAUTION Check the hoist for the required design and the permissible load CAUTION Never step under suspended loads! Warning:...

  • Page 47: Installation Diagram

    Technical documentation 4.4.12. Installation diagram The installation of the plant is carried out in accordance with Hoval's specifications. All plant and electrical supply lines must be placed and installed in accordance with the installation plan or Hoval's specifications. An open area (working area) is required for all work on the CHP plant, in particular installation, maintenance and service.

  • Page 48: Connection Conditions

    Technical documentation 4.4.13. Connection conditions The connection conditions shown here must be complied with. Connection is only allowed to be performed by specialist personnel. Heating circuit Flow connection DN 25, 1" female thread DIN 228-1 Return connection DN 25, 1" female thread DIN 228-1 approx.

  • Page 49: Connection Diagram

    Technical documentation 4.4.14. Connection diagram WARNING Check whether mains voltage and frequency correspond to the specifications on the type plate! All installation work and all subsequent maintenance work on electrical components are only allowed to be carried out with express permission and by trained specialist personnel. The electrical connection must be made to a mains supply with functional earthing.
  • Page 50 Technical documentation Figure 7: Connection diagram 1 Figure 8: Connection diagram 2 The dimensions are given in "mm" and depend on the external dimensions of the CHP plant. Subject to modifications 50 of 131...

  • Page 51: Power Supply

    Technical documentation 4.4.15. Power supply Circuit diagram for full supply Figure 9: Circuit diagram for full supply Subject to modifications 51 of 131...

  • Page 52: Commissioning And Decommissioning

    Commissioning and decommissioning 5. Commissioning and decommissioning The following important points must be observed during installation of the CHP plant! Electrics: It is essential to read the circuit diagram. Failure to do so could result in serious damage to property and personnel injury. Heating: After connecting the CHP plant to the heating system, a minimum volume flow of 1.8 m³/h must flow through the CHP plant.

  • Page 53: Commissioning

    Commissioning and decommissioning 5.1. Commissioning 5.1.1. Safety Operation, set-up and installation of the CHP plant are only allowed to be carried out by trained and, if necessary, authorised specialist personnel in compliance with all assembly and installation regulations. Perfect function and operational reliability of the CHP plant depend to a large extent on correct installation on site.

  • Page 54: Assembly And Installation

    Commissioning and decommissioning 5.1.2. Assembly and installation The CHP plant must be installed proficiently by specialist personnel according to the setup diagram. Comply with the description of the electrical equipment and electrical diagrams. 5.1.3. Preparatory work for installation of the CHP plant ...

  • Page 55: Start-Up

    5.1.9. Carrying out initial commissioning Initial commissioning is only allowed to be performed by specialist personnel.  An employee of Hoval or a service partner must be present at the time of initial commissioning.  The CHP plant and all its peripherals must be fully installed.

  • Page 56: Decommissioning, Corrosion Protection And Disposal

    Commissioning and decommissioning 5.2. Decommissioning, corrosion protection and disposal 5.2.1. Special notes for decommissioning The following safety instructions must be observed when decommissioning the CHP plant. This prevents life-threatening injuries, damage to property and also environmental pollution. CAUTION Comply with all safety information! The plant is only allowed be decommissioned by qualified personnel.

  • Page 57: Corrosion Protection

    Electrical components (motors, switches, cables, etc.) must be disposed of in accordance with regulations. In the event of final decommissioning, Hoval will take back all plant components. Fuels are excluded from this commitment. The owner is responsible for their recycling or disposal.

  • Page 58: Atromatic Operating Instructions

    ATROMATIC operating instructions ATROMATIC operating instructions 6.1. Introduction These operating instructions are intended to help you understand the process of your CHP plant control unit. We recommend that you read this manual carefully before operating your control unit and changing settings. In order to avoid misunderstandings, pay particular attention to the notes marked as follows: Notice:...
  • Page 59 ATROMATIC operating instructions 1. Details 2.6.2. Boiler block 1.1. History 2.6.3. Cascade 1.1.1. Year data 2.6.4. Thermal load connection 1.1.2. Electrical power 2.6.5. Speed-controlled pump control 1.1.2.1. Today 2.6.6. Storage level control 1.1.2.2. Week 2.6.7. CO monitor 1.1.2.3. Month 2.6.8. M-bus 1.1.3.

  • Page 60: Main Screen

    6.3. Main screen The main screen contains an overview of the most important information. In addition, it is your starting point to access the further setting options and further information. The main screen shows 10 areas. Figure 10: ATROMATIC main screen At the top left is the current date and time.
  • Page 61 Chimney sweep function: This function is used by the chimney sweep for regular exhaust gas measurements. See also section 4 – Chimney sweep function. Output / electrical power: Displays the current electrical active power as a number and in the form of a pointer. Presents the total supplied electrical power starting from the date when the CHP plant was commissioned.

  • Page 62: Chimney Sweep Function

    6.3.1. Chimney sweep function For the regular exhaust gas measurements by the chimney sweep, the chimney sweep function button also allows the CHP plant to be started in standby mode. This function allows you to demand the maximum power within the adjustable time (by default 10 minutes) independent of the current nominal output (point 1).

  • Page 63: Details - Menu Structure 1

    Details – Menu structure 1 6.4. When you press the "Details" button, you reach the menu structure 1 and the following window opens: Figure 12: Menu – Details 6.4.1. History – Menu structure 1.1. When you press the "History" button, you reach the menu structure 1.1. and the following window opens.
  • Page 64 Year data: (menu structure 1.1.1.) When you press the "Year data" button, the following window opens. Use the arrow keys (see point 1 of the figure) to go to the desired year for which you want to retrieve the respective data. Figure 14: Menu - Year data Subject to modifications A-TRON Blockheizkraftwerke GmbH...
  • Page 65 Electrical power: (Menu structure 1.1.2.) When you press the "Electrical power" button, the following window appears, in which you can call up the display of the electrical power produced on a daily, weekly or monthly basis. Figure 15: Menu - Electrical power 1 Figure 16: Menu - Electrical power 2 Subject to modifications A-TRON Blockheizkraftwerke GmbH...
  • Page 66 Figure 17: Menu - Electrical power 3 Figure 18: Menu - Electrical power 4 Subject to modifications A-TRON Blockheizkraftwerke GmbH 66 of 131...
  • Page 67 Temperatures: (Menu structure 1.1.3.) Pressing the "Temperatures" button displays the temperature curves from the last seven days "Temperatures (Week)" of generator winding, engine oil, heating circuit return, heating circuit flow, outside temperature, exhaust gas, engine coolant inlet and engine coolant outlet. Figure 19: Menu –...
  • Page 68 Figure 21: Menu – Temperatures 3 Subject to modifications A-TRON Blockheizkraftwerke GmbH 68 of 131...
  • Page 69 Error: (Menu structure 1.1.4.) When the "Error" button is pressed, the following window opens. This window contains a list of the error history. The "Details" button is located to the right of the respective error message (see point 1 of the figure). When this button is pressed, the details of the respective error are displayed in order to ensure fast diagnosis or troubleshooting.
  • Page 70 Log history: (Menu structure 1.1.5.) When the "Log history" button is pressed, all manual interactions with the control unit of the CHP plant (e.g. login of user, change of parameters, emergency stop switch pressed, etc.) are listed, saved and displayed. All processes listed here are saved and can no longer be changed.

  • Page 71: Power, Output, Network, Motor (Menu Structure 1.2.)

    6.4.2. Power, Output, network, motor (menu structure 1.2.) Back in the "Details" menu, the following window opens after the "Power, Output, Network, Motor" button is pressed. This window displays current information about the CHP plant. (see figure below). Figure 26: Menu - Power, Output, Network, Motor Feed-in: If there is a current feed-in into the building's power system and/or the public grid, this is indicated by arrows.

  • Page 72: Temperatures (Menu Structure 1.3.)

    6.4.3. Temperatures (menu structure 1.3.) When you press the "Temperatures" button, the following window opens. In and on the CHP plant there are sensors which measure the current temperatures of various components such as generator winding and bearings, engine oil, heating circuit return, heating circuit flow, exhaust gas, engine coolant circuit inlet and engine coolant outlet.

  • Page 73: Oil Change / Service Interval (Menu Structure 1.4.)

    6.4.4. Oil change / service interval (menu structure 1.4.) Pressing the "Oil change / service interval" button opens the following window. It shows the remaining time in operating hours until the next oil change and service visit. If the time for the oil change has expired, the CHP plant automatically changes to "standby mode"...

  • Page 74: System Information / Language (Menu Structure 1.5.)

    6.4.5. System information / language (menu structure 1.5.) When the "System info" button is pressed, the window shown below opens. The components installed in the CHP plant, the serial number of the SN controller, the system software and the current software version are displayed. (See point 1 of the figure). Furthermore, this window provides information about the currently set "Maximum effective electrical power"...

  • Page 75: Code / Setup (Menu Structure 2.)

    6.5. Code / setup (menu structure 2.) Pressing the "Code" button on the main screen (see Figure 10: ATROMATIC main screen) calls up the password request. This is required because access to the various setting parameters is defined by the user levels. User level 1 contains setting options that the customer / operator can carry out independently following instruction from the service technician.

  • Page 76: Power Curve (Menu Structure 2.1.)

    75 degrees. For the switch-off temperature to be changed to above 75 degrees, a separate enable is required, which is protected by a password. In such a case, consultation with a Hoval service technician is required. Setting options: In this area, the power minimum and maximum individually adjusted to the building must be set.

  • Page 77: Schedule (Menu Structure 2.2.)

    6.6.2. Schedule (menu structure 2.2.) The following menu opens when the "Schedule" button is pressed. With this menu you have several possibilities to limit the maximum output of the CHP plant independent of the power curve at certain times or to set the CHP plant automatically to standby mode (see point 1 of the figure).
  • Page 78 6.6.2.2. Every week If you select "Weekly", a maximum of three time windows are also available for each individual weekday. The schedule is repeated weekly. For setting a time window (see section 6.2.3 Schedule: time windows). Figure 34: Menu – Schedule management 3 6.6.2.3.

  • Page 79: Time / Date (Menu Structure 2.3.)

    Notice:  When making the settings, make sure that the times do not overlap. If the set times overlap, time window 1 has priority over the other two and time window 2 has priority over time window 3.  When selecting the daily schedule, it is possible to select the times, e.g. from 23:00 h to 6:00 h (i.e.

  • Page 80: Lan (Menu Structure 2.4)

    In order to connect the CHP plant to customer-specific networks or new networks, the LAN settings are freely selectable. Tap the "LAN" button and the following window will open. If the information was already available to Hoval, the following boxes will have been filled in already.
  • Page 81 The control unit receives a fixed IP address, so there must be an area in the LAN in which the router allows fixed IP addresses and does not assign them by DHCP. If necessary, contact your IT employee or the Hoval service technician. ...

  • Page 82: E-Mail (Menu Structure 2.5)

    6.6.5. E-mail (menu structure 2.5) The control unit of the CHP plant offers the possibility to automatically send status messages as well as notifications via the e-mail function to various e-mail recipients. When you press the "E-mail" button, the following window opens. In this window (under point 1) there is the possibility to enter e-mail recipients (e-mail addresses) for status messages.

  • Page 83: Additional Functions (Menu Structure 2.6.)

    6.6.6. Additional functions (menu structure 2.6.) The CHP plant has further additional functions which are either available as standard or can be purchased as optional additional packages. Figure 39: Menu – Additional functions The standard equipment includes the following functions: Boiler block Binary outputs Cascade...
  • Page 84 6.6.6.1. Binary outputs (menu structure 2.6.1.) With the help of the "Binary outputs" it is possible to select different system statuses of the CHP plant in a simple way for a higher-level building control unit or a building control station. With this option, potential-free contacts are switched which can be freely selected in the menu.
  • Page 85 Figure 41: Menu – Boiler block Notice: The relay for the boiler block in the control unit of the CHP plant (switch cabinet) should be connected as a normally open (NO) contact. Please contact your Hoval service technician or your heating installer.
  • Page 86 6.6.6.3. Cascade (menu structure 2.6.3.) The cascade function makes it possible to operate several Hoval CHP plants in parallel and highly economically with the aim that only one CHP plant is in the modulation range when the heat demand decreases. The remaining CHP plants are either in standby mode or in full load mode.
  • Page 87 6.6.6.3.1. Setting as master The setting as master requires an initialisation with subsequent characteristic curve setting. Possibility of switching the cascade function on or off. Displays the cascade position. The current position in the cascade depends on the number of operating hours of the CHP plant and can be changed. Possibility of setting the identification as master CHP plant or slave CHP plant.
  • Page 88 6.6.6.3.2. Initialisation When the "Initialisation" button is pressed, the following window appears. For initialisation, the number of participants / slaves (non-master) must first be defined (point 1). Up to five slave CHP plants can be added to the cascade. Example: A cascading of e.g. three CHP plants contains one master CHP plant and two slave CHP plants.
  • Page 89 6.6.6.3.3. Curve allocation Pressing the "Curve allocation" button opens the following window. When assigning characteristic curves, the number of characteristic curves to be set is equal to the number of CHP plants in the cascade. The individual values can be entered in the yellow box, e.g. the modulation start point for CHP plant position no.
  • Page 90 6.6.6.3.4. Setting as slave In addition to the master, the remaining CHP plants must be declared as slaves. To do this, touch the "SLAVE" button in the "Cascade connection" window. The "Current cascade position", the "Master IP" and the "Slave ID" must then be entered. Possibility of switching the cascade function on or off.
  • Page 91 Thermal load connection (menu structure 2.6.4.) (optional for biogas and/or sewage gas operation) This function allows emergency cooling of the Hoval Eco-Plus CHP plant to be controlled in biogas and/or sewage gas operation. This function can also be optionally used for control of another heating circuit regulation.
  • Page 92 6.6.6.5. Speed-controlled pump (menu structure 2.6.5.) When the speed pump "Point 1" is activated, the CHP plant regulates according to the set flow temperature. To allow the pump to be regulated according to speed, the "ON" box must be pressed in the PLC under the "Speed-controlled pump"...
  • Page 93 6.6.6.6. Storage tank filling level control (menu structure 2.6.6.) Hoval offers storage tank management for an additional charge. Four PT1000 sensors are included in the scope of delivery. To activate the storage tank filling level control, press the "Yes" button Then select the number of installed sensors on the left-hand side.
  • Page 94 6.6.6.8. Storage tank discharge pump 6.6.6.8.1. Select your required temperature setting. If the "T-top" switching contact is exceeded, the discharge pump is switched on. If the value falls below the "T-bottom" switching contact, the discharge pump is switched off. 6.13.6.6.9 Boiler block 6.13.6.6.9.1 The boiler block in the menu of the storage tank filling level control has the same physical contacts as the standard boiler block installed at the factory.
  • Page 95 boiler block is automatically deactivated as soon as the storage tank filling level control is activated. 6.6.6.9.2. Select the corresponding sensor. 6.6.6.9.3. Select your required temperature setting. If the "T-top" switching point is exceeded, the boiler is blocked. If the value falls below the "T-top" switching point, the boiler is released. Notice: All switching contacts can be provided with a time delay.
  • Page 96 For connection to CHP plant: See enclosed circuit diagram, page 19 Notice: Work on the CHP plant and the connection of electronic components is only allowed to be carried out by qualified personnel. 6.6.8. M-BUS (menu structure 2.6.8.) Interface for recording digital data from gas and heat meters in (kWh) Subject to modifications A-TRON Blockheizkraftwerke GmbH 96 of 131...
  • Page 97 For connection to CHP plant: See enclosed circuit diagram, page 19 Notice: Work on the CHP plant and the connection of electronic components is only allowed to be carried out by qualified personnel. Subject to modifications A-TRON Blockheizkraftwerke GmbH 97 of 131...

  • Page 98: User Level 2

    6.7. User level 2 After you have entered your password for user level 2, the name "Code" changes to "Setup". When you press the "Setup" button again, the following extended menu appears: Figure 48: Menu – User level 2 Subject to modifications A-TRON Blockheizkraftwerke GmbH 98 of 131...

  • Page 99: Oil Change (Menu Structure 2.6.9)

    6.7.1. Oil change (menu structure 2.6.9) Figure 49: Menu – Oil change In this area, settings for the automatic oil change can be made Confirming by pressing the "Next page" button carries out the automatic oil change. Subject to modifications A-TRON Blockheizkraftwerke GmbH 99 of 131...

  • Page 100: Service Interval (Menu Structure 2.6.10)

    6.7.2. Service interval (menu structure 2.6.10) Every regular maintenance is recorded via the Service interval menu item. An oil change must be carried out with every maintenance, which is also confirmed. Figure 50: Menu – Service interval Confirmation for maintenance Confirmation for oil service Subject to modifications A-TRON Blockheizkraftwerke GmbH...

  • Page 101: Allowed Power (Menu Structure 2.6.11)

    6.7.3. Allowed power (menu structure 2.6.11) Shows the current setting of the allowed power, in this case "Curve". The CHP plant automatically regulates according to the heating circuit return temperature. The allowed power can also be changed to "Manual". This setting is for service purposes only.

  • Page 102: Fresh Oil Pump (Menu Structure 2.6.12)

    6.7.4. Fresh oil pump (menu structure 2.6.12) In addition to the oil change, the level of the oil is continuously checked. If this drops to "low" during operation, fresh oil is automatically refilled. If the "middle" level cannot be reached within a test time, the CHP plant is stopped and an error message is output (error: oil level check, error code: 27).

  • Page 103: System Operator (Menu Structure 2.6.13)

    6.7.5. System operator (menu structure 2.6.13) This menu item is used to enter the plant owner. This setting is carried out at the factory and is only allowed to be changed by Hoval or by qualified personnel approved and certified by Hoval.

  • Page 104: Serial Number (Menu Structure 2.6.14)

    6.7.6. Serial number (menu structure 2.6.14) This menu item is used to enter the serial number. This setting is made at the factory and is not allowed to be changed. Figure 54: Menu - Serial number Subject to modifications A-TRON Blockheizkraftwerke GmbH 104 of 131...

  • Page 105: Temperature Configuration (Menu Structure 2.6.15)

    6.7.7. Temperature configuration (menu structure 2.6.15) Allows you to calibrate individual temperature probes and create warning and shutdown limits, as well as the response time. Figure 55: Menu - Temperature configuration Subject to modifications A-TRON Blockheizkraftwerke GmbH 105 of 131...

  • Page 106: Manual Control (Menu Structure 2.6.16)

    6.7.8. Manual control (menu structure 2.6.16) Sets the CHP plant into manual control mode and thus enables testing of the individual components. This function is only allowed to be used by Hoval or by qualified personnel approved and certified by Hoval! Figure 56: Menu –...

  • Page 107: Other Parameters (Menu Structure 2.6.17)

    This menu item can be used to make changes to various setting parameters for automatic and control mode as well as for the basic settings. These functions are only allowed to be used by Hoval or by qualified personnel approved and certified by Hoval! Figure 58: Menu - Other parameters...
  • Page 108 Automatic mode (menu structure 2.6.17.1) Under this menu item, changes can be made to various nominal setting parameters. This is only allowed to be carried out by Hoval or by qualified personnel approved and certified by Hoval. Points 1 - 4 are used for heating optimisation. All other parameters are factory-set and must not be changed.
  • Page 109 6.7.9.2. Control (menu structure 2.6.17.2) The parameters for the control mode are set at the factory and are not allowed to be changed with the exception of "Lambda value minimum" and "Lambda value maximum" for optimisation of the exhaust gas values. Figure 60: Menu - Control Subject to modifications A-TRON Blockheizkraftwerke GmbH...
  • Page 110 All boxes under the Statistics menu item can be changed if required. Changes are only allowed to be carried out by Hoval or by qualified personnel approved and certified by Hoval. Subject to modifications...
  • Page 111 Miscellaneous (menu structure 2.6.17.4) The Miscellaneous menu item contains setting parameters for the basic setting of the CHP plant. Changes are only allowed to be carried out by Hoval or by qualified personnel approved and certified by Hoval. Figure 62: Menu – Miscellaneous 6.7.10.

  • Page 112: Stop Mode / Error (Menu Structure 2.6.19)

    Figure 63: Menu – Save / load parameters 6.8. Stop mode / error (menu structure 2.6.19) The CHP plant has many safety functions and is set to sensitive settings as standard. This guarantees a high level of protection for the components used. However, the sensitivity can be adjusted by the service technician / factory employee so that the CHP plant can be adapted to local conditions.
  • Page 113 Figure 64: Menu – Error example You can get more information about the errors by clicking the "Info" button. To return the CHP plant to the error-free status, the error can be reset with "Reset" if the current situation permits. Subject to modifications 113 of 131 A-TRON Blockheizkraftwerke GmbH...
  • Page 114 Notice: All errors are recorded in the history. Please notify the service technician / Hoval in the event of an error and state the error and the associated error code. Follow the instructions on the screen to correct the error.

  • Page 115: Error List (Menu Structure 2.6.20)

    6.8.2. Error list (menu structure 2.6.20) List of all possible error messages via the PLC. Please indicate the error code (no.) on request by the service technician. Table 2: Error message Error message short text Error message long text Possible cause of error EMPTY (formerly mains check) The engine control unit (ECU) signals...
  • Page 116 The engine oil pressure switch has Engine oil level too low, oil Engine oil pressure tripped. pressure switch defective EMPTY (formerly coolant pressure) Coolant pump defective, Engine coolant inlet Engine coolant inlet temperature coolant level low, sensor temperature is high defective Coolant pump defective, Engine coolant outlet...
  • Page 117 cascade master. Check the connection to the master. Motor circuit breaker Stop: Software motor circuit breaker Check the generator, software tripped. Check the generator. generator connection cable Error: No current phase L1. Presumed Check power system voltage, Power failure L1 phase failure of L1.

  • Page 118: Warning (Menu Structure 2.6.21)

    6.9. Warning (menu structure 2.6.21) The CHP plant issues warning messages as soon as plant-relevant values approach a critical status. If one or more warnings exist, this is displayed on the main screen in the system status with a yellow warning triangle. Warning window If you click the warning triangle symbol in the main screen, a window appears with the existing errors (point 1).
  • Page 119 You can get more information about the warnings by clicking the "Info" button. In the case of increased temperatures, such as here in the example the exhaust gas temperature (point 3), the CHP plant output is reduced until the normal condition has been restored.

  • Page 120: Standards

    6.10. Standards The control unit complies with the following standards: DIN EN ISO 12100 / DIN EN 954-1 Safety of machinery DIN EN 60204 Electrical equipment of industrial machinery EN 50081-2 / EN 50082-2 Electromagnetic compatibility (EMC) Subject to modifications A-TRON Blockheizkraftwerke GmbH 120 of 131...

  • Page 121: Service And Maintenance

    Service and maintenance 7. Service and maintenance 7.1. Safety Maintenance and servicing work must be carried out exclusively by specialist personnel. The environmental regulations must be observed in this context. Improper handling can lead to serious injuries and material damage. Be aware of the following specific dangers when servicing the CHP plant.

  • Page 122: Cleaning And Lubrication

    Service and maintenance 7.2. Cleaning and lubrication 7.2.1. Cleaning The end user may only carry out superficial cleaning work. All other activities are only allowed to be carried out by specialist personnel. CAUTION Risk of electric shock! Only qualified and authorised electricians may carry out work on the electrical equipment! Switch off the main switch for the power supply and secure it with a padlock! The person who carries out the maintenance and repair work must hold onto the key for this lock! When replacing heavy system parts, only use suitable and faultless equipment and slings.

  • Page 123: Repair Work

    Service and maintenance 7.3.2. Repair work The following points must be observed before carrying out commissioning:  Use the main switch to switch off the central power supply and attach a warning sign to prevent reactivation, or secure the switch with a lock ...

  • Page 124: Connection Work

    Service and maintenance 7.4. Connection work The following points must be observed before starting the CHP plant:  Once again, check all screw connections that have been unfastened previously to ensure that they are firmly tightened  Check whether all previously removed protective devices, covers, etc., have been reinstalled correctly ...

  • Page 125: Remote Maintenance And Installation

    Remote maintenance and installation 8. Remote maintenance and installation maintenance 8.1. Installing the remote module: Before commencing installation, please remember to disconnect the CHP plant from the mains voltage at the main switch 1. Remove the cover from the top of the control panel and mount the remote maintenance module on the top hat rail inside the control panel as shown in the photograph.
  • Page 126 Remote maintenance and installation 3. Plug the USB connector on the LogiLink USB 2.0 network adapter supplied with the remote maintenance module into one of the USB ports on the module. Plug a network cable into the other side of the adapter and connect this to your home network (Internet connection): 4.

  • Page 127: Chp Plant Software Configuration

    5. Plug the other end of the network cable into the RJ45 port on the remote maintenance module: Once all of the connections have been made, the CHP plant can be switched back on at the main switch. 8.2. CHP plant software configuration The LAN setting for the CHP controller now needs to be checked or made.

  • Page 128: Cascade Connection

    The remote maintenance module is factory-set for operation on a DHCP router and will establish a connection automatically. If the network requires a static IP, this must be set by Hoval prior to delivery of the remote maintenance module. 8.3.

  • Page 129: Changing The Micro Sd Card

    8.4. Changing the Micro SD card If the Micro SD card needs to be changed, start by disconnecting the CHP unit from the supply voltage. Then carefully remove the remote maintenance module from the top hat rail. Next, carefully pull out the old Micro SD card and insert the new one. The side with the contacts points towards the board.

  • Page 130: Connection Diagram For The Remote Maintenance Module

    8.5. Connection diagram for the remote maintenance module: 8.5.1. Connecting the individual CHP plant Subject to modifications A-TRON Blockheizkraftwerke 130 of 131...
  • Page 131 8.5.2. Connecting the CHP plant cascade Subject to modifications A-TRON Blockheizkraftwerke 131 of 131...

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