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Baxi Senertec Dachs Pro 20 ST Assembly And Operation Manual

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Dachs Pro 20 ST
EN
Assembly, commissioning
and operation
Dachs Pro 20 ST
Supplement to the translation of the
original German operating instructions
VW EcoBlue 2.0 - Generation 1.2 of iav
i

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Summary of Contents for Baxi Senertec Dachs Pro 20 ST

  • Page 1 Dachs Pro 20 ST Assembly, commissioning and operation Dachs Pro 20 ST Supplement to the translation of the original German operating instructions VW EcoBlue 2.0 - Generation 1.2 of iav...
  • Page 2 All rights reserved. The content of the present instructions is protected by copyright. Any form of duplication, even in extracts, requires the written approval of Baxi SenerTec UK. The present instruction may not be copied, modified or saved in any database whatsoever, be it electronically, mechanically or by any other means of recording. The publisher has the sole right of use.

  • Page 3: Table Of Contents

    Dachs Pro 20 ST Inhaltsverzeichnis 1 Introduction ..............................7 General information ...............................7 Additional documentation ...........................7 Symbols used ................................8 Abbreviations ................................9 Responsibilities ...............................9 1.5.1 Responsibilities of the installer ..................................9 1.5.2 Responsibilities of the operator................................. 10 1.5.3 Responsibilities of the manufacturer ............................... 11 Homologations ..............................12 2 Safety ................................13 General safety instructions ..........................13...
  • Page 4 Dachs Pro 20 ST Control panel description ...........................31 4.3.6 MSR Pro 20 ST ........................................31 4.4.1 CHP unit control panel ....................................32 Scope of delivery ..............................34 Accessories and options ............................35 5 Prior to installation ............................36 Installation regulations ............................36 Installation requirements ...........................37 5.2.1 Installation height ......................................
  • Page 5 Dachs Pro 20 ST 6.9.2 Exhaust gas line dimensioning base ................................ 70 6.9.3 Exhaust gas line - DN80 package ................................71 6.9.4 Exhaust gas line - DN100 (DN80) duct mounting ..........................72 6.9.5 Exhaust gas line - DN100 (DN80) external wall ............................ 73 6.10 Electrical connection............................74 6.10.1 CHP grid connection (CHP unit) ................................
  • Page 6 Dachs Pro 20 ST 9 Settings ...............................104 List of parameters .............................. 104 Setting parameters............................104 Reading out operating data ..........................104 10 Maintenance ...............................105 10.1 General information ............................105 10.2 Maintenance signals ............................105 10.3 Regular maintenance ............................106 10.4 Repair ................................... 106 11 Troubleshooting ............................106 11.1 Error codes ................................

  • Page 7: Introduction

    Dachs Pro 20 ST 1 Introduction General information These instructions describe assembly, commissioning and operation of the Dachs Pro 20 ST overall system with the MSR Pro 20 ST controller unit. These instructions are intended for authorised specialist staff assigned with assembly, commissioning and service, maintenance and repair of the VW EcoBlue 2.0 (Generation 1.2) and is a supplement to the existing VW documentation (iav).

  • Page 8: Symbols Used

    Dachs Pro 20 ST ● 4798.529.xxx, Dachs Pro 20 ST customer information. ● 4798.399.xxx, SenerTec information brochure on heating water treatment. ● 4798.496.xxx, GSM modem for Dachs Pro 20 ST with MSR Pro 20 ST. ● 4798.499.xxx, Analogue modem module for Dachs Pro 20 ST with MSR Pro 20 ST. ●...

  • Page 9: Abbreviations

    Dachs Pro 20 ST Abbreviations DVGW Deutscher Verein des Gas- und Wasserfaches Alternating current [German association of the gas and water industry] FeuVO Feuerungsverordnung Operating hours [German ordinance on firing installations] Gas supplier Combined heat and power generation (here also: CHP unit) Combined Heat and Power Controller Area Network AEGS...

  • Page 10: Responsibilities Of The Operator

    Dachs Pro 20 ST Prior to commissioning: ● A leakage test of the gas duct according to TRGI must be carried out. ● The exhaust gas system is to be approved by the responsible master chimney sweep, i.e. the authority responsible for inspecting gas installations (e.g.

  • Page 11: Responsibilities Of The Manufacturer

    Dachs Pro 20 ST An application with the corresponding DNO is mandatory in Germany, for example. The stipulation of the required cos φ is communicated to the applicant by the DNO once the connection has been approved (VDE-AR-N 4105). Note: The Dachs Pro 20 ST with its capacity is not subject to the German TI-air (<1MW) and does therefore not require any authorisation.

  • Page 12: Homologations

    Dachs Pro 20 ST ● Use of unsuitable heating water. ● Chemical, electro-chemical and electric influences. ● Use of drinking water which does not correspond to the generally accepted rules of practice. The warranty regulations of the General Terms and Conditions of SenerTec GmbH, Schweinfurt, in their respective current version shall apply.

  • Page 13: Safety

    Dachs Pro 20 ST Reference: Please particularly observe standards, guidelines, regulations and legal requirements additionally specifi ed in the iav documentation relevant for planning and installation. Note: In order to integrate the CHP technology into the buildings, standards/directives such as TRGI, TRF, TRWI, VDI 2035 are to be observed.

  • Page 14: Work On Electric And Electronic Equipment

    Dachs Pro 20 ST In the head line of general safety instructions, the following elements are used: + Danger (red): Any non-compliance leads to death or severe injury. + Warning (orange): Any non-compliance may lead to death or severe injury. + Caution (blue): Any non-compliance may lead to personal injury.

  • Page 15: Gas Connection

    Dachs Pro 20 ST 2.1.3 Gas connection Attention! Danger: Danger The gas line is a safety-relevant component and may only Risk of explosion caused by room air saturated with gas. be mounted by authorised Danger of su ocation caused by under-saturation of specialist staff .

  • Page 16: Special Safety Instructions

    Dachs Pro 20 ST Special safety instructions 2.3.1 Machine in running operation After being switched on, the machine starts automatically and parts are put in rotation. Among other things, the exhaust gas fl ow contains nitrogen oxides and carbon monoxide. Engine components and the exhaust gas system heat up considerably. If the machine is operated while the acoustic enclosure is open (e.g.
  • Page 17 Dachs Pro 20 ST Warning Danger of accidents caused by missing safety equipment. Unauthorised changes to the system may lead to severe injuries. • Check the electrical and mechanical safety equipment before operating the unit. • Do not operate the machine if the fl ywheel cover is not installed.

  • Page 18: Assembly And Repair

    Dachs Pro 20 ST 2.3.2 Assembly and repair Some Dachs Pro 20 ST components exceed the maximum recommended load to be lifted by individual persons. These include pre-mounted components on delivery as well as some spare parts. When working with heavy loads, lifting devices are to be used and diffi cult to move parts to be secured.

  • Page 19: Servicing

    Dachs Pro 20 ST 2.3.3 Servicing When operating the Dachs Pro 20 ST, acidic condensate forms. Condensate and waste products from the neutralisation process (e.g. when using the SenerTec neutralisation box) has to be handled appropriately. Unit-specifi c safety regulations depend on the functional principle of the device type used.

  • Page 20: Technical Specifications

    Dachs Pro 20 ST 3 Technical specifications Technical data The technical data refer to the Dachs Pro 20 ST overall system including Volkswagen EcoBlue 2.0 (Generation 1.2) CHP unit in combination with the MSR Pro 20 ST system controller, 2 SE940 buffer vessels and one frequency converter. Reference: The specified values serve as basis for projecting.

  • Page 21: Volkswagen Ecoblue 2.0 (Generation 1.2) Chp Unit

    Dachs Pro 20 ST 3.1.2 Volkswagen EcoBlue 2.0 (Generation 1.2) CHP unit Tab.2: Technical data: Volkswagen EcoBlue 2.0 (Generation 1.2) CHP unit General unit parameters Device category DE I 2ELL Gas type (natural gas according to DVGW G 260) Methane number >...

  • Page 22: Msr Pro 20 St System Controller

    Dachs Pro 20 ST 3.1.3 MSR Pro 20 ST system controller Tab.3: Technical data - MSR Pro 20 ST system controller Electrical connection L/N/PE 230 V~ / 50 Hz Protection type (EN 60529) IP 40 Protection class (DIN 57700) Protection class 1 Ambient air temperature min.

  • Page 23: Dimensions And Connections

    Dachs Pro 20 ST Dimensions and connections 3.2.1 VW EcoBlue 2.0 (Generation 1.2) dimensions and connections 1344 mm Fig. 7: Dimensions of EcoBlue2.0 with cladding Gas connection Electronic ports (e.g. CAN) Frequency converter supply Frequency converter return Fuel connection (gas connection) Dachs outlet connection (flow to buffer)

  • Page 24: Buffer Vessel Se940 Dimensions And Connections

    Dachs Pro 20 ST 3.2.2 Buffer vessel SE940 dimensions and connections Fig. 10: Dimensions Buffer vessel SE940 (complete) 24 | Technical specifications 14/4798.495.002...

  • Page 25: Fig. 11: Dimensions Buffer Vessel Se940 (Raw Part)

    Dachs Pro 20 ST 2“ TUBE 2“ TUBE 2“ TUBE 2“ TUBE 3368 mm Tube end secured at storage cover 990 mm 600 mm 1178 mm 600 mm Fig. 11: Dimensions Buff er vessel SE940 (raw part) 20-30 mm colourless!! Rp 3/4"...

  • Page 26: Circuit Diagram

    Dachs Pro 20 ST Circuit diagram Internal MSR Pro 20 ST controller wiring diagram X0 grid connection in MSR Pro 20 ST L1 N The wiring diagram illustrates the internal wiring inside the MSR Pro 20 ST, not the external grid connection! L1 N MSR S board 4795.652.xxx (for MSR Pro 20 ST)

  • Page 27: Product Description

    Dachs Pro 20 ST 4 Product description Product information Using the new Dachs Pro 20 ST, the energy costs in buildings with high heat and power consumption can be efficiently lowered in a climate-friendly way. The Dachs Pro 20 ST generates power and heat in one process according to the principle of combined heat and power generation (CHP), directly where it is consumed.

  • Page 28: Operating Principle

    Dachs Pro 20 ST Operating principle The Dachs Pro 20 ST is a typical application in the field of cogeneration of heat and power. A four-cylinder 4-stroke engine drives a water-cooled asynchronous generator. The generated mechanical energy is directly converted into electricity. Simultaneously, the heat generated by the drive is not eliminated as in conventional power plants, but utilised by transfer into a heating system.

  • Page 29: Main Components

    Dachs Pro 20 ST System advantages for planners and installers: ● Reduced time for planning, assembly and commissioning. ● Coordinated system components with clearly defined interfaces for hydraulic and exhaust gas control provide safety during planning and assembly. ● Overall system solution with building heating and simultaneous electricity generation. ●...

  • Page 30: Chp Unit (Vw Ecoblue 2.0 - Generation 1.2)

    Dachs Pro 20 ST 4.3.2 CHP unit (VW EcoBlue 2.0 - Generation 1.2) Engine technology For the engine of the Dachs Pro 20 ST, SenerTec relies on the expertise of Volkswagen AG and uses the Volkswagen EcoBlue 2.0 (Generation 1.2) with the tried and tested four-cylinder line engine type: VW CNG 2.0.

  • Page 31: Control Panel Description

    Dachs Pro 20 ST Control panel description 4.3.6 MSR Pro 20 ST Menu bar Control keys Generator LED Fault clearance key and errorLED Chimney sweep key Infrared interface MSR Pro 20 ST fuse (6.3 A/T, incl. connected system technology) MSR Pro 20 ST main switch (incl. connected system technology) ON/OFF key, STOP LED, automatic mode LED Display...

  • Page 32: Chp Unit Control Panel

    Dachs Pro 20 ST 4.4.1 CHP unit control panel Fig. 22: CHP unit control panel Reference: For the detailed description of the CHP unit control panel, please refer to the iav documentation of VW. ● EcoBlue 2.0 (Generation 1.2) installation manual for Dachs Pro 20 ST, art. no. 4798.522.xxx ●...

  • Page 33: Fig. 23: Main Menu/Default Screen Of The Chp Unit Touch Display

    Dachs Pro 20 ST Input keys With the input keys, sub-menus and individual messages in sub-menus can be accessed directly. This field includes: ● The number keys from 0 to 9 to enter numeric values and ● the two input keys ESC and ENT. Press this key to exit the current screen.

  • Page 34: Scope Of Delivery

    Dachs Pro 20 ST Scope of delivery The scope of delivery of the Dachs Pro 20 ST overall system includes: ● CHP unit (VW EcoBlue 2.0 - Generation 1.2). ● Cladding set for the CHP unit (acoustic enclosure). ● MSR Pro 20 ST controller with mounting accessories. ●...

  • Page 35: Accessories And Options

    Dachs Pro 20 ST Accessories and options The following components must be provided for the Dachs Pro 20 ST on site: ● Temperature-resistant and pressure-proof Raab GmbH exhaust system for the Dachs Pro 20 ST. ● Various line materials and components for the electrical installation (equipotential bonding connection, grid connection, connection lines for CO sensors, external sensors etc.

  • Page 36: Prior To Installation

    Dachs Pro 20 ST 5 Prior to installation Prior to assembly and installation, the constructional requirements for a safe operation of the Dachs and all system components are to be ensured. This includes: ● Spatial requirements expected from the installation location. ●...

  • Page 37: Installation Requirements

    Dachs Pro 20 ST Attention: In Germany, the standard DIN 1988-100 as well as §19 WHG [German law on water management] are to be complied with. Outside of Germany, the respective country-specific regulations and laws are to be adhered to. Reference: Please observe the instructions and information in the iav Documentation of VW on the EcoBlue 2.0 (Generation 1.2) in particular.

  • Page 38: Heating Water Requirements

    Dachs Pro 20 ST 5.2.2 Heating water requirements According to VDI 2035, the admissible total hardness is determined both depending on the total heating output of the unit as well as on the specific system volume. If the Dachs Pro 20 ST is integrated into a heating system in combination with another heating boiler system, the stipulations of the VDI 2035 must be complied with and logged for the entire heating system.

  • Page 39: Heating Installation And Return Temperatures

    Dachs Pro 20 ST For operation, the following protective measures are recommended: ● The volume of recharging water is to be kept low by the installation of sectioning valves in case any repair needs to be carried out and to enable regular inspection of the expansion vessel. ●...

  • Page 40: Exhaust Gas Installation

    Dachs Pro 20 ST 5.2.5 Exhaust gas installation For exhaust gas evacuation of the Dachs Pro 20 ST, a type-approved chimney and/or an exhaust gas duct must be used. In cooperation with an exhaust pipe manufacturer, SenerTec has specifi ed an appropriate pressure-tight and temperature- resistant exhaust gas system designed for the Dachs Pro 20 ST.

  • Page 41: Installation Location Requirements

    Dachs Pro 20 ST Installation location requirements Note: When planning the system, the space requirements of the components have to be taken into consideration. This applies to installation and assembly, but also to subsequent access to all components for maintenance and repair. 5.2.8 Dachs Pro 20 ST space requirements 3368 mm...

  • Page 42: Fig. 28: Dachs Pro 20 St Space Requirement (Top View - 2 × Se940 Buffer Vessels One Next To The Other)

    Dachs Pro 20 ST 2370 mm 130 mm 990 mm 130 mm 990 mm 130 mm Space requirements (L/W/H): approx. 310/240/220 cm 600 mm 600 mm 1170 mm 2370 mm Fig. 28: Dachs Pro 20 ST space requirement (top view - 2 × SE940 buffer vessels one next to the other) 42 | Prior to installation 14/4798.495.002...

  • Page 43: Installation Requirements

    Dachs Pro 20 ST 5.3.1 Installation requirements ● Heating room according to DVGW TRGI. ● Specific installation room. ● Room approved according to the ordinance for use of heating appliances or national regulations. The room must fulfil the following specific criteria: ●...

  • Page 44: Installation Requirements

    Dachs Pro 20 ST 5.3.3 Installation requirements Installation on fl oors/platforms The statics of the fl oor must be suitable for the weight of the Dachs Pro 20 ST. Suffi cient space for maintenance must be ensured. Attention: If required, suitable measures to ensure the required loading capacity of fl oors are to be coordinated with a structural engineer.

  • Page 45: Transport

    Dachs Pro 20 ST Transport If possible, all unit components should be transported to the installation location while still in their packaging. Use suitable transportation aids for heavy loads. Attention: Check the packaging for transportation damage. Reference: Please observe the instructions and information in the iav Documentation of VW on the EcoBlue 2.0 (Generation 1.2) in particular.

  • Page 46: Se940 Buffer Vessel Transport To The Installation Location

    Dachs Pro 20 ST 5.4.3 SE940 buffer vessel transport to the installation location ● The SE940 buffer vessel is only to be transported in its transport packaging. ● Do not remove the transportation packaging before having reached the installation location. ●...

  • Page 47: Connection Diagram

    Dachs Pro 20 ST Connection diagram Hydraulic connection diagram - Dachs Pro 20 ST Fig. 29: Hydraulic connection diagram - Dachs Pro 20 ST 14/4798.495.002 Prior to installation | 47...

  • Page 48: Fig. 30: Variants Of Hydraulic Integration According To The Installation On Site

    Dachs Pro 20 ST for condensing NT/KT boiler without pump Condensing without pump NT/KT boiler without pump Condensing without pump NT/KT boiler without pump Condensing without pump Installation on site: NT/KT boiler without pump Installation on site: Condensing without pump Boiler with pump Installation on site: Boiler with pump F5: Bypass...

  • Page 49: Fig. 31: Electrical Connection Diagram - Msr Pro 20 St

    MSR Pro 20 ST connection diagram Dachs Pro 20 ST - Dachs Pro 20 ST - MSR Pro 20 ST Electrical connection diagram - MSR Pro 20 ST connection bar Connection Terminal Note MSR Pro 20 ST mains connection 230 VAC MSR Pro 20 ST Connection Plug...

  • Page 50: Installation

    Dachs Pro 20 ST 6 Installation General information Installation of the Dachs Pro 20 ST may only be carried out by authorised and certified specialist staff. Product training carried out by SenerTec or by a training institution commissioned by SenerTec is a minimum requirement. All work on the electrical equipment may only be carried out by trained electricians.

  • Page 51: Assembly Of The Msr Pro 20 St At The Chp

    Dachs Pro 20 ST 6.2.3 Assembly of the MSR Pro 20 ST at Position of MSR Pro 20 ST controller the CHP mounting at the CHP Mounting installation at the CHP ► Lift the top rear cladding illustrated and position the washer on the frame component.

  • Page 52: Se940 Buffer Vessel Installation

    Dachs Pro 20 ST Suspension of the MSR Pro 20 ST at the CHP Suspension of the MSR Pro 20 ST at the CHP ► Suspend the pre-assembled MSR Pro 20 ST as illustrated from above at the hinge pin No additional attachments or fixtures for the MSR Pro 20 ST at the CHP are required.

  • Page 53: Fig. 37: Connections At The Se940 Buffer Vessel (Without Insulation On The Left, With Insulation Visible Connections On The Right)

    3368 mm Dachs Pro 20 ST 990 mm 600 mm 1178 mm 600 mm Rp 3/4" threaded connection (fi lling/ discharge) Rp 1 1/4" threaded connection (open) Locking straps for sensor elements Rp 1 1/4" threaded connection (open) Ventilation and equipotential bonding powered by Volkswagen connection Rp 1 1/4"...

  • Page 54: Fig. 40: Se940 Filling And Discharge Connection

    Dachs Pro 20 ST ► Assemble one 45° bracket , one reducer and one KFE valve from the provided installation accessories at the bottom connection of each buffer vessel and seal it. This connection serves for filling and discharge. Insulation assembly at the SE940 buffer vessel Attention: To prevent cracking at the outer cover, at least room temperature (>...

  • Page 55: Frequency Converter Control Box Assembly

    Dachs Pro 20 ST ► Firstly, close the complete zip fastening of the cladding insulation at each buffer vessel. ► Position the cover insulation on each SE940 buffer vessel. ► Route the end of the respective sensor cable harness at each buffer vessel to the back above the cover insulation and out of the cladding insulation.

  • Page 56: Hydraulic Connection

    Dachs Pro 20 ST Hydraulic connection SenerTec scope of delivery SenerTec scope of delivery SenerTec scope of delivery Installation on site for condensing Supply flow heating circuit SE940 SE940 Return flow heating circuit Fig. 44: Hydraulic connection diagram - Dachs Pro 20 ST Dachs (CHP) inlet Dachs (CHP) outlet CHP-internal hydraulics...

  • Page 57: Fig. 46: Variants Of Hydraulic Integration According To The Installation On Site

    Dachs Pro 20 ST for condensing NT/KT boiler without pump Condensing without pump NT/KT boiler without pump Condensing without pump NT/KT boiler without pump Condensing without pump Installation on site: NT/KT boiler without pump Installation on site: Condensing without pump Boiler with pump Installation on site: Boiler with pump F5: Bypass...
  • Page 58 Dachs Pro 20 ST Description of hydraulic integration: The heat transfer to the heating circuit is performed via a controlled pump. This buffer discharge system is controlled by the MSR Pro 20 ST. For the detailed connection/transfer points of the flow and return lines in the heating circuit, please refer to the hydraulic schematic diagrams.

  • Page 59: Fig. 47: Dachs Outlet Connection Set

    Dachs Pro 20 ST Dachs outlet connection set assembly: Note: Positions can be pre- assembled. Step 1 ► Tighten and pre-assemble Connection to the CHP components Step 2 ► Connect the pre-assembled assembly including flat packing to the CHP (Dachs outlet). Alignment to the rear Flat packing 1 1/2"...

  • Page 60: Fig. 49: Dachs Inlet Connection Set

    Dachs Pro 20 ST Dachs inlet connection set assembly: Note: Positions can be pre- assembled. Step 1 Discharge ► Tighten and pre-assemble hose components Step 2 Connection to the CHP ► Connect the pre-assembled assembly Flat packing 1 1/2" including flat packing to the CHP Threaded fitting R 1"...

  • Page 61: Fig. 51: Dachs Pro 20 St Rear View - Dachs Outlet Connection

    Dachs Pro 20 ST Dachs inlet transfer point Fig. 53: Dachs Pro 20 ST rear view - Dachs outlet connection Buff er discharge pump and shut-off set assembly: ► Install the provided buff er discharge pump including shut-off set with thermometer (red) and shut-off valve with check valve in the fl ow to the heating circuit according to the manufacturer instructions.

  • Page 62: Fig. 54: Tf1 Total Filter Components And Installation Position - Fernox

    Dachs Pro 20 ST Heating water filter assembly (TF1 total filter): ► Install the provided TF1 total filter according to the manufacturer instructions. Positioning - see schematic diagram. on site connection line from the SE940 buffer vessel TOTAL FILTER TF1 •...

  • Page 63: Solar Component Connection

    Dachs Pro 20 ST Hydraulic vent positions at the Dachs Pro 20 ST: Manual vent at the Dachs outlet and Dachs inlet Automatic vent at each SE940 buffer vessel Fig. 55: Hydraulic vent positions at the Dachs Pro 20 ST Reference: For hydraulic installations at the Dachs Pro 20 ST, particularly the instructions and information in the iav Documentation of VW on the EcoBlue 2.0 (Generation 1.2) are to be observed.

  • Page 64: Gas Connection

    Dachs Pro 20 ST Gas connection Reference: Please observe the supplementary instructions and information in the iav Documentation of VW on the EcoBlue 2.0 (Generation 1.2) in particular. Chapter 3.9 - Technical data - Gas supply Chapter 6.8 - CHP internal gas system Chapter 6.9 - Gas supply Dachs Pro 20 ST summary: ●...

  • Page 65: Fig. 57: Schematic Diagram For Gas Connection To The Dachs Pro 20 St

    Dachs Pro 20 ST SenerTec scope of delivery BK-G6 gas meter (up to 10 m³/h) powered by Volkswagen Gas fl ow monitor (if required) Fig. 57: Schematic diagram for gas connection to the Dachs Pro 20 ST Attention! Danger - if you smell gas: •...

  • Page 66: Fig. 58: Dachs Pro 20 St Rear View - Assembled Gas Connection

    Dachs Pro 20 ST Gas filter cover: Gas line routing: Alignment to the front ► Install the gas line close to the Dachs Pro 20 ST for connection of the gas hose. connection Leakage check at gas lines: transfer point ►...

  • Page 67: Oil Supply Connection

    Dachs Pro 20 ST Step 5 ► Connect the gas ball valve the transfer point to the gas supply prepared on site. Step 6 ► Tighten the gas hose stress-relieved between the gas ball valve and the 90° bracket Fig. 60: Gas connection installation set Vent the gas line: Reference: Please observe the instructions and information in the iav Documentation...

  • Page 68: Exhaust Gas/Supply Air System

    Dachs Pro 20 ST Exhaust gas/supply air system Reference: Please observe the instructions and information in the iav Documentation of VW on the EcoBlue 2.0 (Generation 1.2) - Chapter 6.9.4 Exhaust gas system and fresh air supply in particular. Extracts from the iav documentation of VW The entire exhaust gas system is to be realised according to DVGW work sheet G640 “Installation of small-scale CHPs”, DIN EN 1856, DIN EN 1443 and DIN EN 13384 point 6 “Exhaust gas routing for gas-fired appliances”...

  • Page 69: Exhaust Gas System

    Dachs Pro 20 ST The exhaust gas system consists of the following components: ● Exhaust catalyser ● Exhaust gas heat exchanger ● Exhaust gas silencer The exhaust gas silencer enables considerable noise reduction inside the unit under the present room conditions. The exhaust gas heat exchanger cools the exhaust gas from the CHP to an outlet temperature of 190 °C.

  • Page 70: Exhaust Gas Line Dimensioning Base

    Dachs Pro 20 ST Please note: The exhaust gas ducts must also be run over the roof always according to DIN 18160. Minimum clearances to dormers, windows or other openings are to be observed. The responsible chimney sweep must always be consulted when planning exhaust gas ducts.

  • Page 71: Exhaust Gas Line - Dn80 Package

    Dachs Pro 20 ST 6.9.3 Exhaust gas line - DN80 package 4.5 (to be shortened on site) Fig. 61: Schematic diagram - DN80 exhaust gas line, horizontal Tab.11: Exhaust gas line - DN80 package Designation T-piece for deflection with 2” connection Capacitor Mechanical vibration absorber...

  • Page 72: Exhaust Gas Line - Dn100 (Dn80) Duct Mounting

    Dachs Pro 20 ST 6.9.4 Exhaust gas line - DN100 (DN80) duct mounting Manufacturer: Raab Type: EW-Alkon for DN80 as construction kit Connection line Depending on the construction layout, additional components may be required Fig. 62: Schematic diagram - Exhaust gas line in DN100 (DN80) duct, vertical Tab.12: Exhaust gas line - DN100 duct mounting Tab.13: Exhaust gas line - DN80 duct mounting Designation...

  • Page 73: Exhaust Gas Line - Dn100 (Dn80) External Wall

    Dachs Pro 20 ST 6.9.5 Exhaust gas line - DN100 (DN80) external wall Manufacturer: Raab Type: DW-Alkon Tab.14: Exhaust gas line - DN100 (DN80) external wall Designation Bottom part for wall/floor assembly 87° angle with support stand V-connection, DW-Alkon to EW-Alkon Pipe element, 1000 mm End element Wall mounting, static, 60 mm clearance...

  • Page 74: Electrical Connection

    Dachs Pro 20 ST 6.10 Electrical connection For all installation work, in particular with respect to protective measures, the respective standards and regulations are to be complied with. Explicit reference is made to the series of DIN VDE 0100, particularly 0100-100, 0100-551, 0100-410 and 0100-430, VDE-AR-N 4105, TCR of distribution network operators and potential special requirements: ●...

  • Page 75: Fig. 64: Schematic Diagram Of Dachs Pro 20 St Grid Connections

    Dachs Pro 20 ST Meter for consumption and supply (bidirectional meter) Supply: Metering of the supply into the grid of the distribution network operator for sale, e.g. according to market conditions (European Energy Exchange) and avoided network tariff s Meter for metering the generated CHP net electricity (meter with non-return device) RCD: Residual current device Mains connection at meter panel...
  • Page 76 Dachs Pro 20 ST Additional information on CHP net electricity metering: At the CHP supply , CHP net electricity generation can be metered according to the German Combined Heat and Power Act (KWKG) 2009. Extract from the German Combined Heat and Power Act (KWKG) 2009: “Net electricity generation refers to the electricity generated by an unit measured at the generator terminals reduced by the unit consumption for operation.

  • Page 77: Chp Grid Connection (Chp Unit)

    Dachs Pro 20 ST 6.10.1 CHP grid connection (CHP unit) Reference: For CHP connection, please observe the supplementary instructions and information in the iav Documentation of VW on the EcoBlue 2.0 (Generation 1.2) on electrical connections in particular. For example: ●...

  • Page 78: Electrical Connection Of The Frequency Converter To The Chp

    Dachs Pro 20 ST 6.10.2 Electrical connection of the frequency converter to the CHP Reference: For frequency converter connection, please observe the supplementary instructions and information in the iav Documentation of VW on the EcoBlue 2.0 (Generation 1.2) in particular. For example: ●...

  • Page 79: Connection Of The Co Sensors To The Chp

    Dachs Pro 20 ST 6.10.3 Connection of the CO sensors to the CHP ► Install the two provided CO sensors inside the installation room according to the manufacturer instructions. Fig. 73: CO sensors Reference: For CO sensor assembly and connection to the CHP, please observe the instructions and information in the iav Documentation of VW on the EcoBlue 2.0 (Generation 1.2) in particular.

  • Page 80: Connections In The Msr Pro 20 St

    MSR Pro 20 ST connection bar Dachs Pro 20 ST Connection Terminal Note MSR Pro 20 ST mains connection 6.10.5 Connections in the MSR Pro 20 ST 230 VAC MSR Pro 20 ST Connection Plug Connection Plug power board designation designation External sensor (AF) Bu er vessel sensor 1...

  • Page 81: Fig. 77: External Sensor (Af)

    Dachs Pro 20 ST External sensor (AF) connection From experience, the north or north west wall are suitable for installation of the outside temperature sensor. However, if the building is heated using several separately controlled heating circuits, the outside temperature sensor has to be installed at the outer wall of the building section with the heating circuit connected to the Dachs.

  • Page 82: Fig. 80: Schematic Diagram - Sensor Cable Harness Extension

    Dachs Pro 20 ST On-site cable extension (if required) Distribution box to be provided for extension Connector powered by Volks Volks wagen Connector Connector Connector Fig. 80: Schematic diagram - Sensor cable harness extension F5, F6 and F7 sensor connection ►...

  • Page 83: Fig. 85: Schematic Diagram - Buffer Discharge Pump Connection Line Extension

    MSR Pro 20 ST Dachs Pro 20 ST Connection Plug Connection Plug power board designation designat External sensor (AF) Bu er vessel sensor 1 (F1) Buff er discharge pump connection Bu er vessel sensor 2 (F2) ► Route the connection lines of the buff er discharge pump to the Bu er vessel sensor 3 MSR Pro 20 ST.

  • Page 84: Fig. 86: Can Bus Cable Harness

    Dachs Pro 20 ST CAN bus cable harness connection Note: The communication between CHP and MSR Pro 20 ST is realised via a CAN bus connection. - CHP connection - Individual single conductors with end sleeves Route and install the CAN bus cable harness provided in the scope of delivery.

  • Page 85: Fig. 89: Can Connection Port At Chp

    Dachs Pro 20 ST ► Route the cable harness to the CHP and connect it to the E-Module as illustrated. ► Connect the cable harness or the single conductors with end sleeves to the CHP controller. Reference: For CAN bus cable harness connection, please observe the supplementary instructions and information in the iav Documentation of VW on the EcoBlue 2.0 (Generation 1.2) in particular.

  • Page 86: Dachs Pro 20 St Equipotential Bonding

    Dachs Pro 20 ST GSM antenna connection ► Remove one stepped nipple at the rear of the controller housing. ► Insert the connection cable harness of the GSM antenna from the outside into the controller. ► Attach the provided slotted bushing in the controller housing.

  • Page 87: Heating Emergency Switch Connection

    Dachs Pro 20 ST 6.10.7 Heating emergency switch connection To ensure that the CHP can be switched off in case of emergency, an external heating emergency switch must be connected. The heating emergency switch is not included in the scope of delivery and must be provided on site. The heating emergency switch has to be installed outside of the installation room.

  • Page 88: Filling The Unit

    Dachs Pro 20 ST 6.11 Filling the unit Note: The Dachs Pro 20 ST is equipped with a system separator in the CHP. The primary circuit of the CHP is already filled on delivery and just needs to be checked/ refilled on commissioning.

  • Page 89: Finishing Work

    Dachs Pro 20 ST 6.12 Finishing work ► Assemble the remaining cladding components of the CHP unit. ● Rear cladding (rear wall) ● Right cladding ● Front cladding (under the CHP control unit/main switch). Rear ● Top, centre cladding wall ●...

  • Page 90: Commissioning

    Dachs Pro 20 ST 7 Commissioning General information Prior to commissioning, the following requirements are to be met: ● All assembly work has been completed. ● The following check list has been completed. ● The electrical equipment of the unit has been completely installed. ●...

  • Page 91: Check List Prior To Commissioning

    Dachs Pro 20 ST Check list prior to commissioning Check list for the installer regarding the technical installation of the of the Dachs Pro 20 ST Operator: Dachs ser.-no.: √ / − Assembly: Has the CHP been aligned with a spirit level? Has the overall system been vented on the water system side? Has the generator been vented on the water system side (according to iav documentation of VW)? Have the buffer vessels been correctly connected to the CHP?
  • Page 92 Dachs Pro 20 ST Extract from the iav documentation of VW (particularly for the CHP): Electric installation: Have the data of the new CHP been registered with the supplier? Is the signal sufficient for wireless modem connection at the installation location? Is the supply voltage correct? Have the cables been routed and connected according to specifications? Fuel supply and connection:...
  • Page 93 Dachs Pro 20 ST Additional preparations for commissioning: Has the application at the energy provider (EVU) been prepared and sent in time? Has the application at the German Federal Office for Economic Affairs and Export Control (BAFA) been prepared and sent in time? Comments HEATING, executing ELECTRICS, executing...

  • Page 94: Commissioning Procedure

    Dachs Pro 20 ST Commissioning procedure Note: Control of the unit during commissioning is performed via the CHP control panel and the menu of the MSR Pro 20 ST controller. See also chapters 8 and 9 These instructions only describe the entries required for commissioning.

  • Page 95: Gas Supply Settings

    Dachs Pro 20 ST Gas supply settings Reference: Please observe the supplementary instructions and information in the iav Documentation of VW on the EcoBlue 2.0 (Generation 1.2) - Chapter 6.9 Gas supply in particular. Oil supply settings Note: This chapter is not relevant for the Dachs Pro 20 ST. The fuel supply is realised exclusively using natural gas.
  • Page 96 Dachs Pro 20 ST Basic screen Press Menu selection Open menu 11 with 11 Service Select menu 11 with and switch to menu item 11/6 with 11/6 Service level change to password Select menu 11/6 with Password Confirm password with press to open the commissioning menu...

  • Page 97: Msr Pro 20 St Settings In Menu 8/1 Date/Time

    Dachs Pro 20 ST MSR Pro 20 ST settings in menu 8/1 Date/time 7.6.4 Menu 8/1/1 Date ► Enter the date in format DD.MM.YYYY. Menu 8/1/2 Time ► Enter the time in 24 hour format. MSR Pro 20 ST settings in menu 1/7 Dachs data 7.6.3 Menu 1/7/3 Hydraulic code ►...

  • Page 98: Msr Pro 20 St Settings In Menu 11/2 Service Tel

    Dachs Pro 20 ST Menu 1/8/6 Country ► Enter the country. The country identifier can be selected from a list. If the country is not listed, “other” has to be selected. Menu 1/8/7 E-mail ► Enter the e-mail address. In the first line, a maximum of 14 characters can be entered. In the second line, a maximum of 21 characters can be entered.

  • Page 99: Advanced Chp Parameter Settings

    Dachs Pro 20 ST 7.6.9 Advanced CHP parameter settings Reference: Please particularly observe the supplementary instructions and information to be observed in the iav Documentation of VW on the EcoBlue 2.0 (Generation 1.2) - in general chapter 7 CHP controller settings. The parameters in chapters 7.5.5, 7.5.6 and 7.5.7 in particular must be adapted.

  • Page 100: Operation

    Dachs Pro 20 ST 8 Operation General information Reference: For detailed information on the operation of the MSR Pro 20 ST, please also refer to the original operating instructions: MSR Pro 20 ST operation and configuration instructions, art. no. 4798.494.xxx. Reference: For the detailed description of the CHP unit control panel, please refer to the iav documentation of VW.
  • Page 101 Dachs Pro 20 ST Menu functions Control key function Operating data Communication back Heat demand Settings Electrical Grid confirm demand Temperatures Service code down Heating Service circuits Domestic hot water The MSR Pro 20 ST controller is controlled via the key pad. The menu is navigated exclusively with the control keys. The current status is indicated in the display.

  • Page 102: Chp Control Panel And Menu Structure

    Dachs Pro 20 ST 5 Heating Note: circuits No “heating circuits” function. The menu is not displayed. 6 Domestic hot Note: water No “domestic hot water” function. The menu is not displayed. 7/01 Modem data 7 Communication 7/02 Configuration 7/03 Service codes sent 7/04 Test / status 7/05 GSM-diagnostics (radio) 8 Settings...

  • Page 103: Start-Up

    Dachs Pro 20 ST Reference: For the detailed description of the CHP unit control panel, please refer to the iav documentation of VW. ● EcoBlue 2.0 (Generation 1.2) installation manual for Dachs Pro 20 ST, art. no. 4798.522.xxx. ● EcoBlue 2.0 (Generation 1.2) user manual for Dachs Pro 20 ST, art. no. 4798.530.xxx. Start-up Switch on the MSR Pro 20 ST at the main switch.

  • Page 104: Settings

    Dachs Pro 20 ST 9 Settings List of parameters Reference: For the full list of parameters regarding the MSR Pro 20 ST, please refer to: ● MSR Pro 20 ST operation and configuration instructions, art. no. 4798.494.xxx. For the detailed description of the CHP unit control panel, please refer to the iav documentation of VW. ●...

  • Page 105: Maintenance

    Dachs Pro 20 ST 10 Maintenance 10.1 General information The Dachs Pro 20 ST includes several components, but at least the MSR Pro 20 ST, CHP unit, 2 × SE940 buffer vessels, frequency converter and buffer discharge pump. Attention: Waste operating media and cleaning agents are to be disposed of in an environmentally friendly way.

  • Page 106: Regular Maintenance

    Dachs Pro 20 ST 10.3 Regular maintenance The Dachs Pro 20 ST including components have to be maintained regularly by authorised specialist personnel according to the maintenance log and recommended servicing measures have to be carried out according to the service manual and maintenance instructions.

  • Page 107: Chp Error Codes

    Dachs Pro 20 ST 11.1.2 CHP error codes Errors at the CHP unit are indicated as a LED status signal at the EGS and/or error ID or alarm ID in the display of the CHP control panel. Reference: Please observe the supplementary instructions and information in the iav Documentation of VW on the EcoBlue 2.0 (Generation 1.2) - Chapters 8 and 10 in particular.

  • Page 108: Decommissioning

    Dachs Pro 20 ST 12 Decommissioning 12.1 Decommissioning procedure Attention: For permanent decommissioning, the unit components, filling and operating media are to be disposed of in an environmentally friendly way. In Germany, the regulations of the German law on recycling and waste management apply. The respective manufacturer instructions as well as local regulations and directives have to be observed.
  • Page 109 Dachs Pro 20 ST Permanent decommissioning of the Dachs Pro 20 ST: Switch off the Dachs Pro 20 ST. Switch off the CHP at the main switch. Switch off the MSR Pro 20 ST at the main switch. Disconnect the fuses and secure them against reconnection. Attach a clearly visible out of order sign at the Dachs.

  • Page 110: Recommissioning

    Dachs Pro 20 ST Reference: Please observe the supplementary instructions and information in the iav Documentation of VW on the EcoBlue 2.0 (Generation 1.2) in particular. 12.2 Recommissioning Note: After extended decommissioning periods, various pumps at the Dachs Pro 20 ST may be blocked. For this reason, the pumps are to be checked for proper function before recommissioning.

  • Page 111: Spare Parts List

    Dachs Pro 20 ST 13.3 Spare parts list For detailed information on spare parts, please refer to the: ● Product catalogue. ● Spare parts catalogue. ● Partner area of the SenerTec website: www.senertec.de. 13.4 Sources of supply Spare parts may only be ordered from local SenerTec service centres. For further information on service centres in your region, please refer to www.senertec.de.
  • Page 112 Dachs Pro 20 ST List of figures Fig. 1: Dachs Pro 20 ST - overall system ............................................20 Fig. 2: EcoBlue 2.0 figures ..................................................21 Fig. 6: Figures of accessories and communication ........................................22 Fig. 4: SE940 buffer vessel figures ..............................................22 Fig. 5: Frequency converter figures ..............................................22 Fig.
  • Page 113 Dachs Pro 20 ST Fig. 52: Components - Buffer discharge pump with shut-off set ....................................61 Fig. 53: Hydraulic schematic diagrams on the buffer discharge pump with shut-off set in the heating circuit flow ................61 Fig. 54: TF1 total filter components and installation position - Fernox ................................62 Fig.
  • Page 114 Dachs Pro 20 ST List of tables Tab. 1: Technical data - Dachs Pro 20 ST overall system (excerpt) ..................................20 Tab. 2: Technical data: Volkswagen EcoBlue 2.0 (Generation 1.2) CHP unit ................................21 Tab. 3: Technical data - MSR Pro 20 ST system controller ......................................22 Tab.
  • Page 115 Dachs Pro 20 ST Notes: 14/4798.495.002 Spare parts | 115...
  • Page 116 Dachs Pro 20 ST Notes: 116 | Spare parts 14/4798.495.002...
  • Page 117 Dachs Pro 20 ST Notes: 14/4798.495.002 Spare parts | 117...
  • Page 118 Dachs Pro 20 ST Baxi Commercial Wood Lane Erdington Birmingham B24 9QP...

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