SenerTec Dachs Gen2 G5.5 Operating Instructions Manual

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Instructions for installation and commissioning

Original operating instructions

Mini CHP unit

Dachs Gen2

G2.9/G5.5/F3.0/F5.5

These operating instructions are intended for authorised experts.

Before commencing your work, please carefully read these instructions.

Store for later reference.

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Summary of Contents for SenerTec Dachs Gen2 G5.5

Page 1 United Kingdom Instructions for installation and commissioning Original operating instructions Mini CHP unit Dachs Gen2 G2.9/G5.5/F3.0/F5.5 These operating instructions are intended for authorised experts. Before commencing your work, please carefully read these instructions. Store for later reference.
Page 2 Carl-Zeiss-Straße 18 • 97424 Schweinfurt, Germany Phone: +49 9721 651-0 • Fax: +49 9721 651-272 Email: info@senertec.com • Web: www.senertec.com Managing directors: Nicolas Friedel, Heinz-Werner Schmidt Commercial register: Schweinfurt district court, registration number HRB 2942 • VAT identification no.: DE 812024506...
Page 3 Contents Contents Safety ................... . 7 General safety instructions .
Page 4 Contents 5.3.4 Specific criteria for the installation room ........... . 46 5.3.5 Installation conditions .
Page 5 Contents 6.7.3 Mounting the controller ..............92 6.7.4 Preparing the controller .
Page 6 Contents Brötje WGB ..........163 Settings for the supplementary heater Settings for the FWS40 FRESH HYDRO domestic hot water module .
Page 7 Important An authorised expert is defined as an expert who has undergone product training with SenerTec or with a training institution commissioned by SenerTec and is thereby authorised by the manufacturer to carry out work on the system.
Page 8 1 Safety Important This appliance can be used by children aged from 8 years and above and persons with reduced physical, sensory or mental capabilities or lack of experience and knowledge if they have been given supervision or instruction concerning use of the appliance in a safe way and understand the hazards involved.
Page 9 1 Safety When working on the electrical equipment, follow the instructions for installation, commissioning, service and spare parts replacement. For your safety, follow the specified connection requirements and the safety precautions. 8098.002.010.06 - v06 - 07102019...
Page 10 1 Safety Danger Voltage is present even when the operating switch is switched off. Risk of death from electric shock! All electrical work must only be carried out by authorised experts. Before commencing work on electrical equipment, you must disconnect the system from the power supply.
Page 11 Any other or further use shall be considered improper use. SenerTec GmbH shall not be liable for damages resulting from improper use. The sole risk shall be borne by the user.
Page 12 1 Safety Operation under ambient conditions other than those described. Operation outside of buildings (outdoors). The CHP system must be configured and integrated into the building in such a way that, during normal operation, the ratio between operating hours and number of starts is, on average, at least 1 operating hour to 1 start.
Page 13 1 Safety Danger If you smell flue gases: Risk of asphyxiation! Switch off the appliance. Open the windows. Locate the source of the flue gas leak and fix it immediately. Warning Missing protective devices Risk of accidents! Check the electrical and mechanical protective devices prior to operation.
Page 14 1 Safety Caution Falling objects. Injury and material damage! Do not place anything on top of the CHP system. Notice Overheating of components in the CHP system. Keep the ventilation opening in the side panel on the controller side open and free from blockages.
Page 15 1 Safety Information on handling strong magnets The generator's rotor contains strong magnets. Exercise increased caution when handling the generator. This is especially important if you work on the disassembled generator. Important Works to be conducted on the open generator are restricted to authorised experts.
Page 16 1 Safety handling of the condensate and the waste products from neutralisation (e.g. when using the SenerTec neutralisation unit). The system-specific safety regulations depend on the functional principle of the respective system type. Warning Acidic condensate in the flue gas tract...
Page 17 Installation of the system under conditions other than those defined by SenerTec. The warranty regulations of the general terms and conditions of SenerTec GmbH shall apply in their latest version. 1.4.2 Warranty Recognition of warranty claims requires proper...
Page 18 Smartphones are not suitable as output devices for manuals and service documents from SenerTec GmbH! Before commissioning The gas pipe must have been checked for leaks according to country-specific directives.
Page 19 1 Safety Regulations The installer is obligated to comply with the country- specific national regulations, directives and standards applicable at the installation site. This includes, for example: The construction regulations. Fire protection. The technical regulations for gas connection. The technical regulations for the flue connection. The safety requirements in accordance with the local regulations and the EU.
Page 20 1 Safety Global and local regulations as well as additional rules of the following companies and authorities have to be observed: Electricity company/distribution network operator Gas supply company Responsible district chimney sweep Main customs office or similar authorities You must fulfil all notification obligations. In the event of technically justifiable deviations from these local regulations, the consent of the responsible supplier must be obtained before installation of the CHP system.
Page 21 2 About this manual About this manual In general This manual is intended for authorised experts commissioned with assembly and commissioning as well as service, maintenance and repair work. Before commencing work, please read this manual carefully. Pay particular attention to the safety warnings. The manual includes inter alia: Information regarding installation and assembly of the system as well as the related requirements.
Page 22 2 About this manual Important Indicates important information. Refers to other documents or chapters in this manual. Lists items are preceeded by a bullet point. 1. Task steps are preceded by an ordinal number. Task results are preceded by an arrow. Task steps in illustrations are preceded by a number in a circle.
Page 23 3 Technical specifications Technical specifications Homologations The following standard is the normative testing basis for type testing of the CHP system: DIN EN 50465:2015-06, gas-fired boilers – appliances for the combined heat and power with a nominal input smaller or equal to 70 kW The CHP system complies with the relevant specifications of the following EU Directives: Machine Directive...
Page 24 3 Technical specifications Model: Dachs Gen2 G5.5 F5.5 Auxiliary electricity consumption Full load 0.080 0.080 Part load 0.065 0.065 Standby mode 0.014 0.014 Other items Standby heat loss 0.101 0.101 stby Ignition burner power consumption — — Annual energy consumption 6366 5548 Sound power level, indoors...
Page 25 3 Technical specifications Model: Dachs Gen2 G5.5 F5.5 Other items Standby heat loss 0.101 0.101 stby Ignition burner power consumption — — Annual energy consumption 6366 5548 Sound power level, indoors Emissions of nitrogen oxides mg/kWh < 240 < 240 (1) Low-temperature operation means a return temperature (at the heater inlet) of 30 °C for condensing boiler, of 37 °C for a low-tempera...
Page 26 3 Technical specifications Model: Dachs Gen2 G2.9 F3.0 Sound power level, indoors Emissions of nitrogen oxides mg/kWh < 240 < 240 (1) Low-temperature operation means a return temperature (at the heater inlet) of 30 °C for condensing boiler, of 37 °C for a low-tempera ture floor-standing boiler and of 50 °C for other boilers.
Page 27 Manufacturer's documentation 3.2.4 Buffer vessel Tab.6 Technical data for hot water storage tank Model SE800 HX SE800 Manufacturer SenerTec GmbH SenerTec GmbH Storage volume Standing loss Permissible heating water temperature °C Max. 95 Max. 95 Permissible operating overpressure max. 3.0 max.
Page 28 3 Technical specifications Fig.1 Pressure drop in system separation (SE800 HX) 1000 1200 V [l/h] 3.2.5 Technical data of the temperature sensor Important The buffer vessel temperature sensors T1 to T4 and the temperature sensors T5 to T7 from the standard delivery of the CHP system have the same characteristic.
Page 29 3 Technical specifications Version with natural gas Version with liquefied gas Heating water connection CHP system inlet/outlet G¾" external thread G¾" external thread Ball valve (from the accessories) G1” internal thread G1” internal thread Permissible operating overpressure 3.0 bar 3.0 bar 3.3.2 Dimensions of SE buffer vessels Tab.10...
Page 30 3 Technical specifications No. Function Connection Connection height [mm] Buffer vessel inlet (from the Rp 1½” 1620 CHP system) Venting R ½” 1830 (1) Buffer vessel outlet = water-side outlet on the buffer vessel; buffer vessel in let = water-side inlet on the buffer vessel; the connected unit/pipe system is shown in brackets (2) R = external thread;...
Page 31 3 Technical specifications No. Function Connection Connection height [mm] Buffer vessel inlet (from the Rp 1½” 1620 CHP system) Venting R ½” 1830 (1) Buffer vessel outlet = water-side outlet on the buffer vessel; buffer vessel in let = water-side inlet on the buffer vessel; the connected unit/pipe system is shown in brackets (2) R = external thread;...
Page 32 3 Technical specifications 1 Low-voltage distribution network of the distribution remuneration, e.g. according to the usual price network operator ~ 400 / 230 V (EEX) and avoided network charges 2 Meter board 4 The generating plant supplies additional electricity. 3 Meter for purchase and delivery (bidirectional meter). To protect the cables and lines (DIN VDE 0100-430), Delivery: Recording of the quantities delivered to the an additional fuse may be required...
Page 33 Operating principle The CHP system is a typical combined heat and power system. A 4-stroke single-cylinder SenerTec special engine drives a water-cooled synchronous generator . The generated mechanical energy is immediately converted into electricity. An integrated frequency inverter is used to feed the generated electrical energy into the grid or to transfer it to the building network for the purpose of internal consumption.
Page 34 4 Description of the product Main components 4.3.1 CHP system Fig.6 Components of the CHP system (figure shows Dachs 5.5 Gen2) 1 ControllerMSR3 16 Flue elbow with siphon and inspection piece 2 Energy Manager 17 Condensing heat exchanger 3 Hydraulic module 18 Flue gas silencer 4 Air intake 19 Diaphragm expansion vessel...
Page 35 4 Description of the product 4.3.2 SE components Fig.7 SE components 1 SE800/SE800 HX buffer vessel 3 FWS40 FRESH HYDRO domestic hot water module 2 Brötje-WGB-i-Serie supplementary heater 8098.002.010.06 - v06 - 07102019...
Page 36 4 Description of the product Control panel description Fig.8 Operating view Display and control panel Touchscreen operation. (1) Activates further setting and display options (2) Menu path status display (3) Activates the chimney sweep mode (4) Activates the service mode (5) Display of the relevant operating data (6) Status display of the individual system components and activated functions...
Page 37 CHP system. A basic flue gas construction kit that is suitable for the relevant object can be obtained via SenerTec. Alternatively, these parts can be obtained as a separate set. The following accessories are available for the CHP system and can be obtained from SenerTec: SE800/SE800 HX incl.
Page 38 5 Before installation Before installation Prior to installation and setup, make sure that the on-site requirements for safe operation of the CHP system and all of its components are met. These on-site pre-requisites include: The spatial requirements for the installation site Access to the installation site The heating water requirements The required air inlet openings...
Page 39 5 Before installation 5.2.2 Heating water requirements Notice Operation of the system with unsuitable filling and supplementary water Risk of damage to the system caused by corrosion or limestone formation The pH value must not exceed the admissible maximum value. pH-values must be determined at a water temperature of approx.
Page 40 When operating the CHP system with domestic hot water module and/or supplementary heater, also observe the manufacturer's specifications. Conductivity: The requirements of VDI 2035 apply. SenerTec recommends a conductivity of < 100 µS/cm Appearance: The requirements of VDI 2035 apply (free from sedimenting substances).
Page 41 The requirements of VDI 2035 (pH8.2–9.5) apply. Total hardness: The requirements of VDI 2035 apply. SenerTec recommends a total hardness of < 16.8 °dH. Conductivity: The requirements of VDI 2035 apply. SenerTec recommends < 100 µS/cm conductivity Oxygen content: The requirements of VDI 2035 apply. Additives: The following agents are approved for the cooling water circuit: Protector F1 from Fernox.
Page 42 The flue bend with siphon and inspection piece are part of the basic flue gas construction kits. A basic flue gas construction kit that is suitable for the relevant object can be obtained via SenerTec. Alternatively, these parts can be obtained as a separate set.
Page 43 5 Before installation 5.2.7 Electrical installation Important The electrical installation must be carried out according to the technical connection conditions of the distribution system operators and in compliance with the applicable standards: G83/2 (Engineering Recommendation G83/2:2012 - Recommendations for the Connection of Type Tested Small- scale Embedded Generators (Up to 16A per Phase) in Parallel with Low-Voltage Distribution Systems) G98/1–3 (Engineering Recommendation G98 Issue 1...
Page 44 5 Before installation Fig.12 Spatial requirements for the CHP 1 Adjustable foot system and position of the 2 Connection side adjustable feet 5.3.2 Spatial requirements for the CHP system with SE800 or SE800 HX Important When planning the system, consider the component's spatial requirements.
Page 45 5 Before installation Fig.13 Recommended setup (buffer vessel on the right): Spatial requirements for the CHP system with SE800 or SE800 HX on the right 1 CHP system 4 CHP system connections 2 SE800 or SE800 HX buffer vessel 5 Brötje-WGB-i-Serie supplementary heater (optional) 3 Zip fastener - insulation and temperature sensor 6 Domestic hot water module (optional) Tab.14...
Page 46 5 Before installation Fig.14 Alternative setup: Spatial requirements for the CHP system with SE800 or SE800 HX on the left 1 CHP system 4 CHP system connections 2 SE800 or SE800 HX buffer vessel 5 Brötje-WGB-i-Serie supplementary heater (optional) 3 Zip fastener - insulation and temperature sensor 6 Domestic hot water module (optional) Tab.15 Minimum clearances for the SE800 and SE800 HX buffer vessels depending on the installed supplementary heater...
Page 47 5 Before installation The room is only used for the installation of heating appliances, heat pumps, combined heat and power systems and fixed combustion engines. No openings to other rooms except for doors. Doors are air-tight and self-locking. The room can be ventilated. For all systems: Sufficient lighting.
Page 48 5 Before installation Condition for setting up the CHP system with additional CHP systems with or without supplementary heater with a total rated output of more than 100 Two openings that lead directly outside, arranged at the top and bottom of the same wall, with free cross-sections of at least 150 cm each plus 1 cm...
Page 49 In case of unsuitable flue gas evacuation, flue gas may escape into the installation room Risk of asphyxiation! SenerTec recommends a suitable flue gas system in accordance with DIN EN 14471:2013+A1:2015 from the manufacturer Skoberne (CE 0036 CPD 9184 001‑2007); at least type T120 H1 W 2 O20 LE E U in the outdoor area, and at least type T120 H1 W 2 O20 LI E U in the indoor area.
Page 50 5 Before installation Important Observe the swivel dimensions for access to the installation site. Lifting equipment must be ready for transport. Important Lifting equipment increases the space that is required for the transport. 5.4.2 Transporting the CHP system Fig.15 CHP system packed (without Important controller and accessories) with The CHP system must only by transported by authorised experts.
Page 51 5 Before installation Buffer vessel inlet (domestic hot buffer vessel inlet (domestic hot water Fig.17 The screwed connection of the water module) connection module) can be removed before transport to the installation site. Fig.18 Control dimension Important buffer vessel inlet (domestic hot water Seal the connection of the module) after transport.
Page 52 5 Before installation Fig.19 CHP system packed with controller 1. Remove the packaging film. and accessories Important Dispose of packaging material correctly. 2. Take the controller and accessories box off the CHP system. 3. Remove the mounting rail from the accessories box. SW-1602002 5.5.2 Aligning and securing the mounting rail...
Page 53 5 Before installation 1. Align the mounting rail on the ground in accordance with the dimension diagram. Fig.21 Dimension diagram for the 1 Mounting rail mounting rail 2 Lag screws (2 ×) 13 mm 3 Dowels (2x) 4 Dowel holes (2 ×) 5 Wall of installation room 2.
Page 54 6 Installation Installation In general Assembly, commissioning, service, maintenance and repair work is restricted to authorised experts only. Work on electrical installations is restricted to authorised experts only. Notice Machine damage due to insufficient frost protection Choose a frost-resistant site for installation of the system. Assembly 6.2.1 Installing the CHP system...
Page 55 6 Installation Important During the following step, continuously check whether the adjustable feet will sink freely into the locating holes in the mounting rail. Fig.24 Installing the CHP system, step 5 5. Carefully lower the CHP system. 6. Remove the outer packaging. Use the outer packaging as a cover to protect the painted surfaces during installation.
Page 56 6 Installation Fig.25 CHP system with buffer vessel on the right 1 CHP system 6 FWS40 HYDRO domestic hot water module 2 Buffer vessel (optional) 3 Insulation fastener and temperature sensor 4 CHP system connections 5 Brötje EcoTherm Plus WBG series supplementary heater (optional) Tab.16 Minimum clearances for the SE800 and SE800 HX buffer vessels depending on the installed supplementary heater...
Page 57 6 Installation Fig.26 CHP system with buffer vessel on the left 1 CHP system 6 FWS40 HYDRO domestic hot water module 2 Buffer vessel (optional) 3 Insulation fastener and temperature sensor 4 CHP system connections 5 Brötje EcoTherm Plus WBG series supplementary heater (optional) Tab.17 Minimum clearances for the SE800 and SE800 HX buffer vessels depending on the installed supplementary heater...
Page 58 6 Installation 6.2.3 Designing the diaphragm expansion vessel Diaphragm expansion vessels in closed central heating installations are appliances intended to compensate changes in volume between the minimum and maximum temperature and are used to achieve a constant pressure in the system. The diaphragm expansion vessel must be designed on-site while taking into consideration the system data listed below.
Page 59 6 Installation Fig.28 Installing the tilt protection 6. Install the tilt protection: 6.1. Place the tilt protection (4) on the marked holes. 6.2. Drill dowel holes (10 mm diameter) through the tilt protection and into the floor. 6.3. Place dowels (3) through the tilt protection and into the dowel holes.
Page 60 With the SE800 HX buffer vessel (with integrated tube heat exchanger), a vent valve must be installed at the buffer vessel inlet (CHP system). The vent valve must be provided by the customer. Availability according to the SenerTec product catalogue 8098.002.010.06 - v06 - 07102019...
Page 61 6 Installation 6.2.8 Fitting the buffer vessel sensors on the SE800/SE800 HX Fig.32 Positioning the tabs for the buffer vessel sensors Fig.33 Installing the buffer vessel sensors 1. Secure four buffer vessel sensors (from the standard delivery) in the tabs on the buffer vessel. 1.1.
Page 62 6 Installation Fig.34 Positioning the temperature sensors on an on-site buffer vessel (examples) X = 100% A Position of the temperature sensors if X ≈ 65% B Position of the temperature sensors if X Height of the buffer vessel outlet in the heating network The positions of the temperature sensor on the buffer vessel are entered in the Energy Manager during commissioning.
Page 63 6 Installation 6. Attach the covering hood (1) to the buffer vessel from above. 6.1. When routing the cables upwards: Route the open cable ends of the buffer vessel sensor between the buffer vessel jacket insulation and the upper buffer vessel insulation to the outside. Important Sensor cables do not carry any mains voltage and must not be routed in parallel to voltage-carrying lines (separate routing).
Page 64 6 Installation Fig.37 Mounting frame for supplementary 1. Screw the two longer threaded rods (1) as far as they will go into the heater (buffer vessel shown without upper screw thread of the buffer vessel. insulation) 2. Screw the shorter threaded rods (3) into the lower screw thread on the buffer vessel as far as they will go.
Page 65 Notice Use of unsuitable fixing material Malfunction The enclosed SenerTec M10 × 180 threaded rods must be used to fit the domestic hot water module to the SE800 or SE800 HX buffer vessels. The threaded rods included in the standard delivery of the domestic hot water module's manufacturer are not suitable for installation on the SE800 and SE800 HXbuffer vessels.
Page 66 6 Installation Fig.41 Installing the domestic hot water 1. Screw the two M10 × 180 threaded rods (1) as far as possible into the module (insulation not shown) screw threads provided on the buffer vessel. 2. Screw one M10 nut (2) onto each of the threaded rods. X of the upper nut to the connector on the buffer The clearance vessel outlet (domestic hot water module) should be approx.
Page 67 6 Installation 6.3.2 Sealing the holes in the base tray Fig.43 Hinging the rear panel back 1. Carefully hinge the rear panel (1) back. Notice Damage to the PE conductor between the base frame and the rear panel. Handle the rear panel carefully when you remove it. 2.
Page 68 6 Installation 6.3.3 Removing the lid of the pump cover Fig.45 Removing the lid of the pump cover 1. Remove the lid of the pump cover. 6.3.4 Removing the transport lock on the frequency inverter Fig.46 Transport lock on the frequency 1.
Page 69 6 Installation Important For transport, the spring assemblies that decouple the engine support from the base frame are secured with four M10 x 70 screws. To loosen the screws, you require a ring spanner and an open- ended or ratchet spanner. This tool allows you to reliably counter the screw with the nut even in the rear U-profile.
Page 70 The accessories kit for the CHP system includes two ball valves Fernox TF1 magnetite and sludge separator. and the For the different areas of application (CHP system with or without buffer vessel) the following heating water pipes are available as sets from SenerTec. Heating water pipes Connection Remark CHP system 1 ×...
Page 71 6 Installation Fig.50 Dimension connection diagram for the heating water pipes – design for optimal venting of the CHP system SW-0703006 A Layout with connection to the left 3 Heating water pipe, 1195 mm B Layout with connection to the right 4 CHP system inlet 1 Heating water circuit 5 CHP system outlet...
Page 72 6 Installation Connecting the CHP system to the heating circuit Important The heating water pipes must be appropriately bent by hand before the installation. In doing so, ensure that the bend radii are sufficient. Fig.52 Connecting the CHP system directly to the heating water circuit 1 CHP system inlet 5 Heating water pipe (CHP system inlet 2 CHP system outlet...
Page 73 6 Installation Automatic venting Important If automatic air vents are required, these must be installed downstream of the heating water pipes in the heating system. Installation on the CHP system is not permitted. 6.4.3 Hydraulic connection to the SE800/SE800 HX buffer vessels Important Route the heating water pipes between the buffer vessel and the...
Page 74 An installation kit is delivered with the buffer vessel. This includes connecting parts for the buffer vessel. Compatible heating water pipes are available as a kit from SenerTec. The ball valves that are required for the installation, along with the Fernox TF1 magnetite and sludge separator are included in the accessories kit for the CHP system.
Page 75 6 Installation Important With the SE800 HX buffer vessel (with integrated tube heat exchanger), a vent valve must be installed at the buffer vessel inlet (CHP system). The vent valve must be provided by the customer. buffer vessel inlet buffer Fig.56 Connecting the 11.
Page 76 6.4.5 Connecting a buffer vessel discharge pump An installation kit with buffer vessel discharge pump incl. accessories is available from SenerTec: Art. no. 8086-012-000. Important Install and connect the buffer vessel discharge pump and the accessories as described in the manufacturer's instructions.
Page 77 6 Installation 4 Isolator with thermometer (red marking) 6 Isolator with thermometer (blue marking) 5 Buffer vessel outlet (heating network), alternative 7 Buffer vessel inlet (heating network) connection when installing a domestic hot water module 1. Connect the shut-off tap with non-return valve (2), buffer vessel discharge pump (3) and isolator with thermometer (4, red marking) to the buffer vessel outlet (1) (alternatively buffer vessel outlet (5), if a domestic hot water module is installed).
Page 78 To connect a supplementary heater from the Brötje-WGB-i-Serie, the following accessories are required: Connection assembly ADH (available from the manufacturer) Connection kit (available from SenerTec): Supplementary heater Connection kit Brötje WGB EVO 20 i Art. no. 8086–007–000 Brötje WGB EVO 28 i...
Page 79 6 Installation for Brötje WGB EVO 20 i: 8 mm diameter, art. for Brötje WGB EVO 28 i: 8.7 mm diameter, art. no. 8044‑007‑000 no. 8044‑008‑000 Important Observe the manufacturer's instructions when carrying out any work on the supplementary heater. 1.
Page 80 Set-point value for gas resting pressure: 18–30 mbar If the resting gas pressure is above 30 mbar, install a gas pressure regulator (available from SenerTec as a kit, art. no. 8086-029-000). 8098.025.xxx.xx Notes on the use of the gas flow regulator for the reduction or stabilisation of the gas inlet pressure 6.5.1...
Page 81 6 Installation 6.5.2 Installing the gas connection Fig.64 Installing the gas connections on the left or right SW-0703012 1 Fire-protection valve with shut-off tap 2 Gas fitting unit on the CHP system Standard delivery includes the following installation kits for the gas connection: For natural gas : Fire-protection valve with gas ball valve, art.
Page 82 6 Installation Fig.66 Flexible gas hose 6. Remove the sealing cap from the gas shut-off valve. 7. Connect the gas hose to the gas shut-off valve. 8. Screw the union nut onto the gas shut-off valve in accordance with the specifications on the information sheet.
Page 83 Fresh air supply via the roof Fresh air supply via an external wall Provide on-site: Purchase from SenerTec: Vent pipe (rain pipe with hood) Kit for outdoor air supply (art. no. 8086-014-000; con tains: HT pipe elbow 87° DN50, transition piece incl.
Page 84 6 Installation Provide on-site: Purchase from SenerTec: HT pipe, DN 75, with sleeve and rubber seal (max. 10 m) Transition piece Supply air opening Breakthrough, sealed on-site (e.g. foamed; do not im mure directly due to the sound insulation) HT elbow, DN 75 Important Air supply with HT pipe, DIN EN 1451-1, flame-resistant.
Page 85 The flue bend with siphon and inspection piece are part of the basic flue gas construction kits. A basic flue gas construction kit that is suitable for the relevant object can be obtained via SenerTec. Alternatively, these parts can be obtained as a separate set.
Page 86 6 Installation 6.6.4 Connecting the flue gas system Caution Sharp edges Risk of cutting! Always wear gloves when cutting plastic pipelines to length. Fig.72 Fitting the flue elbow with siphon 1 Inspection piece with inspection port and inspection piece 2 Rear panel 3 Sealing ring 4 Pipe clamp 5 Flue elbow...
Page 87 6.6.5 Draining the condensate Important SenerTec recommends the use of the optional neutralisation box (art. no.: 4700-517-xxx) to clean and neutralise the condensate. Important When draining the condensate, the locally applicable disposal regulations and the information and installation regulations of the respective manufacturer must be observed.
Page 88 6 Installation 2. Connect the drain pipe to the condensate drain (2). Fig.73 Condensate drainage 1 Filler neck 2 Condensate drain 3 Inspection port 6.6.6 Flue gas evacuation of the supplementary heater – separate assignment For flue gas evacuation of the supplementary heater, follow the manufacturer's instructions.
Page 89 6 Installation Setting parameters in the "Settings" chapter. Follow the manufacturer's instructions. In the event of common flue gas evacuation with the CHP system, safe operation of the appliance cannot be ensured once this setting is reset. A suitable information label must therefore be affixed in the supplementary heater's operating panel cover.
Page 90 6 Installation Dachs G2.9/F3.0 Gen2 CHP system Fig.75 Flue gas resonator installation position 1 Dachs G2.9/F3.0 Gen2 CHP system 4 Diversion 2 Branch piece 5 Flue gas resonator 3 Inspection port In order to avoid malfunctions of the supplementary heater as a result of flue gas pulsations in the CHP system, a flue gas resonator must be installed in the connector downstream of the Dachs G2.9/F3.0 Gen2 CHP system.
Page 91 6 Installation Electrical connection Notice Improper use of the plugs and plug contacts Damage to the plugs and plug contacts Ensure that the contacts click into place correctly. In case of non-compliance the latches may deform. Avoid unnecessary plug cycles. This especially applies to all power connectors as well as to the connections of the mains supply line and the generator line.
Page 92 6 Installation Tab.19 Guide values for fuse protection and line lengths Line length Cross section U < 1% U < 0.5% Δ Δ l < 23 m l < 12 m 2.5 mm l < 37 m l < 18 m 4 mm l <...
Page 93 6 Installation Fig.77 Installing the controller 3. Hook the controller with the mounting bracket into the vertical slotted holes on the side section of the rear panel. 4. Use the square spanner from the controller accessories to open the controller. Important The controller is connected to the controller casing via a potential equalisation line.
Page 94 6 Installation Fig.79 Attaching the logic unit 2. Place the logic unit upright into the cut-outs provided in the controller housing. Fig.80 Cable glands on the rear of the 3. Screw two cable glands M20 (1) and M25 (2) (enclosed with the controller controller) into the corresponding holes on the rear of the controller.
Page 95 6 Installation Fig.82 Inserting the supply line in the 1. Insert supply line 1 (1) through the M25 cable gland. controller 2. Secure supply line 1 using the cable gland. Fig.83 Connecting the supply line 3. Connect the wires in supply line 1 (1) to terminal strips L1, L2, L3, N and PE.
Page 96 6 Installation 6.7.6 Connecting the cable harnesses in the controller Important The plug connections in the controller are designed to be non- interchangeable. Fig.85 Routing the cable harnesses in the MSR3 controller 8098.002.010.06 - v06 - 07102019...
Page 97 6 Installation Connecting the internal cable harness to the controller Fig.86 Inserting the internal cable harness 1. Insert the internal cable harness from CHP system through the side into the controller grommet and into the controller. Fig.87 Hook-and-loop cable ties on the 2.
Page 98 6 Installation Important The plug connections in the controller are designed to be non- interchangeable. 3. Establish the plug connections on the power PCB (1) and the safety PCB (2) in accordance with the following tables. Fig.88 Controller PCBs 1 Power PCB 2 Safety PCB Tab.20 Connections on the power and safety PCBs...
Page 99 6 Installation Fig.90 X400 connection, cable harness of 5. Establish the plug connection to X400 (12-pole plug, cable harness for the frequency converter the frequency converter). Fig.91 Internal cable harness secured to 6. Use the short rubber band (R3, from the accessories) to secure the the cradle clamp right-hand string of the cable harness to the lower cradle clamp.
Page 100 6 Installation 4. Establish the plug connections on the power PCB (1) and the safety PCB (2) in accordance with the following tables. Fig.93 Controller PCBs 1 Power PCB 2 Safety PCB Tab.21 Connections for the pipe bridge's cable harness on the power and safety PCBs Designation Number of poles Function/appliance...
Page 101 6 Installation Standard check Fig.94 PE supply line 1 on the threaded bolt (adjustable foot) PE supply line 1 and the 1. Carry out a PE conductor test between threaded bolt on an adjustable foot . 8098.002.010.06 - v06 - 07102019...
Page 102 6 Installation Fig.95 PE supply line 1 on the housing of the frequency inverter PE supply line 1 and the 2. Carry out a PE conductor test between housing of the frequency inverter . PE conductor test after transport in disassembled state If the CHP system was transported to the installation site in a disassembled state, the following points must be checked.
Page 103 6 Installation Fig.96 PE supply line 1 on the rear panel PE supply line 1 and the rear 1. Carry out a PE conductor test between panel (paint-free location). 8098.002.010.06 - v06 - 07102019...
Page 104 6 Installation Fig.97 PE supply line 1 on the pump housing PE supply line 1 and a pump 2. Carry out a PE conductor test between housing . Important The measurement must be taken across the pump's aluminium body. 8098.002.010.06 - v06 - 07102019...
Page 105 6 Installation Fig.98 PE supply line 1 on the generator cover 3. Carry out a PE conductor test between PE supply line 1 and the generator cover . 6.7.8 Closing the controller 1. Place the logic unit on the controller housing and screw it on tightly. 2.
Page 106 6 Installation Fig.99 Potential equalisation of the gas 1. Connect the potential equalisation to the potential equalisation clamp train of the gas train. 6.7.10 Overview of the external connections on the power PCB Fig.100 External connections on the power PCB X11/1–2 Buffer vessel sensor 1 X13a, X13b 0–10 V/PWM X11/3–4 Buffer vessel sensor 2...
Page 107 6 Installation Single-pole heating emergency switch for single-module systems: Fig.101 Example: Heating emergency Connecting X23: switch with glow lamp Fig.102 Connecting X23 1. Insert the four-core connection cable of the heating emergency switch through a free offset nipple and into the controller. 2.
Page 108 6 Installation Fig.103 Connection X11, power PCB 2. Connect the buffer vessel sensor in accordance with the following table. Tab.22 Connection for the buffer vessel sensors Designation Connection Remark Buffer vessel sensor T1 X11/1 and X11/2 Top buffer vessel sensor T2 buffer vessel sensor X11/3 and X11/4 Buffer vessel sensor T3...
Page 109 6 Installation Fig.105 Connection X22, power PCB 1. Electrically connect the buffer vessel discharge pump to the MSR3 controller as shown in the following connection diagram: Buffer vessel dis Connection Function charge pump L1 (brown) X22a (O) Power supply (output N (blue) X22a (N) ~230 V...
Page 110 6 Installation 1. Establish the connection between the MSR3 controller and the supplementary heater as shown in the figure. Demand or enabling of the supplementary heater at X21b on the power PCB. Error message of the supplementary heater at X20b of the power PCB.
Page 111 6 Installation 6.7.18 Remote shutdown by network operator If it is necessary for the distribution network operator to be able to shut down the Dachs Gen2 CHP system remotely, this can be implemented as follows: 1. Parametrisation of the digital inputs on the frequency inverter using Inverter Service Tool .
Page 112 6 Installation Fig.109 Heating water circuit venting points 2. Vent the heating water circuit at the following points one after the on the CHP system other: 2.1. Vent on the condensing heat exchanger (2): Open it and only close it once air is no longer escaping. 13 mm 25 Nm 2.2.
Page 113 6 Installation Fig.111 Using the air pump to correct the 4. If required, use the air pump to correct the pre-charge pressure. pre-charge pressure HI-V (high Set the air pump on the control dial (cover) to volume per stroke). 5. Unscrew the air pump or pressure gauge and the angle connection from the diaphragm expansion vessel and use the protective cap to close the inspection port.
Page 114 6 Installation Fig.113 Venting points for the coolant circuit 6. Open the vent at the flue gas heat exchanger outlet (2) and only close on the CHP system it again once air is no longer escaping. 7. Open the vent for the coolant pump (1) and only close it again once air is no longer escaping.
Page 115 7 Commissioning Commissioning General Before commissioning, the following conditions must be met: All assembly work has been completed. All items of the checklist have been tested. The system's electrical installation is complete and has been checked. The consumers are electrically connected. The system's hydraulic installation is complete and has been checked.
Page 116 7 Commissioning Checklist before commissioning 7.2.1 CHP system checklist Important This checklist is part of service booklet 8098.007.xxx.xx. Once filled out and signed, the checklist remains with the system. Alternatively, a signed print-out of the electronic form for this checklist can be stored in the service manual. 8098.002.010.06 - v06 - 07102019...
Page 117 7 Commissioning 7.2.2 Buffer vessel checklist Important This checklist is part of service booklet 8098.007.xxx.xx. Once filled out and signed, the checklist remains with the system. Alternatively, a signed print-out of the electronic form for this checklist can be stored in the service manual. 7.2.3 Checklist for the FWS40 HYDRO domestic hot water module...
Page 118 7 Commissioning 7.2.4 Checklist for the supplementary heater Important This checklist is part of service booklet 8098.007.xxx.xx. Once filled out and signed, the checklist remains with the system. Alternatively, a signed print-out of the electronic form for this checklist can be stored in the service manual. Commissioning procedure Important Initial commissioning of the system is restricted to an authorised...
Page 119 The latest software versions can be found in the partner area of the SenerTec homepage. The software versions installed on the system can be found in the Energy Manager by selecting CHP unit > System data > Software versions.
Page 120 7 Commissioning Important Even if the zones are named according to their function (e.g. Heating circuit 1, Domestic hot water circuit, Swimming pool, etc.), the setting parameters in the sub-menus occasionally contain the prefix or suffix heating circuit or the corresponding abbreviation These designations are not based on the function (heating circuit) of the relevant parameter but are solely due to the modular structure of the control software.
Page 121 7 Commissioning Fig.116 Selecting an entry 1. Select the menu entry Friendly Name of the user zone. Important Only entries that are marked with a frame can be edited. A pop-up window with a keyboard opens. Fig.117 Pop-up window Fig.118 Deleting an entry 2.
Page 122 7 Commissioning Important If an outside temperature sensor is installed and has been detected by the control unit, weather-compensated operation will be chosen as a standard. Scheduling: Control via a parametrisable time program Manual: The set-point temperature is kept at a constant level Antifrost: Operation of the system at a reduced set-point temperature.
Page 123 7 Commissioning Fig.121 Activity setpoints list display 1.1. Select the Heat demand > CIRCA > Activity setpoints menu. A list display showing the temperatures and their allocated activities opens. Fig.122 Activity setpoints list display 1.2. Select the temperature that you want to change. A pop-up window with a numeric keypad opens.
Page 124 7 Commissioning Fig.124 Opening the Schedule menu 2. Open Schedule. A pop-up window opens for interactive parametrisation . The weekdays are listed. Switch between the weekdays using Important By direct selection the following settings can be adjusted: Activity Time interval for the activity Potential deletion of an activity Further functions: [Add new status]: Add an additional activity to the time...
Page 125 7 Commissioning Fig.128 Selecting an activity 4. Select the activity (Morning, Away, Home, Evening, Sleep, Custom) using [+] /[–]. Fig.129 Select activity 5. Set the start time for the time interval using [+] and [–] and confirm by pressing [Close]. The end time is defined by the start time for the following activity.
Page 126 7 Commissioning 7. There is the option to add additional activities to an existing schedule. Fig.132 Additional activity Important A time program may only comprise a maximum of six activities for one day. 7.1. To do this, select Add new status. 7.2.
Page 127 7 Commissioning You can use the heating curve to define the relationship between the outside temperature and the flow temperature. The minimum and maximum temperature and slope (gradient) of the heating curve are used to adjust the system operating parameters to the ambient conditions (outside temperature).
Page 128 7 Commissioning 7.3.2 Commissioning wizard Basic information: Before working through the commissioning wizard, switch to the service level ( + authorisation code). For initial commissioning of the CHP system, you have to work through the Servicing > Service Menu > Commissioning wizard menu. The commissioning wizard interactively guides you through those controller software menus which have to be adjusted before initial commissioning.
Page 129 7 Commissioning Launching the commissioning wizard Fig.141 Overview Service Menu 1. Select the wizard Commissioning wizard in the Servicing > Service Menu menu. The Commissioning wizard launches and the Date and time window opens. 2. Starting from this menu, it is possible to perform all the parametrisation processes necessary for commissioning.
Page 130 Important The mechanical offset is system-specific and should be correctly preset at the factory. This value should therefore never be changed without consultation. Please contact: SenerTec Service Hotline. MP004 -Rated power of the module Display of the rated power of the module in watts.
Page 131 7 Commissioning Minimum: 0Oh Maximum: 7000 operating hours (Dachs F5.5 Gen2 and Dachs G5.5 Gen2) Maximum: 9000 operating hours (Dachs 2.9) Increment: Default setting: 7000 operating hours (Dachs F5.5 Gen2 and Dachs G5.5 Gen2) 9000 operating hours (Dachs 2.9) After maintenance is complete, this value must be set to the type-specific values.
Page 132 7 Commissioning BP034 -Position of buffer vessel sensor 1 Important Settings can only be entered in the service level Display and entry of the position of the buffer vessel sensor 1 as a % of the overall height, measured from the base of the buffer vessel. Adjustment range: Minimum: 0 % Maximum: 100 %...
Page 133 7 Commissioning Minimum: 0 % Maximum: 100 % Increment: Basic setting: Setting value for buffer vessel sensor SE800/SE800 HX: 23 % BP039 -Buffer outlet into heating circuit Fig.144 Buffer vessel connections SE800/ Important SE800 HX Settings can only be entered in the service level Display and entry of the position of the buffer vessel outlet to the heating circuit (heating flow) in %%, measured from the base of the buffer vessel Adjustment range:...
Page 134 7 Commissioning BP040 -Buffer charge level Operating program for selecting the basic conditions regarding the buffer charge level. The buffer charge level depends on the hydraulic integration of the buffer vessel. FWS40 FRESH HYDRO domestic If the CHP system is operated with the hot water module, the upper buffer vessel volume will be reserved for the domestic hot water generation.
Page 135 7 Commissioning Basic setting: NP019 -Third party boiler connected to buffer Important Settings can only be entered in the service level Display and entry for whether the second heat generator is connected to the buffer vessel. Possible setting values: Basic setting: NP018 –...
Page 136 7 Commissioning Increment: 1 Min Basic setting: 5 Min Step 10: Electrical demand NP196 -Selected input Important Settings can only be entered in the service level Display and selection of an input on the power PCB of the MSR3 controller for the power demand via external inputs Possible settings: None...
Page 137 7 Commissioning Step 11: Network configuration Network connection Display and setting of the network configuration (DHCP status). Possible settings: DHCP Static Basic setting: DHCP If a wired connection with dynamic IP addressing is established, the default setting can be left. If problems occur with dynamic IP addressing, diagnostics menus are available under Settings >...
Page 138 7 Commissioning Electrical demand External DHW Aux. boiler active Aux. boiler error Release module Ext. heating request Basic setting: Unused MP019 -Function digital input 2 digital input 2 . Display and entry of the function assigned to Possible settings: Unused Electrical demand External DHW Aux.
Page 139 7 Commissioning Ext. heating request Basic setting: Unused MP023 -Function of 230V input 3 230 V input 3 . Display and entry of the function assigned to Possible settings (selection from a list): Unused Electrical demand External DHW Aux. boiler active Aux.
Page 140 7 Commissioning Unused MP050 -Function of relay output 1 relay output 1 . Display and entry of the function assigned to Possible settings: Unused External pump supply External waste pump Release aux. boiler Active state Maintenance state Error state Motorized ball valve Basic setting: Unused MP051 -Function of relay output 2...
Page 141 7 Commissioning Recommendation: When cascading multiple CHP systems, the control signals of the respective electrical shut-off valves should be assigned to this outlet of the corresponding module. MP028 -Function of 0-10V / PWM output 1 Display and entry of the function assigned to 0–10V/PWM-output 1 .
Page 142 7 Commissioning Configuring domestic hot water generation Heat demand > DHW Independent domestic hot water gen Menu eration Set all of the parameters for the menu as required. Heat demand > DHW Controlling the domestic hot water Menu generation with SE DachsControl Set all of the parameters for the menu as required.
Page 143 Settings can only be entered in the service level Display and setting of the PWM signal range in %, in which the pump runs at maximum output. Important The SenerTec discharge pump (Grundfos) outputs an inverted PWM signal to identify the minimum/maximum pump capacity. Adjustment range: Minimum: 0%...
Page 144 7 Commissioning Setting value for the SenerTec discharge pump (Grundfos): 1700 L/h MP044 -Minimum flow rate for buffer discharge Fig.148 Pump curve – minimum flow rate Important Settings can only be entered in the service level Display and entry of the minimum flow rate in L/h for the buffer vessel discharge.
Page 145 7 Commissioning 7.4.2 Removing the main nozzle Warning Outflowing gas Risk of explosion and asphyxiation! Only ever carry out work on the gas train when the CHP system is switched off and the gas valve is closed. Important If a natural gas system is operated with 2K or 2LL gas, the main nozzle must be removed.
Page 146 7 Commissioning Fig.152 Removing the main nozzle 5. Remove the main nozzle from the gas pipe. Leave the nozzle in the system in case the CHP system ever needs to be restored to its as-delivered state. 6. Install the gas train and flue gas back pressure switch in the reverse order.
Page 147 7 Commissioning 7.4.4 Determining and setting the gas pressure (version with liquefied gas drive) Danger Escaping gas Risk of explosion and asphyxiation! Do not use a naked flame, do not smoke, do not operate electrical contacts or switches. Carry out work quickly and immediately close the test opening again.
Page 148 7 Commissioning For more information, see Filling and venting the cooling water circuit, page 113 7.5.2 Attaching the lid of the pump cover Fig.155 Attaching the lid of the pump cover 1. Attach the lid of the pump cover. 7.5.3 Assembling the soundproof enclosure Close the quick-release fasteners: 1.
Page 149 7 Commissioning 7.5.5 Instruction of the user Once commissioning is complete, instruct the user on the following points: 1. Safe operation of the system. 2. Position of the gas valve and the ball valves on the heating-water- side. 3. Position and operation of the operating switch. 4.
Page 150 8 Operation Operation Details on operation and setting of the system as well as an overview of the software functions available at the time of printing, can be found here: 8098.020.xxx.xx Operating and setting instructions for the MSR3 controller - Dachs Gen2 General The Energy Manager touch display on the MSR3 controller is used to operate the CHP system as well as view and enter the system parameters.
Page 151 8 Operation Normal operating mode : Outside temperature display/ if maintenance is due soon : Display of the remaining operating hoursuntil the next maintenance (4) Operating mode (7) System data display window (display depending on system components) (7.1) Display window when the buffer vessel is installed (displayed temperatures correspond to buffer vessel temperatures 1–4) (8) Display window when no buffer vessel is installed (displayed CHP system inlet )
Page 152 8 Operation Colour Status Flashing frequency Depending on the operating sta Error on an external appliance, e.g. second heat generator, Once every four seconds heating controller, etc. (CHP system ready for operation) Warning messages, e.g. outside temperature sensor, etc. (CHP system ready for operation) Maintenance is due in <...
Page 153 8 Operation Calling up a sub-menu from the menu view Fig.161 Selecting a sub-menu 1. Switch to a sub-menu by selecting a [sub-menu symbol]. The sub-menu window opens as a list. symbol points to additional sub-menus. Currently selected menus and parameters are displayed in the header.
Page 154 8 Operation Fig.165 Switch to the higher-level menu 3. Switch to higher-level menus by selecting the corresponding menu in the header. 4. Return to the menu view using Fig.166 Additional information 5. Access additional information about the parameters by selecting : Description of the parameter Five-digit identification number Symbol ID (e.g.
Page 155 8 Operation Fig.169 Entry of the symbol ID 2. Enter the symbol ID (mp01 here) using the numeric keypad. Important You can search for a unique symbol ID (five-digit, e.g. mp010) or a group of parameters by entering only the first few digits of the symbol ID (e.g.
Page 156 8 Operation Fig.173 Modifying settings 3. Modify the settings. 3.1. Modify settings using (1). 3.2. Confirm the settings using [Save] (2). 8.2.2 Service code display in the dashboard view Fig.174 Service code display in the Active service codes are displayed in the dashboard view. dashboard The display comprises: 1.
Page 157 8 Operation 8.2.5 Reset errors Important The system can only be unlocked if the corresponding error has been remedied. It can be unlocked from any authorisation level. Two error types can require unlocking: General [Locking error]: Unlock using [Reset]. [Locking error] that was triggered by the safety PCB: Unlocking using [Unlock by code].
Page 158 8 Operation Fig.179 Debug error using [Unlock by code] 2.2. Select [Unlock by code], if displayed. Important If the code is not confirmed within one minute or if an incorrect code is entered, the system will generate a new code. The Unlocking the Dachs window opens and the system creates an [Unlocking code].
Page 159 8 Operation Fig.183 Selecting 1. Select A pop-up window opens for entering the service level code. Fig.184 Entering the service level code 2. Enter the four-digit code using the numeric keypad. You do not have to confirm your entry. You can switch to the service level directly after entering the fourth digit of the code.
Page 160 8 Operation Start the CHP system Fig.187 Start the CHP system 1. Press and hold for three seconds. The automatic mode is activated. The CHP system starts up when a demand exists. Starting the CHP system in chimney sweep mode Fig.188 Switching on the CHP system 1.
Page 161 8 Operation Fig.191 Parametrising Nominal output in 3.1. Select [Nominal output in chimney mode]. chimney mode A pop-up window opens, in which the power level can be set: Minimum load = power level 1, full load = power level 3 Fig.192 Pop-up window Nominal output in 3.2.
Page 162 8 Operation Shutting down the CHP system Fig.195 Shutting down the CHP system 1. Press and hold for three seconds. The CHP system shuts down. Frost protection For systems, in which temperatures below +5 °C may occur, frost protection of the entire system must always be ensured. Suitable measures, such as, for example, heating of the installation room, shall therefore be taken.
Page 163 9 Settings Settings List of parameters All of the parameters that are required for the initial commissioning are Commissioning section. A wizard available inServicing > described in the Service Menu > Commissioning wizard guides you through the necessary steps for commissioning. A detailed description of all of the displays and parameters is available in the following document: 8098.020.xxx.xx Operating and setting instructions for the MSR3...
Page 164 9 Settings Data point Unit Brötje WGB EVO Brötje WGB EVO Brötje WGB EVO 20 i 28 i 38 i Consumer circuit 1 1859 Flow temp setp cons request °C Boiler 2250 Pump overrun time Minutes 2320 Pump modulation Boiler setpoint 2322 Pump speed min 2323 Pump speed max Configuration...
Page 165 9 Settings Tab.27 Power increase for Brötje WGB EVO 20 i supplementary heater Data point Unit Value Boiler 2452 Controller delay fan output 10.2 Burner control 9524 Required output LF 10.2 Tab.28 Power compensation for Brötje WGB EVO 28 i supplementary heater at 2 ×...
Page 166 9 Settings 9.4.2 Configuring the circulation unit (if available) Fig.197 Configuring the circulation unit 1. Set the switch-on times and operating mode (on/time/off) on the timer. 2. Set the circulation temperature on the temperature controller. Important The circulation temperature should be lower than the hot water temperature to avoid continuous operation of the circulating pump.
Page 167 Standard inspection and maintenance operations Important Maintenance work on the system is restricted to authorised experts. 10.3 Repairs Important Repairs are exclusively restricted to authorised experts. Up-to-date repair, replacement and spare parts instructions in the partner area: www.senertec.com 8098.002.010.06 - v06 - 07102019...
Page 168 11 Troubleshooting 11 Troubleshooting 11.1 Service codes 11.1.1 Structure of service codes The service code display has the following structure: Fig.198 Structure of service codes 1 Service code type (example: A = warning) 2 Service code category (example: 18 = CHP system) 3 Service code number (example: 43 = short circuit of the lube oil temperature sensor) The service codes are categorised into three types A, H and E:...
Page 169 11 Troubleshooting Service code Description A18.31 Engine flue gas temperature sensor is either shorted or measures a temperature above range A18.32 Flue gas temperature sensor at the condensing heat exchanger open A18.33 Flue gas temperature sensor at the condensing heat exchanger closed A18.34 Engine coolant temp sensor at the generator is either removed or measures a temperature below range...
Page 170 11 Troubleshooting Service code Description A18.142 Engine flue gas temperature below minimum A18.143 Engine flue gas temperature above maximum A18.144 Air intake pressure difference too high A18.145 Air intake pressure difference too high A18.160 Coolant pump supply voltage below minimum of specified voltage range A18.161 Electrical error: Coolant pump A18.162...
Page 171 11 Troubleshooting blocking Service code, type H – Tab.35 Service codes, power PCB Service code Description H18.01 Commissioning required H18.02 No valid grid protection selected in the frequency converter. H18.03 There's an active demand, but even after some waiting time the system is not able to start. H18.10 Communication timeout between frequency converter and controller unit CHP H18.11...
Page 172 11 Troubleshooting Service code Description H19.43 Reset detected H19.44 Communication timeout for control unit detected H19.45 The gas pressure switch reports that gas pressure is too low H19.47 The temperature of the safety unit is too high Tab.36 Service codes, frequency inverter Service code Description H16.01...
Page 173 11 Troubleshooting Service code Description H16.67 System stop: System error at grid monitoring detected H16.68 DC link voltage above maximum H16.69 System stop: System error in safety function detected H16.70 AC relay on grid side: contacts welded H16.71 AC relay on frequency converter side: contacts welded H16.72 Smooth DC residual current is outside the permissable range H16.73...
Page 174 11 Troubleshooting Service code Description E19.13 Circuit test of coolant temperature sensor failed E19.14 Heating water temperature above maximum E19.15 Measuring channels of heating water temperature sensor differ above deviation limit E19.16 Circuit test of heating water temperature sensor failed E19.17 Flue gas temperature above maximum E19.18...
Page 175 12 Decommissioning 12 Decommissioning 12.1 Decommissioning procedure Important Before decommissioning, the CHP system must run for at least 30 minutes in order to remove all condensate residues from the flue gas system. 12.1.1 Temporary decommissioning Duration of the downtime: One to six months. Can be done by the user.
Page 176 12 Decommissioning 12.2 Recommissioning procedure Important If the CHP system had been out of service for more than six months, recommissioning must only be carried out by an authorised expert. Important After extended downtimes, the cooling water pump and/or heating water pump may be blocked.
Page 177 13 Disposal 13 Disposal Important Removal and disposal of the system is restricted to authorised experts in accordance with local and national regulations. 13.1 Disposal/recycling 1. Follow the instructions for permanent decommissioning. 2. Uninstall the external electrical connections of the controller. 3.
Page 178 13 Disposal Important Prior to disposal, the rotor of the generator must be subjected to heat treatment at temperatures of >350 °C so that the magnets will loose magnetism. 12. Sort all of the parts and dispose of them according to the local regulations.
Page 179 The range of spare parts on offer is subject to constant changes and adjustments. Current information about spare parts: SenerTec Center Partner area of SenerTec's website: www.senertec.com Product catalogue Spare parts catalogue Important Spare parts can only be obtained via the regional SenerTec Center. 8098.002.010.06 - v06 - 07102019...
Page 180 15 Appendix 15 Appendix 8098.002.010.06 - v06 - 07102019...
Page 181 15 Appendix 8098.002.010.06 - v06 - 07102019...
Page 182 15 Appendix 8098.002.010.06 - v06 - 07102019...
Page 183 © Copyright All technical and technological information contained in these technical instructions, as well as any drawings and technical descriptions supplied, remain our property and shall not be multiplied without our prior consent in writing. Subject to alterations.
Page 184 SenerTec Kraft-Wärme-Energiesysteme GmbH Carl-Zeiss-Straße 18 • 97424 Schweinfurt, Germany Phone: +49 9721 651-0 • Fax: +49 9721 651-272 info@senertec.com • www.senertec.com 8098.002.010.06 - v06 - 07102019...

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