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Baxi Senertec Dachs Pro 20 ST, Assembly And Operation Manual

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Baxi Senertec Dachs Pro 20 ST Assembly And Operation Manual Download Page 114

14/4798.495.002

114 | Spare parts

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. 4:  Technical data - SE940 buffer vessel ....................................................................................................................................................................................................................22
Tab. 5:  Technical data - Frequency converter .................................................................................................................................................................................................................22
Tab. 6:  Accessories and communication data ................................................................................................................................................................................................................22
Tab. 7:  Electrical output depending on installation height and air pressure .....................................................................................................................................................37
Tab. 8:  Admissible water hardness according to VDI2035 .........................................................................................................................................................................................38
Tab. 9:  Gas line dimensioning ..............................................................................................................................................................................................................................................70
Tab. 10:  Exhaust gas line minimum duct dimensions.................................................................................................................................................................................................70
Tab. 11:  Exhaust gas line - DN80 package .......................................................................................................................................................................................................................71
Tab. 12:  Exhaust gas line - DN100 duct mounting .......................................................................................................................................................................................................72
Tab. 13:  Exhaust gas line - DN80 duct mounting..........................................................................................................................................................................................................72
Tab. 14:  Exhaust gas line - DN100 (DN80) external wall .............................................................................................................................................................................................73

Summary of Contents for Senertec Dachs Pro 20 ST

Page 1: ...ly In case of non compliance the warranty for any resulting damage will become void The safety instructions are particularly important Supplement to the translation of the original German operating instructions VW EcoBlue 2 0 Generation 1 2 of iav Article no 14 4798 495 002 Changes and errors reserved Assembly commissioning and operation Dachs Pro 20 ST i EN ...

Page 2: ...erved 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 The right to changes and errors is reserv...

Page 3: ...6 2 3 2 Assembly and repair 18 2 3 3 Servicing 19 3 Technical specifications 20 3 1 Technical data 20 3 1 1 Dachs Pro 20 ST overall system 20 3 1 2 Volkswagen EcoBlue 2 0 Generation 1 2 CHP unit 21 3 1 3 MSR Pro 20 ST system controller 22 3 1 4 2 SE940 buffer vessels 22 3 1 5 Frequency converter 22 3 1 6 Accessories and communication 22 3 2 Dimensions and connections 23 3 2 1 VW EcoBlue 2 0 Genera...

Page 4: ...on requirements 43 5 3 2 Ambient conditions 43 5 3 3 Installation requirements 44 5 4 Transport 45 5 4 1 Access to the installation location 45 5 4 2 CHP unit transport 45 5 4 3 SE940 buffer vessel transport to the installation location 46 5 5 Unpacking and preparations 46 5 6 Connection diagram 47 6 Installation 50 6 1 General information 50 6 2 Assembly 50 6 2 1 CHP installation 50 6 2 2 Partial...

Page 5: ...ure 94 7 4 Gas supply settings 95 7 5 Oil supply settings 95 7 6 Commissioning settings 95 7 6 1 Service level selection and start of MSR Pro 20 ST commissioning 95 7 6 2 Menu sequence during MSR Pro 20 ST commissioning 95 7 6 4 MSR Pro 20 ST settings in menu 8 1 Date time 97 7 6 3 MSR Pro 20 ST settings in menu 1 7 Dachs data 97 7 6 5 MSR Pro 20 ST settings in menu 1 8 Dachs Pro 20 ST location in...

Page 6: ...bleshooting 106 11 1 Error codes 106 11 1 1 MSR Pro 20 ST error codes 106 11 1 2 CHP error codes 107 11 2 Error memory 107 11 2 1 MSR Pro 20 ST error memory 107 11 2 2 VW EcoBlue 2 0 Generation 1 2 error memory 107 11 3 Error finding 107 12 Decommissioning 108 12 1 Decommissioning procedure 108 12 2 Recommissioning 110 13 Spare parts 110 13 1 General information 110 13 2 Spare parts overview 110 1...

Page 7: ...of the VW EcoBlue 2 0 Generation 1 2 and is a supplement to the existing VW documentation iav These instructions serve installers as a guideline and additional documentation for complete installation of the Dachs Pro 20 ST overall system For this reason some chapters refer to the original VW operating instructions iav The operator of the system may use these instructions as a source of information...

Page 8: ...cuments Attention Danger This symbol warns against the risk of personal injury 1 3 Symbols used The following symbols are used throughout the entire instructions This symbol serves as a warning and highlights general hazards necessary measures or helpful notes This symbol marks lists This symbol indicates actions to be taken 1 Numbered lists mark action steps the order of which is important The fo...

Page 9: ... PSI Buffer vessel interface 1 5 1 Responsibilities of the installer Disassembled transport as well as assembly commissioning service maintenance and repair 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 equi...

Page 10: ...ndard IEC 60364 Electrical Installation of Buildings is to be complied with i Notification and authorisation obligation Global and local regulations and TCR technical connection requirements of Electric utility distribution network operators DNO Gas suppliers GS Water authorities Chimney sweeps Building inspection Main customs office are to be observed with regard to registration obligations In ca...

Page 11: ...ment alteration repair Unsuitable operating media non admitted lubricants 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 Our Dachs products with CE mark have been developed and manufactured in accordance with the EC directives applicab...

Page 12: ...ectrical controls for household and similar use DIN EN 303 1 Heating boilers with forced draught burners DIN EN 60335 1 Household and similar electrical appliances Safety DIN 4702 Part 2 Central heating boilers test code DIN V VDE 0126 Automatic disconnection device between a generator and the public low voltage grid DIN EN 60068 2 1 2 30 Environmental testing DIN EN 61000 3 2 3 and DIN EN 61000 4...

Page 13: ...nings and described in these instructions Please note the safety warnings attached to the machine The machine may only be operated if all safety equipment is in place Hazardous areas between the unit and equipment on site have to be secured Regularly check all safety equipment warning systems and automatic shutdowns Before initial commissioning the exhaust gas system including safety equipment e g...

Page 14: ...tribution Secure de energised supply lines against reactivation Use a test device to ensure that the system has been de energised Seek medical assistance following an electric shock Attention Danger Work on the electronic equipment may only be carried out by authorised specialist staff The following danger symbols are used General danger Danger due to moving parts Harmful substances Electrical vol...

Page 15: ...ll not assume any liability for any damage resulting from this unintended use The operator shall bear the entire risk Attention Danger The unit may only be operated according to its specified intended use During system testing the Dachs Pro 20 ST may only be operated with specified modules and approved system technology Any unintended use may lead to personal injury or damage to the machine The fo...

Page 16: ...u notice the smell of exhaust gas Ensure sufficient fresh air supply Check the exhaust gas system for leakage Immediately repair any leakage In case of any physical impairment immediately contact the emergency medical assistance service Warning Danger of burns caused by hot surfaces Severe burns may be the consequence Before commencing any work wait for the machine to cool down Wear gloves Cool bu...

Page 17: ...nt before operating the unit Do not operate the machine if the flywheel cover is not installed Do not carry out any changes to the safety equipment In case of injury immediately seek medical assistance Caution Danger caused by machine noise Hearing impairment may be the consequence Wear hearing protection when working on the running machine Seek medical assistance if you notice any impairment to y...

Page 18: ...ges Cutting injuries may be the consequence Always wear gloves when carrying sharp machine cladding and housing components Seek medical assistance after initial treatment of the wound Caution Danger caused by excessive weight of machine components When working on the machine the maximum lifting loads may not be exceeded Use lifting equipment Work with others Seek medical assistance if you notice a...

Page 19: ...al burns caused by acids and alkaline solutions Chemical burns may be the consequence Wear protective glasses when transferring condensate Wear gloves when handling the condensate Condensate is to be properly disposed of Thoroughly rinse eyes with clear water Rinse off exposed skin surfaces with plenty of clear water Seek medical assistance for follow up treatment Reference Please particularly obs...

Page 20: ...Overall system general parameters Operating mode Grid parallel operation Fuel Natural gas H L according to DVGW G 260 Gas appliance type B23P Noise emission sound pressure level according to DIN 60804 50 dB A Flow temperature Dachs outlet connection max 90 C Return temperature Dachs inlet min 30 C max 70 C Ambient air temperature installation site min 5 C max 40 C Electrical connection 400 V AC 50...

Page 21: ...efficiency according to EU RL 2004 8 EC 3 94 7 Electrical unit parameters Voltage 400 V Current type 3 N Frequency 50 Hz System power factor inductive calculated min 0 95 System input current regenerative IN 29 2 A Starting current 4 50 A Air inlet unit parameters Fresh air demand for combustion min 80 kg h Ventilation opening size at installation site according to DVGW G600 min 170 cm2 Exhaust ga...

Page 22: ... actuators etc Terminals for grid connection Height Width Depth approx 75 33 5 17 5 cm Weight approx 12 kg TOTAL FILTER TF1 Hydrozyklonischer und magnetischer Leitungsfilter Einzigartige Wirkungsweise zur Entfernung aller magnetischen und nicht magnetischen Verunreinigungen Zum Einbau in vertikale und horizontale Rohrleitungen Dosierpunkt für Fernox Produkte der F Reihe In Sekundenschnelle ohne Au...

Page 23: ...onnections of VW EcoBlue 2 0 please refer to the EcoBlue 2 0 Generation 1 2 installation manual for Dachs Pro 20 ST art no 4798 522 xxx Chapter 5 2 3 2 1 VW EcoBlue 2 0 Generation 1 2 dimensions and connections 1344 mm 1 Gas connection 2 Electronic ports e g CAN 3 Frequency converter supply 4 Frequency converter return 5 Fuel connection gas connection 6 Dachs outlet connection flow to buffer 7 Dac...

Page 24: ...14 4798 495 002 24 Technical specifications Dachs Pro 20 ST 3 2 2 Buffer vessel SE940 dimensions and connections Fig 10 Dimensions Buffer vessel SE940 complete ...

Page 25: ...E940 raw part Fig 12 Buffer vessel SE940 connection 1 Rp 3 4 threaded connection filling discharge 2 Rp 1 1 4 threaded connection open 3 Locking straps for sensor elements 4 Rp 1 1 4 threaded connection open 5 Ventilation and equipotential bonding connection 6 Rp 1 1 4 threaded connection open 7 G 1 1 2 threaded connection closed reserve 8 Rp 1 1 4 threaded connection open 1178 mm 600 mm 3368 mm 6...

Page 26: ... F1 6 3 A T MSR S board 4795 652 xxx for MSR Pro 20 ST The wiring diagram illustrates the internal wiring inside the MSR Pro 20 ST not the external grid connection L1 N PE X9 Reference The detailed circuit diagram of the VW EcoBlue 2 0 Generation 1 2 is available as PDF for download in the partner area of the SenerTec website The most important sections of the detailed circuit diagram are summaris...

Page 27: ...rs Integration in any existing heating system Energy centre for power and heat Maintenance and service codes to the installer As a small scale power plant that is as powerful as it is efficient the Dachs Pro 20 ST lends itself to the supply of large apartment buildings from twelve residential units and commercial operations By means of local heat networks multiple buildings can also be supplied wi...

Page 28: ...controllers have been specially developed for the requirements of the Dachs Pro 20 ST and fulfil the following tasks Start and operation of the Dachs Pro 20 ST Feed of electrical energy into the public grid and building systems Feed of thermal energy into the heating system Monitoring of the operational parameters of the Dachs Pro 20 ST Monitoring of the electrical energy feed into the grid Monito...

Page 29: ... planning and assembly Overall system solution with building heating and simultaneous electricity generation Advanced and intelligent system control technology Simple layout for easy assembly with clear interfaces Optimum space utilisation thanks to compact design 4 3 1 Dachs Pro 20 ST overall system WMZ at NT KT boiler for condensing 2 CO sensor SE940 1 SE940 2 Frequency converter Buffer discharg...

Page 30: ...T is controlled intelligently and easily via the MSR Pro 20 ST system controller developed by SenerTec 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 4 3 2 CHP unit VW EcoBlue 2 0 Generation 1 2 4 3 3 MSR Pro 20 ST 4 3 4 2...

Page 31: ...incl connected system technology 8 MSR Pro 20 ST main switch incl connected system technology 9 ON OFF key STOP LED automatic mode LED 10 Display Control key function back up confirm down 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 When selecting a menu point the respective symbol ...

Page 32: ... display shows all available variables measurements and parameters aligned in a menu structure The menu structure can also be navigated without using the input and menu control keys by touching the touch display see below If the background lighting is switched off it can be turned on by touching the touch display or by pressing any key If no control element is pressed for two minutes the backgroun...

Page 33: ...ion LED flashes if the CHP unit is in operation The red Fault LED indicates a major fault The blue Remote control LED flashes if the CHP controller is in automatic mode Press this key to exit the current screen This key has the same function as the button in the navigation bar of the touch display Press this key to apply any entries This key has the same function as the button in the navigation ba...

Page 34: ...ffer vessels Frequency converter in control box incl electrical wiring to the CHP unit Basic installation set sensor cable harness clamps for equipotential bonding heating water filter TOTAL FILTER TF1 Fernox buffer discharge pump with shut off set and thermometer connection set for gas and heating water 2 CO sensors GSM antenna etc Operator documentation folder with the overall technical document...

Page 35: ...nts may be purchased from SenerTec GmbH as accessories for the Dachs Pro 20 ST Neutralisation unit Analogue modem option for the GSM modem for bad wireless connection Neutralisation unit For neutralisation condensate cleaning and proper discharge of condensate we recommend using the optionally available neutralisation unit for the Dachs Pro 20 ST article number 4700 517 000 Fig 24 Neutralisation b...

Page 36: ... electrical installations Fundamental principles assessment of general characteristics definitions VDE AR N 4105 Generator units with low voltage distribution networks Technical minimum requirements for generator units to be connected to and operated in parallel with low voltage distribution networks 5 Prior to installation 5 1 Installation regulations Prior to assembly and installation the constr...

Page 37: ...of the Dachs Pro 20 ST depends on the installation height as well as the air pressure at the location installation Installation height Air pressure height Electrical output 0 m 1013 mbar 19 2 kW 100 m 1000 4 mbar 18 9 kW 500 m 951 6 mbar 18 kW 1000 m 893 8 mbar 16 9 kW 1500 m 839 6 mbar 15 9 kW 2000 m 788 7 mbar 14 9 kW 2500 m 740 8 mbar 14 kW Tab 7 Electrical output depending on installation heig...

Page 38: ...ar Attention In case of incorrect treatment of heating water the warranty for any resulting damage to the unit will become void Table according to VDI 2035 Total heating output in kW Specific system volume 20 l kW 20 l kW to 50 l kW 50 l kW 50 16 8 dH 3 0 mol m3 11 2 dH 2 0 mol m3 0 11 dH 0 02 mol m3 50 to 200 11 2 dH 2 0 mol m3 8 4 dH 1 5 mol m3 0 11 dH 0 02 mol m3 200 to 600 8 4 dH 1 5 mol m3 0 ...

Page 39: ... 4751 T2 is to be observed absolute temperature of the heating vessel 100 C Maximum and minimum return temperature Admissible return temperatures in control operation are 30 C to 70 C The temperatures must be under 30 C during permanent operation Temperatures below 10 C are admissible Reference Please observe the instructions and information in the iav Documentation of VW on the EcoBlue 2 0 Genera...

Page 40: ...tribution networks Attention Danger Supply air apertures must not be obstructed Closed supply air apertures may lead to incomplete combustion as well as to the formation of carbon monoxide This may lead to poisoning In cooperation with an exhaust pipe manufacturer SenerTec has specified an appropriate pressure tight and temperature resistant exhaust gas system designed for the Dachs Pro 20 ST Proc...

Page 41: ...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 i Fig 27 Dachs Pro 20 ST space requirement front view 2 SE940 buffer vessels one behind the other 1178 mm 600 mm 3368 mm 2200 mm 600 mm powered by Volkswagen 1750 mm 990 mm 2200 mm 2132 mm Space requirements L W H approx 340 210 220 cm ...

Page 42: ... 3100 mm 600 mm 600 mm 600 mm 990 mm 600 mm 2370 mm 1170 mm 900 mm 2370 mm 990 mm 990 mm 130 mm 130 mm 130 mm 100 mm Fig 28 Dachs Pro 20 ST space requirement top view 2 SE940 buffer vessels one next to the other Space requirements L W H approx 310 240 220 cm ...

Page 43: ...heating pumps combined heat and power stations and stationary combustion engines No openings to other rooms except doors Sufficient lighting Room ventilation Frost protected Socket recommended Appropriately labelled emergency switch outside of the room The Dachs Pro 20 ST must not be operated in rooms where considerable air pollution by hydrogen halide is to be expected For example Hairdressers Pr...

Page 44: ...ro 20 ST has to be at least 170 cm i Required installation surface For correct and safe assembly as well as for subsequent maintenance the Dachs Pro 20 ST requires an installation surface of approx 7 5 m 5 3 3 Installation requirements Space requirements L W H approx 340 210 220 cm 2 SE94 buffer vessels on the broad side behind the CHP unit Space requirements L W H approx 310 240 220 cm 2 SE94 buf...

Page 45: ... installation location Note Please also note the swivel dimensions for access to the installation location i The SE940 buffer vessel is pre assembled before delivery Lifting devices are to be provided for transportation Note Lifting devices increase the space required during transportation i Reference Please observe the instructions and information in the iav Documentation of VW on the EcoBlue 2 0...

Page 46: ...red at the means of transportation at all times during transportation One buffer vessel weighs approx 170 kg without insulation When transporting the buffer vessel to the installation location suitable lifting aids are required When planning the transportation to the installation location the external dimensions are to be taken into consideration 5 5 Unpacking and preparations Inspect the packagin...

Page 47: ... scope of delivery Installation on site WMZ SenerTec scope of delivery 1 at NT KT boiler for condensing SE940 2 F1 F2 F3 F4 F6 AF F5 F7 VF RF UP The sensor positions F5 F6 and F7 are to be adapted to the local hydraulic system Fig 29 Hydraulic connection diagram Dachs Pro 20 ST Hydraulic connection diagram Dachs Pro 20 ST ...

Page 48: ...condensing NT KT boiler without pump F6 KF Condensing without pump F6 KF Boiler with pump F6 KF F5 F7 F5 F5 F7 F7 NT KT boiler without pump F6 KF Condensing without pump F6 KF Boiler with pump F6 KF F5 F7 F5 F5 F7 F7 NT KT boiler without pump F6 KF Condensing without pump F6 KF Boiler with pump F6 KF F5 F7 F5 F5 F7 F7 F5 Bypass F6 Supply flow heating circuit F7 Return flow heating circuit KF Boile...

Page 49: ...F2 Buffer vessel sensor 3 F3 Buffer vessel sensor 4 F4 X1b X1c X1d X1e X2 X2a F5 X2b F6 X2c F7 X2d X2e Prog input X2f Prog input X3 X3a X3b X3c X4 X4a X4b Pulse input 1 X4c Pulse input 2 X5 X5a PWM signal X5b X6 X6 X7 X7 CAN bus controller PCB X8 X8 230 VAC X0 DE G P1 X5a G P1 Ground blue PWM output brown MSR Pro 20 ST connection bar MSR Pro 20 ST power board MSR Pro 20 ST connection diagram Dachs...

Page 50: ...e iav Documentation of VW on the EcoBlue 2 0 Generation 1 2 are to be observed Reference For CHP installation please observe the instructions in the iav documentation of VW on EcoBlue 2 0 Generation 1 2 Chapter 6 Installation assembly in the EcoBlue 2 0 Generation 1 2 installation manual for Dachs Pro 20 ST art no 4798 522 xxx Reference For assembly of cladding components please observe the instru...

Page 51: ...d as accessories Attach the mounting bracket 8 as illustrated with the distance plate 7 using the 3 M8 20 RIPP screws and 3 M8 RIPP nuts at the controller housing Attach the hinge plate 9 as illustrated using the 4 M6 20 RIPP screws at the mounting bracket 8 6 2 3 Assembly of the MSR Pro 20 ST at the CHP Fig 34 Mounting position of the MSR Pro 20 ST at the CHP Fig 35 Mounting at the MSR Pro 20 ST ...

Page 52: ...ffer vessel The connection lines between the transfer at the respective ball valve of the heating water hose to the buffer vessel are to be provided and dimensioned on site i Note Using the slotted holes 4 for screw connection at the hinge plate of the controller mounting the MSR Pro 20 ST can be precisely aligned i 5 6 2 4 SE940 buffer vessel installation The Dachs Pro 20 ST design enables CHP in...

Page 53: ...t the air vent 5 of each buffer vessel and seal it Note The SE940 buffer vessel is delivered with assembled buffer insulation It has to be removed after transport to the installation location i Controller PCB 1 Rp 3 4 threaded connection filling discharge 2 Rp 1 1 4 threaded connection open 3 Locking straps for sensor elements 4 Rp 1 1 4 threaded connection open 5 Ventilation and equipotential bon...

Page 54: ...ed sensor cable harnesses to each buffer vessel and route the end of the cable harness upwards out of the cladding insulation of the buffer vessel Attention To prevent cracking at the outer cover at least room temperature 15 C is required during assembly Carefully attach the buffer insulation during assembly The insulation elements are supplied ready for installation Do not carry out any changes t...

Page 55: ...ponents for the respective connection out of the accessory installation set of the Dachs Pro 20 ST and have them ready for assembly i Assemble the provided frequency converter according to the manufacturer instructions on a wall near the Dachs Pro 20 ST overall system 6 2 5 Frequency converter control box assembly Reference For frequency converter connection please observe the instructions in the ...

Page 56: ... Dachs CHP inlet Supply flow heating circuit Return flow heating circuit SE940 SenerTec scope of delivery SenerTec scope of delivery Installation on site WMZ SenerTec scope of delivery 1 at NT KT boiler for condensing SE940 2 F1 F2 F3 F4 AF UP Fig 44 Hydraulic connection diagram Dachs Pro 20 ST Fig 45 Hydraulic connection diagram CHP internal ...

Page 57: ...nsing NT KT boiler without pump F6 KF Condensing without pump F6 KF Boiler with pump F6 KF F5 F7 F5 F5 F7 F7 NT KT boiler without pump F6 KF Condensing without pump F6 KF Boiler with pump F6 KF F5 F7 F5 F5 F7 F7 NT KT boiler without pump F6 KF Condensing without pump F6 KF Boiler with pump F6 KF F5 F7 F5 F5 F7 F7 F5 Bypass F6 Supply flow heating circuit F7 Return flow heating circuit KF Boiler sen...

Page 58: ... delivery for hydraulic integration Dachs inlet connection set screw connection to CHP fittings manual vents heating water hose and ball valve Dachs outlet connection set screw connection to CHP fittings 3 bar safety valve manual vents heating water hose and ball valve Magnet filter TF1 total filter Fernox Pressure gauge Buffer discharge pump with shut off set and red thermometer to be installed i...

Page 59: ... hose 1 l 2000 11 Flat packing 1 12 Ball valve G 1 x Rp 1 1 2 3 4 5 6 7 8 9 10 11 12 Fig 48 Dachs Pro 20 ST rear view Dachs outlet connection Dachs outlet transfer point Step 1 Tighten and pre assemble components 2 to 8 Step 2 Connect the pre assembled assembly including flat packing 1 to the CHP Dachs outlet Alignment to the rear Connection to the CHP Step 3 Connect the ball valve 12 to the trans...

Page 60: ... R3 4 x DN 20 18 Discharge hose DN 20 l 3000 mm Safety valve discharge In case of overpressure water escapes through the discharge of the safety valve Ensure that the escaping water is discharged safely Attention Do not connect the discharge of the safety valve rigidly to a discharge line at a wall as this leads to noise transmission Note Positions 2 to 12 can be pre assembled i Step 1 Tighten and...

Page 61: ...f set with thermometer red and shut off valve with check valve in the flow to the heating circuit according to the manufacturer instructions Positioning see hydraulic schematic diagram Install the provided shut off unit with thermometer blue in the return from the heating circuit according to the manufacturer instructions Positioning see hydraulic schematic diagram Attention For installation the a...

Page 62: ...Temperaturbereich maximale Temperatur 125 C Niedrigere Temperatur Maximaler Betriebsdruck 3 bar Maximaler Durchfluss 50 l min Magnetische Eigenschaften Neodym Magnetbaugruppe 9000 Gauß Werkstoff glasfaserverstärktes Nylon Produktverwendung Der Total Filter TF1 von Fernox ist ein revolutionärer Leitungsfilter britisches Patent Nr 0806091 5 ist beantragt Er kombiniert eine Hydrozyklonbehandlung mit ...

Page 63: ...cumentation of VW on the EcoBlue 2 0 Generation 1 2 are to be observed Fig 55 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 6 5 Solar component connection 6 6 Cooling circuit connection Note This chapter is currently not relevant for the Dachs Pro 20 ST i Note This chapter is currently not relevant for the...

Page 64: ... BK G6 0 06 10 m h Attention Gas installation is to be implemented in accordance with the technical regulations of the local gas suppliers and the TRGI TRF and may only be carried out by specialist staff with respective authorisation for working with gas Note Installation may require a GS 10 Type M gas flow monitor Local regulations apply Regarding energy tax exemption a gas meter or thermal energ...

Page 65: ...o not rely on your own sense of smell and consult other persons If the cause of the smell of gas cannot be identified although all gas fixtures are closed the gas supplier has to be notified immediately Even a faint smell of gas the cause of which cannot be determined has to be reported to the gas supplier If a smell of gas comes from rooms that are not easily accessible the police or fire departm...

Page 66: ... Pro 20 ST for connection of the gas hose Leakage check at gas lines Tighten the provided fire safety valve including shut off valve the 3 4 plug has to be removed first at the end of on site gas line and carry out a pressure test of the gas line with the prescribed test pressure according to TRGI Attention Observe the flow direction of the gas filter 1 Gas filter 2 Bracket R 3 4 x Rp 3 4 3 Pipe d...

Page 67: ...n installation set Vent the gas line Attention The gas hose including the internal gas duct may only be vented under supervision Open the gas valve and ensure gas supply to the Dachs Pro 20 ST Vent the gas line according to TRGI 8 1 1 1 3 After venting close the vent valve at the gas fitting Finally check the tightness by means of leak spray or a leak detection device to check the entire gas duct ...

Page 68: ...national regulations have to be complied with The combustion air is taken in via the air intake duct and supplied to the gas mixer via an air duct with air filter Fresh air is added via an intake in the housing The interface to the exhaust gas outlet is to be realised at the top edge of the CHP using an external DN 50 thread It has to be ensured via the exhaust gas system that the maximum exhaust ...

Page 69: ...s the siphon of the condensate trap has to be filled with water 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 specified an appropriate pressure tight and temperature resistant exhaust gas system designed for the Dachs Pro 20 ST Sufficient experience is only available fo...

Page 70: ... up to 200 C with suitable and approved aluminium lined mineral wool 30 mm thick i 6 9 2 Exhaust gas line dimensioning base Number of Dachs Pro 20 ST units per exhaust gas line Number of possible deflections Dimensioning of the horizontal exhaust gas line unit up to duct Dimensioning of the vertical exhaust gas line duct assembly According to DIN EN 13384 1 Potential diameters of the exhaust gas s...

Page 71: ...xhaust gas line horizontal No Designation 1 T piece for deflection with 2 connection 2 Capacitor 3 Mechanical vibration absorber 4 Pipe element 1000 mm 5 Pipe element 500 mm 6 Assembly clamp fitting 7 Ceramax 150 g sealing paste 8 Silencer AGG 760 50 9 Siphon 200 x 18 x 1 mm 10 T piece with bolt 11 Crimping cover up to 200 C 12 Floor ceiling bracket 13 Compensation element 14 Panel sheets 90 ...

Page 72: ...0 mm with threaded rod 3 Pipe element 1000 mm 80 mm lug 4 Pipe element 1000 mm 80 mm 5 Spacer clips 80 mm 6 Rain collar end element 80 mm 7 Shaft access cover 340 340 80 mm 6 9 4 Exhaust gas line DN100 DN80 duct mounting 6 7 5 4 3 1 2 9 8 Depending on the construction layout additional components may be required for DN80 as construction kit Connection line Manufacturer Raab Type EW Alkon Tab 12 Ex...

Page 73: ...Wall rosette 6 9 5 Exhaust gas line DN100 DN80 external wall Tab 14 Exhaust gas line DN100 DN80 external wall Fig 63 Schematic diagram DN100 DN80 external wall exhaust gas line vertical 1 4 6 5 3 7 2 Wall panel as accessory Manufacturer Raab Type DW Alkon For wall mountings please note Every 4 meters wall fittings are to be installed 3 meters of free overhang with static clamp fitting 1 5 meters o...

Page 74: ... DIN VDE 0100 551 and VDE AR N 4105 the grid connection must not be implemented at an end electrical circuit The connection has to be fixed no plug e g in a power distribution panel sub distribution and via an isolating unit with a minimum contact clearance of 3 mm e g fuse LS switch Other consumer loads may not be branched off at the grid connection terminals Attention Electric installation as we...

Page 75: ...O CONNECTION DIAGRAM Controller MSR Pro 20 ST MSR Pro 20 ST controller min 5 x 10 mm2 Cu min 5 x 10 mm2 Cu e g D0 circuit breaker Neozed 50gG CHP Electricity meter CHP Electricity meter e g D0 circuit breaker Neozed 50gG powered by Volkswagen powered by Volkswagen Dachs Pro 20 ST Dachs Pro 20 ST RCD I n 30 mA RCD I n 30 mA Z1 Meter for consumption and supply bidirectional meter Supply Metering of ...

Page 76: ...bration regulations and must be equipped with a non return device There are different types of meters SenerTec recommends mechanical meters as these are calibrated for 16 years A technical solution would be a calibrated bus bar meter in an electrical circuit distribution i This is the latest information at time of printing Attention The installation position of the meter has to be coordinated with...

Page 77: ... of VW 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 VW EcoBlue 2 0 Generation 1 2 installation manual for Dachs Pro 20 ST art no 4798 522 xxx Circuit diagram extracts VW EcoBlue 2 0 Generation 1 2 art no 4798 537 xxx The detailed circuit...

Page 78: ... to the CHP according to the iav documentation of VW Connect the cable harness of the frequency converter to the CHP according to the iav documentation of VW Connect the cable harness of the frequency converter to the frequency converter according to the iav documentation of VW Reference For frequency converter connection please observe the supplementary instructions and information in the iav Doc...

Page 79: ... supply Insert the grid supply from the outside into the controller Secure the stepped nipple inside the controller housing Connect the L N and PE ports of the supply to the spring type terminals at the X0 connection bar Secure the grid supply with 2 cable ties at the strain relief rail Reference For CO sensor assembly and connection to the CHP please observe the instructions and information in th...

Page 80: ...vessel sensor 4 F4 X1b X1c X1d X1e X2 X2a F5 X2b F6 X2c F7 X2d X2e Prog input X2f Prog input X3 X3a X3b X3c X4 X4a X4b Pulse input 1 X4c Pulse input 2 X5 X5a PWM signal X5b X6 X6 X7 X7 CAN bus controller PCB X8 X8 230 VAC X0 G P1 X5a G P1 Ground blue PWM output brown MSR Pro 20 ST connection bar MSR Pro 20 ST power board Connection bar Connection bar Connection bar Plug designation Plug designatio...

Page 81: ...onnectors Sensor F1 connection to X1b Sensor F2 connection to X1c Sensor F3 connection to X1d Sensor F4 connection to X1e Secure the sensor lines with cable ties at the bottom stress relief rail of the MSR Pro 20 ST Fig 77 External sensor AF Fig 78 External sensor AF connection Fig 79 F1 F4 sensor connection From experience the north or north west wall are suitable for installation oftheoutsidetem...

Page 82: ...liens of the sensor cable harnesses to the respective X2a X2b X2c connectors Sensor F5 connection to X2a Sensor F6 connection to X2b Sensor F7 connection to X2c Secure the sensor lines with cable ties at the bottom stress relief rail of the MSR Pro 20 ST Fig 80 Schematic diagram Sensor cable harness extension Distribution box to be provided for extension F3 and F4 connection to X1d and X1e On site...

Page 83: ...nnection cable length in scope of delivery 2 m Note The connection lines in the scope of delivery have a length of 2 m and may need to be extended Refer to the schematic diagram i PWM signal L N PE Details X5a connector PWM signal buffer discharge pump X9 X9a X9b X10 X10a X10b X10c X10d X11 X11a X11b X12 X12a X12b X13 X13a X13b X14 X14a X14b X14c X14d X15 X15 Art no 2063 001 000 Changes and errors...

Page 84: ...cure the cable harness as illustrated with two cable ties and the rubber lug at the controller housing Secure the connection line with 2 cable ties at the strain relief rail Route the cable harness to the CHP and connect it to the E Module as illustrated Note The communication between CHP and MSR Pro 20 ST is realised via a CAN bus connection i Fig 86 CAN bus cable harness Fig 87 CAN connection in...

Page 85: ...connection to PSI CAN CHP E Module X8 3 single conductor black bk X8 4 single conductor brown bn X8 5 single conductor white wh 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 For example VW EcoBlue 2 0 Generation 1 2 installation manual for Dachs Pro 20 ST ar...

Page 86: ...ontroller Attach the provided slotted bushing in the controller housing Route the connection line to the controller PCB as illustrated Connect the connector to the GSM modem adapter Secure the connection line as illustrated with two cable ties and the rubber lug at the controller housing Position the GSM antenna in the centre on top of the controller housing Main equipotential bonding rail Equipot...

Page 87: ...n site The heating emergency switch has to be installed outside of the installation room When the heating emergency switch is pressed CHP operation as well as all energy supplies to the CHP via gas line generator and ignition are disconnected The control system of the unit remains operational and the respective components remain live After resetting the heating emergency switch the unit starts aut...

Page 88: ...For hydraulic installations and venting at the Dachs Pro 20 ST please observe the instructions and information in the iav Documentation of VW on the EcoBlue 2 0 Generation 1 2 in particular Fig 95 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 Filling possibility at each SE940 buffer vessel KFE valve behind...

Page 89: ...v documentation of VW on EcoBlue 2 0 Generation 1 2 Chapter 6 2 Basic module installation in the EcoBlue 2 0 Generation 1 2 installation manual for Dachs Pro 20 ST art no 4798 522 xxx Fig 96 CHP cladding frame components 4 3 5 7 8 6 Rear wall Front side main switch Note The top rear cladding 3 has only been set on loosely for MSR Pro 20 ST controller assembly and partially secured after controller...

Page 90: ...irement Install the pre fuses and check the connection in the main and sub distribution Prior to commissioning the following points have to be observed A leakage test according to TRGI has to be carried out at the gas line The exhaust gas system has to be approved by the responsible master chimney sweep i e the authority responsible for inspecting gas installations in the case of shared chimneys T...

Page 91: ...external sensors F1 F7 18 Has the GSM antenna in the MSR Pro 20 ST been connected and positioned on the controller housing 19 Has the buffer discharge pump been correctly connected in the MSR Pro 20 ST voltage supply and PWM signal 20 Has the frequency converter been correctly connected to the CHP according to iav documentation of VW 21 Have the CO sensors been correctly connected to the CHP accor...

Page 92: ... case of defect or misuse Monitoring of the minimum admissible operating pressure for fuel supply 47 Has a leakage test been carried out 48 Has an external reinforced hose been installed for vibration decoupling to the external gas connection Exhaust gas system 49 Has the exhaust gas system been designed according to applicable regulations 50 If required has a condensate discharge been installed 5...

Page 93: ...___ Signature Reference Please observe the supplementary instructions and information in the iav Documentation of VW on the EcoBlue 2 0 Generation 1 2 Chapters 11 1 and 11 2 in particular Note After commissioning the manufacturer label is to be installed at the Dachs Pro 20 ST overall system By attaching the manufacturer label adhesive label to the housing of the CHP unit the installer confirms pr...

Page 94: ...ription of the settings to be made refer to chapter 7 6 Commissioning settings Press the illustrated button until the green LED next to the AUTOMATIC symbol flashes top LED The Dachs is then operational Not before all settings have been made the Dachs can be put into operation by pressing the ON OFF key at the control panel Note In case of any irregularities during the functional check after commi...

Page 95: ... entering the password with Set the first character of the password by pressing or and switch to the next character or confirm the entry by pressing Proceed in the same way for additional characters Start of commissioning Confirm the password by pressing to open menu 11 06 Select menu item 11 6 2 and open the commissioning menu by pressing Press or to browse to menu Date time 11 6 2 1 and select i...

Page 96: ... open the commissioning menu Select menu 11 6 with change to password Confirm with change to menu 1 7 Confirm with change to menu 8 1 Press after entering the last value to go back to commissioning and press to change to 11 6 2 3 location info Press after entering the time to go back to commissioning and press to change to 11 6 2 2 Dachs data Confirm with change to menu 1 8 Press after entering th...

Page 97: ...ttings in menu 8 1 Date time 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 7 6 5 MSR Pro 20 ST settings in menu 1 8 Dachs Pro 20 ST location information Menu 1 8 1 Name 1 Enter name 1 A maximum of 20 characters can be entered Menu 1 8 2 Name 2 Enter name 2 A maximum of 20 characters can be entered Menu 1 8 3 Street Enter the street A maximum o...

Page 98: ...um of 2 15 characters can be entered The first two digits of the country code 00 are already set by default Only the last two digits of the country code have to be entered For example 49 for Germany When entering the telephone number the first digit 0 is not required due to the country code Menu 11 2 1 Service tel no 2 Enter the second service phone number A maximum of 2 15 characters can be enter...

Page 99: ...rol P1 power at mot V3 control 100 Confirm commissioning confirm 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 7 7 Finishing work 7 7 1 Commissioning protoco...

Page 100: ...ration 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 8 1 General information 8 2 Control panel Fig 97 MSR Pro 20 ST control panel 1 Menu bar 2 Control keys 3 Generator LED 4 Fault clearance key and errorLED 5 Chimney sweep key 6 Infrared interface 7 MSR Pro 20 ST fuse 6 3 A T incl connected system tech...

Page 101: ...s with different access rights In order of the extended access rights these levels are The operator level The extended operator level The service level 1 Operating data 2 Heat demand 1 01 Run hours since start 1 03 Operating hours 1 04 Starts 1 07 Dachs Pro 20 ST data 1 08 Dachs Pro 20 ST location information 1 09 Pulse input 1 X4b 1 10 Pulse input 2 X4c 1 11 Operating data on 31 12 1 12 Show late...

Page 102: ... 03 Service codes sent 7 04 Test status 7 05 GSM diagnostics radio 8 01 Date time 8 03 Display brightness 8 04 Display contrast 10 01 Data of last S Code 10 02 Service codes system 10 03 Dachs service codes 11 01 Maintenance 11 02 Service tel no 11 03 Config in output 11 04 Operator level 11 05 Operator advanced level 11 06 Service level 11 07 Master level 9 01 Generator power 9 02 Voltage L1 9 03...

Page 103: ... Dachs to STOP bottom LED flashing 2 Switch off the CHP unit at the main switch 3 Switch off the MSR Pro 20 ST at the main switch For systems in which temperatures of less than 5 C might occur the overall system must be protected from frost at all times This can be done by taking suitable measures during installation like filling glycol into the heating system or by providing appropriate heating 8...

Page 104: ... Commissioning settings in this manual Reference For a detailed description of the unit parameter settings refer to MSR Pro 20 ST operation and configuration instructions art no 4798 494 xxx 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 Note The displays and access rights for cha...

Page 105: ...ntenance is indicated by the Dachs Pro 20 ST in various ways Maintenance signal on the MSR Pro 20 ST display Maintenance signal in the CHP unit control panel After proper assembly the assembly instructions and further documents are provided in the service pocket at the controller Check whether the check list in the assembly instructions has been fully completed and signed If the check list is miss...

Page 106: ... observe the supplementary instructions and information in the iav Documentation of VW on the EcoBlue 2 0 Generation 1 2 in particular 11 Troubleshooting 11 1 Error codes 11 1 1 MSR Pro 20 ST error codes At the MSR Pro 20 ST controller of the Dachs Pro 20 ST errors are indicated as service codes on the MSR Pro 20 ST display and by a red service code LED Depending on the service code there is a def...

Page 107: ...Data of last S Code 10 2 Service codes system 10 3 Dachs service codes 11 2 Error memory 11 2 1 MSR Pro 20 ST error memory 11 2 2 VW EcoBlue 2 0 Generation 1 2 error memory 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 Reference Please observe the supplementary instructions an...

Page 108: ... 4 Take appropriate frost protection measures in the installation room Attention Ensure that the Dachs and the heating system are not subjected to frost or ensure appropriate protection measures like filling the system with antifreeze if a frost free condition cannot be guaranteed Decommissioning is distinguished by the following types Temporary decommissioning Duration of decommissioning 1 to max...

Page 109: ...h 2 Disconnect the fuses and secure them against reconnection Recommendation Disconnect the fuses from the terminals 3 Disassemble the electrical installation at the MSR Pro 20 ST and the CHP unit 4 Close the shut off valve at the gas line and secure it against reopening Close the connections after disassembling the line 5 Extract the lubrication oil via suction and fill the operating media into s...

Page 110: ...ay become loose at recommissioning and affect the valve seals In this case it may be not possible to start the engine i 1 Open the heating water feed and return 2 Open the shut off valve at the gas line 3 Switch on the Dachs Pro 20 ST Switch on the CHP at the main switch Switch on the MSR Pro 20 ST at the main switch 4 Start the Dachs Pro 20 ST 13 Spare parts 13 1 General information The spare par...

Page 111: ...and authorised specialists only Disclaimer of warranty In particular for damage which cannot be directly or indirectly traced back to the manufacturer e g misuse or in the event of Incorrect planning and assembly e g fuel supply hydraulic and electrical connections exhaust gas evacuation Commissioning servicing maintenance and repair by buyers or third parties Natural wear and tear Incorrect impro...

Page 112: ...ce requirement front view 2 SE940 buffer vessels one behind the other 41 Fig 28 Dachs Pro 20 ST space requirement top view 2 SE940 buffer vessels one next to the other 42 Fig 29 Hydraulic connection diagram Dachs Pro 20 ST 47 Fig 30 Variants of hydraulic integration according to the installation on site 48 Fig 31 Electrical connection diagram MSR Pro 20 ST 49 Fig 32 X1 grid connection of the CHP u...

Page 113: ...78 Fig 70 Frequency converter cable harness 78 Fig 71 Connection of the frequency converter cable harness to the CHP 78 Fig 72 Frequency converter control cabinet 78 Fig 75 Grid connection at the MSR Pro 20 ST 79 Fig 76 X0 grid connection in the MSR Pro 20 ST 79 Fig 73 CO sensors 79 Fig 74 CO sensor positioning 79 Fig 77 External sensor AF 81 Fig 78 External sensor AF connection 81 Fig 79 F1 F4 se...

Page 114: ...el 22 Tab 5 Technical data Frequency converter 22 Tab 6 Accessories and communication data 22 Tab 7 Electrical output depending on installation height and air pressure 37 Tab 8 Admissible water hardness according to VDI2035 38 Tab 9 Gas line dimensioning 70 Tab 10 Exhaust gas line minimum duct dimensions 70 Tab 11 Exhaust gas line DN80 package 71 Tab 12 Exhaust gas line DN100 duct mounting 72 Tab ...

Page 115: ...14 4798 495 002 Spare parts 115 Dachs Pro 20 ST Notes ...

Page 116: ...14 4798 495 002 116 Spare parts Dachs Pro 20 ST Notes ...

Page 117: ...14 4798 495 002 Spare parts 117 Dachs Pro 20 ST Notes ...

Page 118: ...Dachs Pro 20 ST Baxi Commercial Wood Lane Erdington Birmingham B24 9QP ...

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