Viessmann BM-190/238 Assembly Instructions Manual Download

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5780045 GB

10/2017

Please store this document in a safe place.

Assembly instructions

for the specialist

VITOBLOC 200

model BM-190/238

Part no. 7639779

Block-type thermal power plant for biogas operation

Summary of Contents for BM-190/238

Page 1: ...5780045 GB 10 2017 Please store this document in a safe place Assembly instructions for the specialist VITOBLOC 200 model BM 190 238 Part no 7639779 Block type thermal power plant for biogas operation ...

Page 2: ...ipment as intended and complying with the assembly instructions operating instructions and service instructions Only authorised professionals should service and repair it Only operate this technical equipment in the combinations and with the accessories and replacement parts referred to in the assembly instructions operating instructions and service instructions Only use other combinations accesso...

Page 3: ...hts and finishes 13 3 Transportation 14 3 1 Unload by fork truck 14 3 2 Block type thermal power plant storage conditions 14 3 3 Cranage 15 3 4 Setting up 16 3 5 Removing the transport securing devices 17 4 Installation 18 4 1 Qualification of personnel 18 4 2 Scope of delivery 18 4 3 Requirements on the technical room 19 4 4 Peripheral connections of the cogeneration module flowchart 20 4 5 Perip...

Page 4: ...INSTRUCTION The construction and operation of the block type thermal power plant and the work package in relation with it are based on the following Statutory regulations Technical directives documenting the state of the art in engineering EN DIN VDE VDI DVGW directives emission control act Accident prevention regulations of the professional associations and the Factory Act Regulations of the loca...

Page 5: ...age Mechanical damage at the alternator Engine Engine block Oil pan Cooling water lines Touching the engine when it is hot Opening of shutoff or drain valves Risk of burning Scalding due to outflow of cooling water Oil test fitting quick acting closure Actuating the ball closure Scalding due to outflow of engine oil Rotating parts of the engine Touching Risk of damage Ignition Ignition coils Ignit...

Page 6: ... Hazard combinations Hazards in connection with the site environment Hazards due to accidental starting and unexpected cranking Hazards due to shutting down emergency stop Hazards due to changes of rotational speed Hazards due to power failure Hazards due to failure of the control loop Hazards due to fracture during operation 1 1 1 1 1 1 1 1 High remaining hazard Ignoring safety instructions can b...

Page 7: ...watch out for leaks when carrying out service work on the open machine and to ensure that the sound absorbing hood is closed during operation Hazards due to breakage in operation Particular care is required when the CGP module is lifted by crane observe the crane hook and the transport lugs Breakage can cause leaks in overheated components Hot engine oil heating or cooling water can gush out For e...

Page 8: ...nstallations national annexes VDE 0105 100 Operation of electrical installations Part 100 General requirements DIN EN 50178 VDE 0160 Electronic equipment for operation in power installations VDE 0100 Construction of power installations of nominal voltages up to 1000 V DIN EN 50156 1 VDE 0116 1 Electrical equipment for furnaces and ancillary equipment Part 1 Requirements for application design and ...

Page 9: ...ncy low temperature 2 2 2 9 3 2 total efficiency 85 1 87 8 90 0 Energy generation electrical energy three phase voltage V 400 frequency Hz 50 internal electrical energy requirements5 kW 2 8 heat energy heat HT forward return temperature C 85 65 heat energy heat NT forward return temperature C 40 42 7 Fuels and filling amounts quality of fuel lubricating oil cooling water and heating water refer to...

Page 10: ...ure max C 180 1 output data in accordance with ISO 3046 Part 1 at 1 000 mbar of air pressure air temperature 25 C relative humidity 30 and cos φ 1 All other data for the module apply to parallel operation data for other installation conditions on request 2 The output power display is geared towards the generator counting arrow system not the consumer counting arrow system That means that the outpu...

Page 11: ...ooling water flow rate m h 20 Exhaust heat exchanger Heat output Tolerance 8 kW 123 Exhaust temperature Inlet outlet C approx 520 150 Cooling water temperature Inlet outlet C 83 9 88 3 Pressure loss Exhaust end mbar 10 Pipe material 1 4571 Exhaust head material Inlet 1 4828 Outlet 1 4571 Water jacket pipe material ST 50 Mixture cooling high temperature turbo charger Heat output Tolerance 8 kW 17 C...

Page 12: ...imensioning as per customer s conditions Extended plant design with stand by operation network measuring voltage in front of the system tie circuit breaker X1 terminal 7 8 9 N PE Ölflex 5 x 1 5 mm system tie circuit breaker feedback is on signal from the NSHV or from the system tie field X1 terminal 12 13 Ölflex 5 x 1 5 mm system tie circuit breaker feedback is off signal from the NSHV or from the...

Page 13: ...xhaust outlet Flange EN 1092 1 DN 150 PN 10 KO Condensed water discharge Pipe DIN EN 10220 Ø 22 x 2 0 GAS Gas inlet Flange EN 1092 1 DN 65 PN 16 2 HV HR Heating flow return Flange EN 1092 1 DN 65 PN 16 GV GR2 Mixture cooler flow return Pipe fitting DIN EN 10226 R 1 external thread AL Extract outlet Flange 580 x 580 P20 1 cogeneration modules Vitobloc 200 BM 190 238 have optional noise covers and e...

Page 14: ...ork truck CAUTION Use suitable devices fixtures to avoid damage to the cogeneration module during unloading and transportation by fork truck Fig 2 Unloading by fork truck 3 2 Block type thermal power plant storage conditions The block type thermal power plant should be transported and stored protected from moisture max rel humidity 70 Do not expose the cogeneration module to air with dust or halog...

Page 15: ... fitted at the sides of the base frame Fig 3 Observe the minimum frame dimensions CAUTION Use suitable devices fixtures to prevent damage to the cogeneration module during transportation by crane Do not attach the rope pull at or otherwise subject projecting parts to load CAUTION It should only be put into place with a crane and ropes with a mounted sound absorbing hood because it might otherwise ...

Page 16: ...rne noise CAUTION Make sure that the foundation base has the required height 150 mm for drainage of condensed water H W L Fig 4 block type thermal power plant with base Switching cabinet side 3600 1600 Fig 5 Locating plan for sylomer strips Minimum base size for Vitobloc 200 BM 190 238 L 3 600 mm W 1 600 mm H 150 mm The scope of delivery includes 7 green SR 55 sylomer strips 1 500 x 100 x 50 mm bl...

Page 17: ...mm Tab 7 Minimum distances in the technical room 3 5 Removing the transport securing devices Remove the packaging and send it for recycling Remove four transport securing devices at the elastic supports of the engine and alternator Fig 7 Fig 7 Remove four transport securing devices at the elastic supports of the engine and alternator CAUTION Always remount the transport locking device when the blo...

Page 18: ...by a specialist for gas systems Specialized personnel according to VDMA 24186 0 are personnel mechanic foreman technician engineer with the required vocational qualification Vocational qualification includes at least complete training in an industrial or trade occupation or higher level education in building services All work shall comply with the applicable technical rules and the requirements of...

Page 19: ...to an absolute minimum and documented at the time of start up The room where it will be erected should be made pursuant to the applicable firing directive and applicable construction law ordinances regulations We recommend integrating the CHP module into the fire protection strategy for safe operation To increase workplace safety for the operator we recommend that you install a CO monitor in the i...

Page 20: ... cooling water pump 24 membrane expansion unit 25 cooling water heat exchanger 26 dirt trap 27 shut off valve 28 hot water filling and draining tap 29 bleed valve 31 exhaust gas heat exchanger 32 sound absorber 33 condensate water output KO 34 exhaust gas output AGA 35 catalyst 36 neutralization 41 lambda regulating valve 42 magnetic valve 43 zero pressure regulator 44 gas connection GAS 45 gas fi...

Page 21: ...N To ensure proper cooling of the module the inlet and outlet air openings must not be closed The fresh air must not contain dust halogens etc and must not be warm The fresh air has to be free of dust should not contain any halogens such as chlorine or fluorine and may not be heated up Extract air duct The extract air fan in the fan box of each cogeneration module conveys the air through a custome...

Page 22: ...To ensure proper operation of the block type thermal power plant a constant and sufficient flow of heating water must be maintained The return temperature to the block type thermal power plant heating water inlet temperature should not normally be more than 65 C The combined heat and power CHP unit must be protected against silting from the existing heating system It is recommended that you instal...

Page 23: ...ply the shutoff devices with 24 V direct voltage battery supply Connect the block type thermal power plant to the available gas supply system by a branch line NOTE It is recommended to choose a larger dimension for the block type thermal power plant connection lines so they can serve as gas buffer This can compensate pressure fluctuations if boilers are fired If the available gas pressure is not a...

Page 24: ...NOTE Special provisions should be observed if several modules are connected via manifold Install the following in the exhaust gas line Mating flange to the block type thermal power plant outlet flange to correspond to connection dimensions in chapter 2 Axial expansion joint with stainless steel bellows for isolation of structure borne noise and compensation of heat stress fit directly onto on the ...

Page 25: ...haust gas line The exhaust gas condensate is substantially acidic and has a pH value of 2 to 3 This is why the condensate may only be discharged into the discharge channels and never outwards in conformity with the DWA set of rules for the DWA A 251 worksheet on Condensates from Condensing Boilers and in consultation with the local waste water office For environmental reasons it is advisable to us...

Page 26: ... cable in cable conduits outside the cable ducts Do not route cables over objects with sharp edges Do not kink the cable Do not pull at the cable Install the cable to avoid trip hazard Install the cable to exclude damage of the cable 4 10 2 Connection to buyer s consumers Feed the power cable incl LAN cable on site service through the cable guide on the top of the control cabinet Electrical loads ...

Page 27: ...es The lock is open in the initial position the dot marks on the lock are 180 to one another Lock the sound absorbing hood and turn the spanner 90 the dot marks on the lock are now 90 to one another Press on the sound absorbing hood while turning the spanner another 90 the dot marks on the lock are now opposite one another Opening Raise the sound hood plate and press against the corresponding fram...

Page 28: ..._________________________ _______________________________________ Contact _______________________________________ Telephone Fax _______________________________________ Email _______________________________________ CHP unit type _______________________________________ Serial number on type plate next to fan _______________________________________ System location ____________________________________...

Page 29: ...e injection of the generated electricity parallel network operation yes _________________ Confirmation of the installation specialist Page 3 3 Heating system Comments 3 1 The heating water connection and the heating water pump are of sufficient dimension as specified in the documentation yes _________________ 3 2 The hydraulics of the heating system is ready for start up i e filled with a thermal ...

Page 30: ...ype thermal power plant is secure The integration of the gas equipment complies with European norms and directives and with the planning and installation instructions The gas flow pressure complies with the technical requirements yes _________________ 6 2 The installation of the gas pipeline is complete expansion joint gas filter of adequate size connected ventilated and leak tested Ensure voltage...

Page 31: ... We hereby confirm the proper installation of all the gas pipelines for the above project We have executed the installation on the basis of applicable norms and directives e g no bending of expansion joints and tested it for leaks Gas specialist firm Date Stamp Signature We hereby confirm the proper installation and testing of the exhaust gas system of the installed cogeneration module for the abo...

Page 32: ...rical installation firm Name _____________________________ Tel No ___________________ Process control equipment instrumentation Name _____________________________ Tel No ___________________ Planning office Name _____________________________ Tel No ___________________ Owner Name _____________________________ Tel No ___________________ Proposed system maintenance HVAC firm Name _____________________...

Page 33: ...after mains supply yes no Emergency generation service yes no Under load tap changer available yes no Number of load taps Parallel network operation Manual module actuation yes no Module actuation by internal clearance signal yes no Module actuation by reservoir level control yes no Module actuation by Viessmann process control system MMM yes no Module actuation by customer s DDC system yes no Eme...

Page 34: ...Declaration of conformity according to Machine Directive 34 Assembly instructions VITOBLOC 200 BM 190 238 5780045 GB 6 Declaration of conformity according to Machine Directive ...

Page 35: ...Notes VITOBLOC 200 BM 190 238 Assembly instructions 35 5780045 GB ...

Page 36: ...36 5780045 GB Subject to change without notice Viessmann Werke GmbH Co KG D 35107 Allendorf phone 49 6452 70 0 fax 49 6452 70 2780 www viessmann de ...

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