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Viessmann EM-363/498, Technical Description

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 Legal Notice 

2 

ESS Energie Systeme & Service GmbH 

VITOBLOC 200 EM-401/549 / EM-363/498

 

5414 733   0

9/20

09 

This equipment satisfies the basic 
requirements of the appropriate 
standards and directives. Its conformity 
has been demonstrated. These 
documents and the original conformity 
declaration are stored on the premises 
of the manufacturer.  

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

Important general instructions for application  

Only use this technical equipment as intended and in 
compliance 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, 
accessories and wear parts if they are explicitly 
intended for the specific application and do not impair 
the performance features or safety requirements. 

Subject to change without notice. 

This is a component of the original operating 
instructions. 
Figures, steps in certain functions and technical data 
may differ slightly due to constant advancements.  

Updating the documentation 

Please get in contact with us if you have suggestions 
for improvement or have discovered any irregularities. 

 
 
 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

 

Summary of Contents for EM-363/498

Page 1: ... as much as 96 Primary energy savings 27 5 VITOBLOC 200 Block type thermal power plant for natural gas operation in accordance with the requirements of the EU Gas Equipment Directive and EU Machine Directive model EM 401 549 Electrical power 401 kW Thermal output 549 26 kW Fuel input 1 053 kW model EM 363 498 Electrical power 363 kW Thermal output 498 kW Fuel input 960 kW ...

Page 2: ...essionals 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 accessories and wear parts if they are explicitly intended for the specific application and do not impair the performance features or safet...

Page 3: ...st gas purification system 12 2 8 Lubricating oil supply system 12 2 9 OPTIONAL Sound insulation hood and exhaust ventilator cowl 12 2 10 Series production accessories 13 2 11 Monitoring equipment 13 2 12 Switching cabinet 16 2 13 Check list for stand by operation 18 3 Service and maintenance 19 3 1 Service and maintenance list 20 4 Technical Data 22 4 1 Operating parameters for the cogeneration m...

Page 4: ...il system with storage tank dimensioned for 1 service interval Fault memory for recording complete chains of faults with operating parameters for systematic fault analysis Starter system with charger and no service shakeproof batteries Remote action system with transfer clamps for the operational and centralised fault indication via potential free contacts to building process control technique pro...

Page 5: ...factor ENEV 2007 The primary energy factor abbreviated fp gives the ratio of primary energy used to final energy released and this factor not only includes energy transformation but also transport In other words that means that the lower the primary energy factor is the better it is for ascertaining the annual primary energy needs The fewer resources utilised by the form of energy used and its tra...

Page 6: ...t via this rotating movement with a synchronous alternator The thermal collectable energy comes from the combustion process in the spark ignition engine It is distributed to the exhaust gas heat the collector pipe the engine block and engine lubricating oil and it is used for heating water The entire efficiency of a cogeneration module results from the total of the electrical and thermal collectab...

Page 7: ...ium molybdenum steel in the forging die and they are made slanted The pistons are made of a low expansion aluminium alloy The form of the piston crown creates an open combustion chamber Three grooves are embedded into the piston crown for the piston rings The camshaft is made of a cast iron chromium alloy with hardened cams and lodged at the ends and between the pistons It is arranged lying low in...

Page 8: ...age relay and the rotating motions of the electrical starter engine can overlap in any conceivable tracking situation The free wheel overrunning clutch ensures that the pinion is entrained if the rotor shaft is driving although the connection between the pinion and the rotor shaft is loosened when the pinion runs more quickly overrunning Components The engine starter is equipped with an engage rel...

Page 9: ...t a current Sealing control unit It consists of monitoring electronics for installation in the switching cabinet of the cogeneration module and a pressure guard It is suited to gas regulator lanes with two safety valves and it checks the safety function of the valves before starting or after shutting off It has the job of discovering any unacceptable leak in one of the gas valves and preventing th...

Page 10: ...ation with a low speed guard and an additional permanent magnet exciting machine The standard 2 3 chorded stator winding allows low harmonic wave network parallel operation A damper winding is installed for parallel operation with other alternators A winding temperature guard is also installed Special characteristics This brushless self exciting three phase internal pole synchronous alternator sat...

Page 11: ... 1 4571 The outer case is made of normal steel and has water connections on the side with flange connections in accordance with DIN Special characteristics The output chamber can be disassembled so that it can be easily ecologically and inexpensively cleaned by mechanical means The exhaust gas heat transfer unit is integrated into the engine cooling cycle i e the inner cooling cycle That means tha...

Page 12: ...and electrical level control with an alarm contact oil minimum and oil maximum and a refilling contact with valve triggering a lubricating oil storage tank a fresh oil tank with an external consumption display a filling connection a drip oil tub and a collecting tub under the cogeneration module Special characteristics The drip oil and collecting tub take the entire content from the engine oil tub...

Page 13: ...galvanised licensed in conformity with DVGW exhaust gas heavy canvas connection already mounted on optional exhaust ventilator cowl box flat flange 550 x 550 mm P20 Supply Provided loose for assembly by the customer 2 10 2 kWh current meter Each cogeneration module is equipped with a calibrated kWh current meter including the converter NOTE The calibration seal from the state approved testing offi...

Page 14: ...alve 42 magnetic valve 43 zero pressure regulator 44 gas connection 45 gas filter provided loosely by the customer 46 gas ball cock with thermal safety valve 47 sealing control 51 added lubricating oil tank fresh oil 52 automatic refill for lubricating oil with level display 61 lubricating oil return from oil screen 62 crank space ventilation 63 oil screen 64 combustion air 65 air filter 66 gas ai...

Page 15: ...loosely by the customer 46 gas ball cock with thermal safety valve 47 sealing control 51 added lubricating oil tank fresh oil 52 automatic refill for lubricating oil with level display 61 lubricating oil return from oil screen 62 crank space ventilation 63 oil screen 64 combustion air 65 air filter 66 gas air mixer 67 alternator 68 exhaust gas collection line 69 engine 70 speed controller and butt...

Page 16: ...ly valve 230 V socket for servicing Key switch for safety switch off emergency stop Battery charger Microprocessor control Window technique display for showing operating and off normal values 2 separate microprocessors one each for the start stop routine for parallel and stand by operation including lambda regulation and mains protection mains monitoring Separate password protected access levels f...

Page 17: ... GmbH 17 5414 733 09 2009 2 12 2 Basic circuit diagram of the electrical connection in parallel and stand by operation Fig 4 The schematic diagram of electrical connections in parallel operation Fig 5 The schematic diagram of electrical connections in parallel and stand by operation ...

Page 18: ...he network section switch are not supplied by the block type thermal power plant The triggering and feedback from the switches are placed with the customer s electrician and the supplier of the block type thermal power plant If the higher level regulation provided by the customer cannot guarantee automatic restart without malfunctions after mains malfunction the fault messages from the plant syste...

Page 19: ... replacement is done on a regular basis and forms what is known as inspection and service regular service Definition of limited time components according to DIN 31051 Limited time components are parts whose service life is shorter than the service life of the entire cogeneration module and that cannot be extended by technically feasible and commercially reasonable means They essentially include cy...

Page 20: ...the general operating data e g check the mixed temperature A B C check the exhaust gas counterpressure after the engine A B C make a general check of sealing and whether all screws are tight A B C check the function of automatic oil refilling check the level adjustment A B C open the oil refilling cock mark the oil level A B C set the service interval back A B C general module cleaning A B C chang...

Page 21: ...i3 i4 check the turbocharger and change wherever necessary i2 i3 i4 change the ignition coils i2 i4 starter i2 i4 check the plate heat transfer unit and replace wherever necessary i2 i4 check the mixed cooler and replace wherever necessary i2 check the cylinder head and replace wherever necessary i2 i4 check the oxidation catalyst and replace wherever necessary i4 overhaul the engine Tab 5 Mainten...

Page 22: ...neration 26 9 efficiency in parallel operation electrical efficiency 32 8 36 0 38 1 heat efficiency high temperature 52 0 51 0 52 1 heat efficiency low temperature 1 0 1 3 2 5 total efficiency 85 8 88 4 92 7 Energy generation electrical energy three phase voltage V 400 frequency Hz 50 internal electrical energy requirements 2 kW 6 4 heat energy heat HT forward return temperature C 85 65 heat energ...

Page 23: ...500 Exhaust gas exhaust gas volume flow moist at 120 C m h 1 750 exhaust gas mass flow moist kg h 2 200 exhaust gas volume flow dry 0 O2 0 C 1012 mbar Nm h 861 maximum acceptable counterpressure by module mbar 15 1 Output data in accordance with DIN 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 op...

Page 24: ...efficiency 88 0 88 9 89 7 Energy generation electrical energy three phase voltage V 400 frequency Hz 50 internal electrical energy requirements 2 kW 6 4 heat energy heat forward return temperature C 85 65 Fuels and filling amounts quality of fuel lubricating oil cooling water and heating water refer to the current operational regulations filling quantity lubricating oil ltr 90 added fresh oil tank...

Page 25: ...ow moist kg h 2 250 exhaust gas volume flow dry 0 O2 0 C 1012 mbar Nm h 910 maximum acceptable counterpressure by module mbar 15 1 Output data in conformity with DIN 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 at request 2 2 cooling water pump ven...

Page 26: ...ake output C 80 85 8 cooling water volume flow m h 37 6 Exhaust gas heat exchanger heat output tolerance 5 kW 241 exhaust gas temperature intake output C 465 120 cooling water temperature intake output C 84 9 88 6 pressure loss on the exhaust gas side mbar 10 material of pipes 1 4571 materials of exhaust gas head intake 1 4828 output 1 4571 material of the water cooling jacket ST 50 Mixed cooling ...

Page 27: ... 5 mm earthing cable from the module to the potential equalisation rail provided by the customer dimensioning as per customer s conditions Extended plant design with stand by operation network measuring voltage in front of the system tie circuit breaker Ölflex 5 x 1 5 mm system tie circuit breaker feedback is on signal from the NSHV or from the system tie field Ölflex 5 x 1 5 mm system tie circuit...

Page 28: ...g oil heat output tolerance 5 kW 231 cooling water temperature intake output C 80 85 cooling water volume flow m h 43 2 Exhaust gas heat exchanger heat output tolerance 5 kW 213 exhaust gas temperature intake output C 475 120 cooling water temperature intake output C 84 4 88 1 pressure loss on the exhaust gas side mbar 10 material of pipes 1 4571 materials of exhaust gas head intake 1 4828 output ...

Page 29: ...earthing cable from the module to the potential equalisation rail provided by the customer dimensioning in accordance with customer s conditions Extended plant design with stand by operation network measuring voltage in front of the system tie circuit breaker Ölflex 5 x 1 5 mm system tie circuit breaker feedback is on signal from the NSHV or from the system tie field Ölflex 5 x 1 5 mm system tie c...

Page 30: ...output flange EN 1092 1 DN 200 PN 10 AKO condensate water drainage pipe DIN EN 10220 Ø 22 x 2 0 gas gas intake flange EN 1092 1 DN 65 PN 16 V R heating forward return flange EN 1092 1 DN 80 PN 16 GV GR2 mixed cooler forward return pipe nipple DIN 2999 R 1 AL exhaust gas output flange 550 x 550 P20 1 The sound absorbing hood exhaust ventilator cowl is optionally available with the Vitobloc 200 EM 4...

Page 31: ...y cogeneration modules not in operation with an engine shut off valve that is 100 sealed to exhaust gas A return temperature increasing mechanism is needed when the heating water return temperature is below 60 C A separate return temperature increasing mechanism should be provided with the EM 401 549 model for the low temperature mixed cooling circuit Condensate flows out of the cogeneration modul...

Page 32: ...m 2 000 mm 2 000 mm 2 000 mm C 4 140 mm 5 240 mm 6 040 mm 6 600 mm 7 450 mm 7 000 mm D 1 940 mm 2 840 mm 3 440 mm 3 600 mm 4 450 mm 4 000 mm E 1 300 mm 1 800 mm 1 800 mm 2 020 mm 2 000 mm 2 020 mm F 2 500 mm 2 800 mm 2 800 mm 4 000 mm 3 500 mm 4 000 mm G 800 mm 800 mm 800 mm 1 100 mm 1 500 mm 1 500 mm H 890 mm 900 mm 940 mm 1 650 mm 1 650 mm 1 650 mm I 2 490 mm 2 500 mm 2 540 mm 3 850 mm 4 650 mm ...

Page 33: ...1 mm made of stainless steel and connections pressure resistant to pulsation to 4 000 Pa Free drainage should be provided for the condensate water with at least a 3 inclination over the siphon U pipe at a height of approximately 150 mm for keeping exhaust gas from escaping from the condensate water drain Ventilation Provide cooling and combustion air that is not preheated and free of dust halogen ...

Page 34: ...fication system 12 Exhaust ventilator cowl 12 F Flange coupling 10 G Gas 10 H Heat transfer system 11 Heating 33 I Installation 31 Installation space 33 Introduction 4 L Lubricating oil supply system 12 M Microprocessor control 16 Monitoring equipment 13 N noise 10 O Operating resources 33 P Piping 11 Plate transfer heat unit 11 Product description 7 R Repair 19 S Sample installation plans 32 Serv...

Page 35: ...Notes VITOBLOC 200 EM 401 549 EM 363 498 ESS Energie Systeme Service GmbH 35 5414 733 09 2009 ...

Page 36: ... competence centre SYSTEMS mobile units software solutions switching cabinet systems SERVICE start ups service strategies training courses Subject to change without notice ESS Energie Systeme Service GmbH Celsiusstraße 9 D 86899 Landsberg am Lech Tel 08191 9279 0 Fax 08191 9279 23 info ess landsberg de www ess landsberg de 799 000 016 ...

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