Viessmann Vitobloc 200 EM-140/207 Operating Instructions Manual Download

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6130329 GB

04/2019

To be kept carefully!

Operating instructions

for specialists

VITOBLOC 200

block-type thermal power plant module for natural gas operation

model EM-50/81

model EM-199/263

model EM-401/549

model EM-70/115

model EM-238/363

model EM-530/660

model EM-140/207

model EM-260/390

Summary of Contents for Vitobloc 200 EM-140/207

Page 1: ...rating instructions for specialists VITOBLOC 200 block type thermal power plant module for natural gas operation model EM 50 81 model EM 199 263 model EM 401 549 model EM 70 115 model EM 238 363 model EM 530 660 model EM 140 207 model EM 260 390 ...

Page 2: ... technical equipment as intended and com plying with the assembly instructions operating instruc tions and service instructions Only authorised profes sionals 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 com...

Page 3: ...1 Authorized personnel 24 3 2 Measuring and setting points for the commissioning 25 3 3 Commissioning instructions for the CHP module 28 4 Programming 32 4 1 Operator s and indicator unit of the CHP module 32 4 2 CHP module control level 1 Display change operating values 34 4 3 CHP module control level 2 Manual mode 36 4 4 CHP module control level 3 Display change of parameters 38 5 Usage and oper...

Page 4: ...r instructions are disregarded CAUTION HIGH VOLTAGE DANGER TO LIFE Only suitably qualified personnel elec tricians are authorized to open the module control panel or other electric control instrumentation I C sys tems Covers of the CHP module must not be removed without having received special instructions 1 2 Introduction into the unit s func tions and operation The manufacturer shall familiarize...

Page 5: ...ife endangering electric shock risk of injury mechanical damage to the engine alternator engine engine block oil pan cooling water pipes touching the hot machine opening various shut off or drain cocks risk of burns scalding from discharged cooling water oil test nipple snap closing operating the check ball scalding from discharged engine oil rotating engine parts touching risk of injury ignition ...

Page 6: ... from the ambient conditions Risks from unexpected starting unexpected spinning Risks from shutting down the plant emergency off Risks from changing the speed Risks from power supply cuts Risks from a failure in the control circuitry Risks from breakages during operation 1 1 1 1 1 1 1 Risks from operating the plant in an explosive environment 1 high residual risk failure to observe the safety regu...

Page 7: ...e contact of such acid with the skin should therefore be avoided under any circumstances and the relevant safety regulations are to be ob served The same applies to the glycol containing cooling water and the engine lubrication oil Should you have come in contact with such materials wash the affect ed parts of the body thoroughly and treat them with suitable body care products Waste gas might esca...

Page 8: ... inside the technical room Prohibition sign P 06 No access for unauthorized persons Prohibition sign P 02 Fire naked light and smoking not per mitted Prohibition sign P 11 No access for persons wearing a pacemaker CAUTION Only a specialist firm with personnel specifically trained in these fields of re sponsibility by the CHP module manu facturer is authorized to carry out the assembly work the ini...

Page 9: ... oil Exhaust gas is toxic Therefore exhaust gas pipes must not only be tight and stable but also made of a suitable material Keep the ambience of the engine as well as step ladders and stairs free from oil and grease since accidents as a result of skidding may have serious consequences Open the coolant circuit only after the engine has cooled down If it must be opened at the engine s operating tem...

Page 10: ...ded purpose operating supplies will be an environmental hazard Do not let them penetrate the ground or flow into the sewer system 2 1 Consumables 2 1 1 Natural gas the fuel Gaseous fuels consist largely of methane propane and butane as well as traces of higher hydrocarbons and inert components such as carbon dioxide and Nitrogen The valid regulations applicable for gas installa tions must be obser...

Page 11: ...e assembly instructions as well as the directives contained in worksheet G 260 or G 261 respectively issued by the Deutsche Vereinigung des Gas und Wasserfaches e V DVGW Fuel values to be observed parameter value calorific value Hi N 5 kWh Nm3 methane number 1 MZ 80 minimum flow pressure in the controlled system for the gas 20 mbar 2 maximum flow pressure in the controlled system for the gas 50 mb...

Page 12: ...out during the first mainte nance or in the case of special types of gas after approx 400 1 000 and 2 000 operating hours Please note that also the trends of several analyses must be taken into consideration when assessing the wear and tear apart from complying with the limits as such The following characteristic values need to be analyzed and recorded designation unit measuring method viscosity m...

Page 13: ...e of in the most optimal way and that the oil analyses can be safely assessed we recommend the conclusion of a maintenances contract with Viessmann Kraft Wärme Kopplung GmbH Brands of engine oil approved for natural gas operations Table 5 Approved gas engine oils This engine oil must be used for all MAN engines Lambda 1 and Turbo Here the extended oil change intervals of the BHKW manufacturer Vies...

Page 14: ...ing re sources see Table 6 Approved anti freeze agents A minimum concentration of 38 vol of anti freeze agent must always be ob served since the corrosion protection will not be ensured with less than the 38 vol as required How to handle anti freeze concentrate WARNING When handling anti freeze concentrate wear protective gloves and goggles Please observe the safety data sheet can be obtained from...

Page 15: ...24 13F W Kühlmittel D 542 1993 Elf Lub France Elf Antifreeze Special Glacelf SX EUROL Mineralölhandels GmbH Eurol Afrostin EVVA Austria EVVA Antifreeze Fina Europe S A Fina Termidor P 100 Fuchs Mineralölwerke GmbH Fricofin Kühlerfrostschutz Genol Genol Antifreeze Ginuoves Georges S A York LT 716 Henkel Härtol GmbH Frostox MB 02 Hoechst Genantin Extra B INA Industrija Zagreb Croatia INA Antifriz AI...

Page 16: ... kw 600 kW 8 4 dH 0 11 dH 0 11 dH 600 kW 0 11 dH 0 11 dH 0 11 dH Table 7 Quality characteristic values for the filling and supplemental water for heating plants with Vitobloc 200 CHP modules CAUTION The mud separator provided by the cus tomer should be cleaned every half year Preventing corrosion Corrosion in heating plants can essentially be attributed to the presence of oxygen in the hot water T...

Page 17: ...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 op posite one another Opening Raise the sound hood plate and press against the corresponding frame Caution There is the danger of breakage if th...

Page 18: ...ol suppliers If having been in contact with the concentrate Objects Wipe off any spillage with an absorbent material and dispose it as special refuse Skin Wash the relevant parts of the body with water and soap Eyes Rinse they eyes thoroughly for 15 min under run ning water with the lids spread apart and seek medical advice thereafter Mixing coolant CAUTION Do not use containers designated for dri...

Page 19: ...the top sound insulation cover at rear Fig 2 item 1 Vent the cooling system at the gas separator bypass Fig 2 item 2 Vent the cooling system at the cooling water distributor Fig 2 item 3 Close the stop cock at the cooling water distribu tor Fig 2 item 3 and remove the pressure hose Close the stop cock at the exhaust gas heat exchanger Fig 2 item 4 and remove the pres sure hose WARNING When venting...

Page 20: ...konnte nicht gefunden werden Brands of oil ap proved for gas fuelled engines How to handle engine lubrication oil WARNING When handling engine lubrication oil wear protective gloves and goggles Please observe the safety data sheet can be obtained from suppliers of lu brication oil If having been in contact with engine oil Objects Wipe off any spillage with an absorbent material and dispose it as s...

Page 21: ...rip tion of the CHP module Check the engine oil level with the dipstick Fig 3 item 2 remove the dipstick clean it with a clean lint free cloth insert it again right down to the stop pull it out once again WARNING Do not fill in engine lubrication oil above the MAXIMUM notch at the dipstick Fig 4 The oil should level between the two notches at the dipstick Fig 3 Lubrication oil intake at the cover ...

Page 22: ...led and vented in con sultation with the heating installation firm after the entire heating system has been completed In addition a filling and draining tap must be installed by the customer in close proximity to the CHP in the hot water inflow WARNING When filling the heating system ob serve the regulations concerning oper ating resources pursuant to section 2 1 4 Heating water Filling the heatin...

Page 23: ...ot tilt the battery because acid can leak from the battery vents First Aid Rinse acid spills in the eye immediately with clear water for some minutes and seek medical advice immediately thereafter Neutralize acid spills on the skin or clothing immediately with the help of acid neutralizer or soapsuds and rinse thoroughly with water Consult a doctor immediately if you have drunk acid Maintenance Ke...

Page 24: ...ut being filled with lubrication oil or coolant When starting the engine do not use any addition al starting aid such as a start pilot Do not switch off the engine when running under full load let it idle for approx 5 min so as to facili tate the temperature compensation especially at the exhaust gas turbocharger Never fill cold coolant into an overheated engine Do not fill in engine oil above the...

Page 25: ...be an aid especially for the duly au thorized personnel that have been trained about the measuring and setting points on the module s control panel by the CHP module manufacturer The marking on the assemblies and the cables of the actually delivered modules as well as the order related switching and assembly diagrams are binding 3 2 1 Measuring and setting points on the module s control panel Fig ...

Page 26: ...em 11 analog box item 12 ignition control item 13 Lambda probe item 14 transport locking device engine feet on the left hand side item 15 revolution transducer pick up of the ignition item 16 cooling water temperature sensor item 17 ignition coils item 18 lubrication oil pressure sensor oil pressure sensor item 19 starter item 20 actuator governor item 21 throttle gas air mixer governor item 22 co...

Page 27: ... item 11 analog box item 12 ignition control item 13 Lambda probe item 14 transport locking device engine feet on the left hand side item 15 revolution transducer pick up of the ignition item 16 cooling water temperature sensor item 17 ignition coils item 18 lubrication oil pressure sensor oil pressure transducer item 19 starter item 20 actuator governor item 21 throttle gas air mixer governor ite...

Page 28: ...em gas system exhaust gas system ventilation system lubrication oil system cabling record the results in the commissioning protocol 4 Check the connection of the power cables switching diagram sheet 1 module control panel X1 L1 L2 L3 1Q1 as well as N and PE or PE N bridge Cu rail 5 Check the connection of the measuring circuit voltage switching diagram sheet 1 module control panel in the case of p...

Page 29: ...k and of the measuring circuit voltage module control panel check rotating field of network at 1F1 and the measuring circuit voltage at 1F3 19 Switch on all fuse and circuit breakers module control panel 20 Check the rotating field and the potential equality of the measuring circuit voltage switching diagram sheet 2 module control panel check rotating field and potential equality of the measuring ...

Page 30: ...r values at level 1 see section 4 3 change the set value of the probe voltage and of the pa rameters at level 3 of the module control if necessary see section 4 5 34 Test the potential free messages switching diagram sheet 23 module control panel potential free messages connected to X5 at the client s request 35 Test the regulation of the floating value switching diagram sheet 19 module control pa...

Page 31: ... reports the switching positions correctly the alternator switch will be activated to be on load again To return to mains operations switch on fuse 1F3 again in order to check the behaviour while the load is re connected and the frequency is regulated PLEASE NOTE After the recovery time the alternator switch will receive a deactivation command Then the on site system tie circuit breaker will be re...

Page 32: ...its for higher operator levels Authorized personnel only Key F5 Printing display printing menu status printout parameter printout Key F6 Level change operator level Only after password has been entered Key F7 Error display error messages on the screen in plain text press function key F7 when the red LED Fault is lit but no error messages are displayed in plain text Key F8 Reset only when an error ...

Page 33: ...f the CHP module item 1 operating mode AUTO MATIC MODE HAND MANUAL MODE OFF item 2 external request heat current power stand by off item 3 voltage per phase item 4 current item 5 capacity item 6 function key assignment item 7 NS system tie circuit breaker ON item 8 GS alternator switch OFF item 9 number of module starts item 10 operating hours Legend on Fig 10 ...

Page 34: ...ith function key F2 for infor mation only example Fig 11 2 x F2 further temperatures return to the basic configuration with key C 4 2 2 Display of voltage current U I values display the menu with function key F4 for infor mation only example Fig 12 2 x F4 busbar voltage return to the basic configuration with key C Fig 11 Display of engine values with function key F2 Fig 12 Display of U I values wi...

Page 35: ...con firm the values of month and year in the same way After the last value year has been confirmed with key E the field selection will reappear date underlined once Cancel the value selection cancel the value selection value change with key C repeat value selection as described above Change the field selection return with key C until the field selection under lined once is displayed again repeat t...

Page 36: ... level 3 The LED Fault is flashing flash signal during password operations short on long off as compared with the flash signal of an error message long on short off 4 3 2 Functions of level 2 Manual mode change to level 3 with function key F6 NOTE The display shows the menu Manual mode Fig 17 In addition to the LED Fault the LED Ready is now flash ing ready for manual mode enter the function as in...

Page 37: ...em 1 it is possible to return to level 1 and back to level 2 with function key F6 If the menus Engine values or U I values are displayed in the manual mode keys 1 and 4 as well as 2 and 8 at level 2 will remain active In the case of longer test runs press any key such as F6 at least every 60 min NOTE All passwords will be erased automati cally if no key has been pressed within 60 min 4 3 3 Deletio...

Page 38: ...l 3 will also allow a change to level 2 In order to change from level 1 to level 3 press function key F6 twice The display will show the first page of the menu Parameters field selection underlined once select a field either with arrow keys 2 or 8 changing to a new menu page with other parameters or with arrow keys 4 or 6 time or value confirm the field selection with key E select a value decrease...

Page 39: ...order to check and test operating values in the manual mode it is possi ble to return to levels 1 or 2 with func tion key F6 In the case of longer test runs press any key such as F6 at least every 60 min NOTE All passwords will be erased automati cally if no key has been pressed within 60 min 4 4 3 Erasure of passwords WARNING As a means of protection against unau thorized use and access all passw...

Page 40: ... governor setting 6 output regulator monitor ing monitoring period e g 15 min limit e g 5 kW if the set value for the output deviates either way by more than 5 kW for more than 15 min the machine will trip 7 output regulator dead band regulator dead band e g 1 kW no re adjustment if the actual output value levels within 1 kW of the set value for the output 8 knocking output minimum output reductio...

Page 41: ...zes the started engine and does not repeat the start e g 650 rpm 20 set speed overspeed set value for the speed maximum limit of the overspeed if the set limit is exceeded the machine will trip 21 fan start up time after run time start up time until module start after run time e g 30 min active from the warm up limit 60 C and module start 10 sec after run at 60 C 22 cooling water pump start up tim...

Page 42: ... will trip if this value is exceed 1 min after the machine has tripped a fault message will be issued additionally after a 10 second time delay oil pressure transducer function monitoring 34 offset Lambda probe voltage the analog value can be corrected 35 offset NiCrNi the analog value can be corrected 36 offset cooling water tempera ture the analog value can be corrected 37 offset PT 100 2 the an...

Page 43: ... the operating mode AUTO Fig 23 item 1 LED display of the operating mode Ready the green LED Ready will be lit when the au tomatic mode is ready for operation and the Lambda control valve is in its start position Fig 23 item 2 LED display of the operating mode Operation the green LED Operation will be lit when the engine is running and alternator contactor has been switched on in the Operation mod...

Page 44: ...nternet connection must allow UDP packets over port 3003 direction ess telecontrol de There are no incoming packets When the CHP unit is switched on the TeleControl LAN is recognised automatically and is operational immediately After commissioning you should contact the CHP Service department at Viessmann Landsberg Tel 49 0 08191 9279 60 to check whether the data from the corresponding CHP unit is...

Page 45: ... kW kW kW kW Lambda probe voltage mV mV mV mV mV mV mV oil pressure bar bar bar bar bar bar bar exhaust gas temperature C C C C C C C cooling water tempera ture C C C C C C C heating water tempera ture before module C C C C C C C heating water tempera ture after module C C C C C C C irregularities leakages others Important The oil level must be marked at the tank after each maintenance oil consump...

Page 46: ...gas from escaping from the condensate water drain Hydraulic seals must be executed so that the water level can be checked and filled The condensate line must be checked regularly blockages and sufficient water seal Follow the assembly instructions for the exhaust gas systems for Vitobloc 200 If the block type thermal power plant is used in resi dential areas we urgently recommend providing 2 conse...

Page 47: ...lp injured persons immediately and call a first aider if necessary The flame of a gas fire as such cannot be extinct Cool a burning object if necessary e g by with drawing oxygen close doors and windows Burning gas gas under control Prevent the flames from spreading When flames are spreading fight the spreading fire with fire extinguishers Keep calm Fire fighting equipment Use CO2 extinguishers no...

Page 48: ...cleaning work remove the oil contamination with kitchen paper towels cloths Citrus cleaning agent or brake cleaner dispose the contaminated cloths in the special refuse only in the case of larger modules check also the floor pan and clean it if necessary find leakages if the oil cooler is leaking wash off the protective crème after you have fin ished work and apply skin care crème WARNING When han...

Page 49: ...otential cause of a fault may require various measures such as a visual inspection to identify me chanical thermal or other damage a check whether the installation has been carried out correctly position mounting connections establishing the operating condi tions or the functional performance or a check of the operating values measuring and set values operat ing supplies etc Fig 25 Display of a fa...

Page 50: ...l mechanism has switched off oil tank empty or refill cock closed minimum cooling water pressure acknowledge fault with function key F8 call customer service if error message1 is repeated cooling water pressure switch has tripped pressure too low minimum gas pres sure establish whether the gas supply is interrupted acknowledge fault with function key F8 call customer service if error message1 is r...

Page 51: ...cknowledge fault with function key F8 call customer service if error message1 is repeated speed control system defective worn out or incorrectly set underspeed pick up acknowledge fault with function key F8 call customer service if error message1 is repeated engine stalled or pick up defective synchronization faulty acknowledge fault with function key F8 call customer service if error message1 is ...

Page 52: ...y F8 call customer service if error message1 is repeated battery or charger defective external fault eliminate the fault on site and acknowledge with function key F8 external fault on site contact X1 26 27 Lambda start posi tion acknowledge fault with function key F8 call customer service if error message1 is repeated Lambda control valve does not reach the start position control valve defective e...

Page 53: ...er service if error message1 is repeated external pump monitoring X1 28 29 fault caused by knocking acknowledge fault with function key F8 call customer service if error message1 is repeated optional knocking monitoring has tripped maximum gas pres sure acknowledge fault with function key F8 call customer service if error message1 is repeated optional maximum gas pressure monitoring gas pressure t...

Page 54: ...ata remove the internal CHP module starter batteries and store them in a suitable place where they can be connected with a battery charger and duly main tained ensure that the technical room of the CHP module is kept free from frost and draught air all the time during the shutdown of the module depending on the actual conditions on site the module will have to be fully covered although it must be ...

Page 55: ...f operation WARNING The heating and cooling water pipes are under pressure WARNING Please observe the safety instructions for handling the above media as laid down in chapter 2 as well as the rele vant disposal regulations Before lifting the CHP module the piping and ca bling must be completely removed see also the shipping instructions in the assembly instructions Please be careful when not trans...

Page 56: ...56 6130329 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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