Viessmann Vitobloc 200 EM-238/363 Operating Instructions Manual

Brand: Viessmann

Model: Vitobloc 200 EM-238/363

Type: Operating Instructions Manual

This manual is also suitable for

Vitobloc 200 EM-530/660

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

Legal notice

2 Operating instructions for the natural gas-fuelled CHP module VITOBLOC 200

6130329 GB

This equipment satisfies the basic require-

ments of the appropriate standards and di-

rectives. Its conformity has been demon-

strated. These documents and the original

conformity declaration are stored on the

premises of the manufacturer.

NOTE

The Vitobloc 200 cogeneration module is

not suited to 60 Hz operation which means

that it is in particular not available to the

American and Canadian market.

Important general instructions for application

Only use this 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 combinations, acces-

sories 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.

 Table of Contents 
VITOBLOC 200 Operating instructions for the natural gas-fuelled CHP module  3 
6130329 GB 
 
 
Instructions for operating the CHP ................................................. 4 
1 Qualification of the personnel ...................................................................................... 4 
2 Introduction into the unit’s functions and operation .................................................. 4 
3 Hazard warnings pursuant to the Machinery Directive ............................................... 4 
4 Residual dangers from operating a combined heat and power plant ........................ 6 
5 Requirements concerning the technical room ............................................................ 8 
6 Regulations for the prevention of accidents causing personal injury ....................... 9 
Preparations ................................................................................... 10 
1 Consumables ............................................................................................................... 10 
2 Filling Fuels.................................................................................................................. 17 
Commissioning .............................................................................. 24 
1 Authorized personnel .................................................................................................. 24 
2 Measuring and setting points for the commissioning .............................................. 25 
3 Commissioning instructions for the CHP module ..................................................... 28 
Programming ................................................................................. 32 
1 Operator’s and indicator unit of the CHP module ..................................................... 32 
2 CHP module control level 1: Display & change operating values ........................... 34 
3 CHP module control level 2: Manual mode ............................................................... 36 
4 CHP module control level 3: Display & change of parameters ................................ 38 
Usage and operations ................................................................... 43 
1 Duties of the plant operator ........................................................................................ 43 
2 Remote monitoring with TeleControl LAN ................................................................. 44 
3 Operations log for CHP modules ................................................................................ 45 
4 Requirements for optimal operation .......................................................................... 46 
5 Emergency ................................................................................................................... 47 
Cleaning ......................................................................................... 48 
Trouble-shooting ........................................................................... 49 
1 Fault messages from the CHP module that cannot be acknowledged .................... 50 
Shutdown ....................................................................................... 54 
1 Temporary shutdown .................................................................................................. 54 
2 Final shutdown (decommissioning) ........................................................................... 55 

Instructions for operating the CHP

4 Operating instructions for the natural gas-fuelled CHP module VITOBLOC 200

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1 Instructions for operating the CHP

1.1 Qualification of the personnel

The combined heat and power plant (CHP) has been

designed and built according to the state-of-the-art

and on the basis of the latest safety regulations. Spe-

cial attention has been paid to user friendliness. Op-

erating a CHP module and handling the required

operating resources should not cause any problems

at all, if the personnel is suitably trained and thinks

pro-actively.

Pursuant to VDMA 24186-0, skilled and specialist

staff (fitters, foremen, technicians, engineers etc.) is

personnel with the relevant professional qualification,

i.e. the completed vocational training in at least one

field of building service engineering or a higher quali-

fication.

In order to run the CHP module safely, efficiently as

well as in an environmentally-friendly and most opti-

mal way, only operating personnel will be admitted

who know these operating instructions precisely and

who have been duly familiarized with the plant opera-

tion.

LIABILITY

The manufacturer cannot be held liable,

if these safety instructions and any oth-

er 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 the plant operator

or the personnel assigned to operate the plant with

the functions of the CHP module as well as how to

operate it and hand over the technical documents.

NOTE

Details of pictures or illustrations and

descriptions contained in these operat-

ing instructions may deviate from the

CHP module actually delivered as a re-

sult of ongoing technical developments.

1.3 Hazard warnings pursuant to the

Machinery Directive

The combined heat and power plant module has been

designed to generate power and heat at the same

time. In order to do so, an internal gas combustion

engine will drive a three-phase synchronous alterna-

tor. The table below contains information about poten-

tial risks in accordance with the relevant safety regula-

tions that may arise during the assembly and mainte-

nance work during usual or reasonably predictable

operations. Therefore, only skilled and specialist per-

sonnel who have been duly instructed are authorized

to operate the unit and carry out any maintenance

work.

Instructions for operating the CHP

VITOBLOC 200 Operating instructions for the natural gas-fuelled CHP module 5

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Article § 5(1)1a of the Equipment & Product Safety Act (GPSG):

What risks may arise during usual or reasonably predictable operations?

source of danger:

dangerous activity:

consequence:

switchgear:

feeder circuit-breaker

alternator contactor

power cable

removal of covers

reaching under the covers

connecting work at terminals

life-endangering electric shock

terminal X1/7,8,9

caution, external voltage.

terminals may still be live during connec-

tion work, although the feeder circuit-

breaker has been switched off

life-endangering electric shock

contactors and relays

relays or contactors being switched

manually

undefined circuits causing considera-

ble damage (to motor/alternator)

danger of short circuit and, possibly,

electric shock

alternator:

power and control connec-

tions

removing the cover sheets of the termi-

nal boxes

touching terminals and control PCBs

life-endangering electric shock

covers and cowl panels

removal of covers

or reaching under the covers

inserting objects into the ventilation slits

life-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:

ignition coils

ignition cables

spark plugs

loosening ignition cables

removing spark plugs

life-endangering electric shock (high

voltage)

damage to the engine

battery:

battery terminals

removing the terminal covers

placing metal objects on the terminals

short circuit and risk of burns

risk of explosion

battery acid

opening the battery chambers

risk of chemical burns

observe the battery safety instructions. (see chapter: 2.8)

fan:

rotating fan wheel

opening the covers,

reaching into the fan wheel

risk of injury

gas pipes:

screwed gas pipe connections

test nipples

opening various crewed connections

opening test nipples

gas leakage

risk of explosion

exhaust gas pipes:

exhaust gas pipes

adapter socket

opening various exhaust gas flanges

opening adapter sockets

touching un-insulated exhaust gas pipes

touching un-insulated adapter sockets

exhaust gas leakage

risk of poisoning

risk of burns

Table 1 CHP module hazard warnings

Instructions for operating the CHP

6 Operating instructions for the natural gas-fuelled CHP module VITOBLOC 200

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1.4 Residual dangers from operating a combined heat and power plant

What active risks are the operating personnel ex-

posed to from CHP module operations?

Irrespective of the actual conditions where a com-

bined heat and power plant will be installed, the rele-

vant fundamental safety regulations for the shipment

and the installation applicable to all trades (power,

gas, heating, ventilation) must be observed.

The following table makes reference to potential re-

sidual dangers which may still arise from the opera-

tion of a combined heat and power plant, even if the

relevant safety measures have been taken.

Risk analysis pursuant to DIN EN 12100:

What residual dangers is the operating

personnel exposed to when operating a CHP

production/test run

transportation

storage

assembly

installation

commissioning

programming at the control panel

operations

cleaning (CHP cold)

trouble shooting

maintenance

de-commissioning

disassembly

disposal

Mechanical risks 1 1 1

Electrical risks 1 1 1 1

Thermal risks 2 2 2 2 2 2

Risks from noise 2 2

Risks from vibration

Risks from radiation 2 2 2 2 2 2

Risks from materials and substances 2 2 2 2 2 2 2 2

Risks from disregading ergonomic principles

Risks from skidding, stumbling and falling

Combinations of risks

Risks arising 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 regulations may have fatal consequences.

2 residual risk – failure to observe the safety regulations may cause health damage.

Table 2 Risk analysis pursuant to DIN EN 12100

Mechanical risks

Mechanical risks will occur, when safety covers have

to be removed during trouble-shooting or while

maintenance measures are carried out. This concerns

largely the cover grilles of the fan box and the coup-

ling cover as well as the timing belt cover, depending

on the type of plant.

This work must only be carried out by suitably trained

and specialist personnel.

Electrical risks

Electrical risks will occur, when safety covers have to

be removed during the commissioning (factory trial

run), during trouble-shooting or while maintenance

measures are carried out. This concerns largely the

lid of the alternator’s terminal box or switches and

protective covers of the switchgear, e.g. when syn-

chronizing devices are adjusted or the alternator and

mains voltage is measured.

When working on the ignition system, suitable protec-

tive clothing must be worn, since electric shocks can

be transmitted from defective ignition cables.

This work must only be carried out by suitably trained

and specialist personnel.

Instructions for operating the CHP

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Thermal risks

The combustion engine in the CHP module as well as

the heat extraction components and the exhaust gas

piping downstream may get very hot for operational

reasons and develop temperatures of some hundred

degrees centigrade in exposed areas. The piping and

the components are insulated as far as possible.

However, some spots are freely accessible for instal-

lation and service purposes. They can get very hot

during operations and are not protected against unin-

tentional contact, e.g. measuring nipples for the ex-

haust gas counter pressure.

In the event of a breakdown, the pressure relief valve

can trip and discharge hot cooling water, which may

cause the risk of scalding.

Risks from noise

When working on the CHP module and the sound-

insulating lid is open during operations, e.g. during

trouble-shooting and while maintenance work is car-

ried out, the relevant ear protection must be worn.

Risks from radiation

Electromagnetic fields emanating from generators in

the block-type thermal power station can temporarily

disturb any heart pacemaker in its immediate vicinity.

The signs of a potential disturbance might be dizzi-

ness, palpitations or an irregular pulse. The heart

pacemaker functions normally as soon as the person

wearing it moves away from the generator.

Risks from materials and substances

Like a car, the CHP module will be started with batter-

ies. These batteries are filled with acid which has a

caustic effect. The 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 escape uncontrollably if there are

leaks in the waste gas system (causing the hazard of

carbon monoxide poisoning). However, it is normally

conducted outside by the extract ventilator cowl

through an extract air duct. Therefore it is important to

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.

Risks from breakage during operation

Exercise particular care and attention when lifting the

CHP modules on a crane hook or on their lifting eyes.

In the event of a breakage, thermally overloaded

components may develop leakages, so that hot en-

gine oil, but also heating or cooling water may get

discharged as a result of burst hoses or broken-off

measuring nipples.

It cannot be excluded under extremely rare circum-

stances that an engine breaks, as it can happen with

cars as well, so that fragments are catapulted through

the air.

Parts containing exhaust gas may get leaky and toxic

carbon dioxide may get discharged in the event of a

breakage/rupture or as a result of corrosion. Please

switch off (shut down) the CHP module immediately

and activate the ventilation.

The personal protective clothing includes

ear protection (when working with the sound-

insulating lid open during operations);

protective gloves and goggles, when handling battery

acid, glycol and engine lubrication oil.

Instructions for operating the CHP

8 Operating instructions for the natural gas-fuelled CHP module VITOBLOC 200

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1.5 Requirements concerning the technical room

CAUTION

Smoking and open fire are not permit-

ted. Flammable materials or liquids

must not be stored or used close to the

CHP module. Keep fire extinguishers

and other fire fighting equipment within

reach.

We recommend, similar to the require-

ment of the old Heating Room Directive,

installing a fire extinguisher of the ap-

propriate size (at least 9 l) in the tech-

nical room.

WARNING

In order to avoid breakdowns or dam-

age, the contamination of the combus-

tion air with halogen hydrocarbons (as

contained in spray cans, solvents,

cleaning agents, paint, adhesives etc.)

and excessive amounts of dust must be

excluded.

The technical room for the CHP module must be frost-

proof and well ventilated. The supply and extract air

openings must not be closed or their size be reduced.

The room temperature must not drop below +10 °C.

NOTE

The following signs shall be put up both

outside and 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 initial commission-

ing as well as the maintenance and re-

pair work and to install the fuel, exhaust

gas as well as the power connections.

Any work on pipelines containing gas or

on live parts must be carried out by duly

authorized specialist firms.

LIABILITY

According to Article § 10 of the Energy

Saving Directive, the operator shall ar-

range for the plant’s cleaning and

maintenance, the latter on the basis of

a maintenance schedule. In the course

of such measures, the proper function-

ing of the entire plant shall be checked.

Any defects identified shall be rectified

immediately. During the warranty peri-

od, the maintenance shall be carried

out in line with the maintenance sched-

ule by duly authorized personnel.

NOTE

We recommend concluding a mainte-

nances contract with a company that

has been authorized to do such work by

the manufacturer.

Instructions for operating the CHP

VITOBLOC 200 Operating instructions for the natural gas-fuelled CHP module 9

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1.6 Regulations for the prevention of accidents causing personal injury

When installing the CHP module and before the commissioning:

● No persons must stay under loads suspended from

a crane hook. Keep the lifting gear in proper condi-

tions.

● Read the operating instructions carefully before the

commissioning of the CHP module.

● Affix the prohibition sign “No access for unauthor-

ized persons“ well visible at the entrance of the

technical room of stationary engines.

● Only suitably trained personnel are authorized to

operate the CHP module. Make sure during work

on the engine that it cannot be started by unauthor-

ized persons.

● Protect rotating machine parts (e.g. coupling, fan)

against accidental contact. Do not get too close to

any rotating parts, while the engine is running.

Wear tight-fitting garments.

● Use only proper tools for work.

● Do not touch an engine at operating temperature

with bare hands: There is a risk of burns. Protect

exhaust gas pipes against accidental contact. The

insulation must be made of fire-proof material that

is resistant to fuel and lubrication 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 temperature, observe the instructions in

the chapter “Maintenance and care“ of the operat-

ing instructions.

● Neither open nor re-tighten pipelines and hoses

under pressure (lubrication oil circuit, coolant circuit

and possibly the hydraulic oil circuit): There is a

risk of injury caused by leaking liquids.

● As a matter of principle, smoking and open fire in

the engine room are not permitted. Please observe

the regulations for gas installations.

● Wear goggles when working with compressed air.

● Operating supplies (such as fuels and lubricants)

are flammable and constitute a health risk. They

must only be kept in containers that cannot be con-

fused with those for drinks.

● Please observe the manufacturer’s regulations for

handling batteries.

Caution: Battery acid is toxic and caustic. Bat-

tery gas is explosive.

● When working on the electric system, disconnect

the battery’s grounding cable first, so as to avoid a

short circuit.

● When carrying out welding work observe the “In-

formation bulletins for welders“.

Preparations

10 Operating instructions for the natural gas-fuelled CHP module VITOBLOC 200

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2 Preparations

LIABILITY

Inform the warranty office in writing be-

fore commissioning the plant, when us-

ing the specified or approved operating

supplies (see assembly instructions in

the chapter „Notification about the

plant’s readiness for commissioning“),

as this is the prerequisite for having any

warranty claims acknowledged.

When being used improperly or not fort he intended

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 observed.

● Smoking and open flames are not permitted.

● Leakages in the gas supply system pose a risk of

explosion and must be eliminated immediately.

● Fire extinguishers and other fire fighting equipment

must be kept within reach.

● Do not store any flammable materials in the engine

room.

Preparations

VITOBLOC 200 Operating instructions for the natural gas-fuelled CHP module 11

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Gas quality

WARNING

Natural gas and the combustion air

must not contain any phosphorus, ar-

senic, heavy metals or dust, and halo-

gens only in quantities up to the limits

stipulated.

The natural gas must be technically

free from mist, dust and liquids and

must not contain any substantial quan-

tities of corrosive components. The

methane number and the calorific val-

ue of the biogas must remain constant.

PLEASE NOTE

The methane number (not to be con-

fused with the methane content) is a

measurement for the knock susceptibil-

ity of the type of gas concerned. A too

low methane number will result in

knocking combustion and thus damage

the engine. We would like to point out

that the methane number will consider-

ably drop, especially if a liquid gas mix-

ture (propane/air and butane/air) is

added. We therefore recommend verifi-

cation with the local gas supplier that

this is not done so.

INSTRUCTION

As for the rest, please observe the

instructions in the chapter „Gas

connection“ of the 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 mbar

maximum gas pressure varia-

tions (short variations due to

control activities)

± 3 mbar

maximum changing speed of

the gas pressure 3)

3 mbar/min

relative humidity 

< 60 %

Temperature of gas mixture

downstream of gas/air mixer TG

10 °C < TG < 30 °C

chlorine content Cl

< 80 mg / Nm3CH4

fluorine content F

< 40 mg / Nm3CH4

total chlorine/fluorine Σ(CI,F)

< 100 mg / Nm3CH4

dust content < 5 m

< 10 mg / Nm3CH4

oil vapour

< 400 mg / Nm3CH4

silicon content Si

< 2 mg / Nm3CH4

sulphur content S

< 200 mg / Nm3

hydrogen sulfide H2S

< 150 ppm

< 228 mg / Nm³

ammonia content NH3

< 40 ppm

< 30 mg / Nm³

Table 3 Fuel values during the operation of a CHP module

Operations with a lower methane number might be possible

after the CHP module manufacturer has examined the

circumstances.

For the Vitobloc 200 EM-401/549 and EM-530/660

modules, the minimum flow pressure is 30 mbar.

Flow pressure in the module’s control system for the gas.

Preparations

12 Operating instructions for the natural gas-fuelled CHP module VITOBLOC 200

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2.1.2 Engine lubrication oil

Principles

The use of lubrication oil that the CHP module manu-

facturer specifies for the relevant type of gas is a

prerequisite for the safe and wear-resistant operation

of the engine. Especially in view of possible warranty

claims in a case of damage, we like to emphasize the

operator’s duty of care.

The service life of the lubrication oil depends on the

operating conditions, especially

- the gas quality,

- the ambient conditions,

- the operating mode of the CHP module and

- the quality of the lubrication oil.

The contaminants contained in special types of gas,

such as dumpsite gas and biogas, can considerably

reduce the service life of the lubrication oil.

It is necessary to establish the relevant changing

interval by analyzing the old oil, with the first of these

analyses being carried 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

mm²/sec (cSt)

DIN 51 366, ASTM D 445.

DIN EN ISO 3104, (DIN 51 562-1*)

water content

DIN 51 366, ASTM D 1744.

(EN ISO 12937*)

glycol content

ppm

DIN 51 375, ASTM D 4291

TBN (total base number)

% or mgKOH**/g

ISO 3771

TAN (total acid number)

acc. to TBN

ASTM 664

SAN (strong acid number)

mgKOH**/g

ASTM 664

i ph (Initial ph value)

on request

oxidation 5.8 µm

A/cm

DIN 51 451

nitration 6.1 µm

A/cm

DIN 51 451

wearing metals

aluminium

mg/kg

DIN 51 396-2

chromium

mg/kg

DIN 51 396-2

copper

mg/kg

DIN 51 396-2

iron

mg/kg

DIN 51 396-2

lead

mg/kg

DIN 51 396-2

tin

mg/kg

DIN 51 396-2

silicon

mg/kg

DIN 51 391, ASTM D 5185

sodium

mg/kg

DIN 51 396-2

* CHP module with MAN engine

** potassium hydroxide

Table 4 Characteristic values of a lubrication oil analysis

Preparations

VITOBLOC 200 Operating instructions for the natural gas-fuelled CHP module 13

6130329 GB

The lubrication oil must be sampled directly from the

lubrication oil circuit, while the engine is running, or

from the lubrication oil pan immediately after the en-

gine has stopped. The first cubic centimetres of the

sample must be returned into the engine. Then fill the

clean sampling bottle and send it to the laboratory

without any delay.

Change the lubrication oil filter cartridges

• in accordance with the operating instructions or

the maintenance schedule, or

• at least once a year.

• Make the old oil available for recycling.

• Prevent the oil from seeping into the sewer system

or into the ground. Attention: Risk of drinking

water contamination.

• Treat disused filter inserts and cartridges as spe-

cial refuse.

In order to ensure that your plant is looked after and

taken care 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

Viessmann Kraft-Wärme-Kopplung GmbH are

applicable. For any warranty claims, the specific

maintenance intervals must be followed and if

required, demonstrated by means of oil analyses at

own responsibility.

Other engine lubricants

All other engine lubricants can be used at own re-

sponsibility according to the approved list of MAN

Truck & Bus AG (Document: MAN-Werksnorm

M3271-2 for natural gas). The oil change is subject to

the shortened maintenance intervals stated there and

must be carried out at own responsibility as per the

specifications / conditions.

approval granted to

product designation

viscosity class

synthetic oil gas-fuelled engines

Petro-Canada

Sentron LD 8000

SAE-40

Preparations

14 Operating instructions for the natural gas-fuelled CHP module VITOBLOC 200

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2.1.3 Coolants

Mandatory components

The cooling system must be filled with a mixture of

drinkable tap water and an anti-freeze agent contain-

ing a corrosion-preventive additive for engine cooling

systems.

- 62 vol.-% water

Suitable for this purpose is potable tap water with the

analysis values that are restricted as follows:

appearance: colourless, clear, and free from mechan-

ical contaminants

hardness: maximum 20° dGH

chloride: maximum 100 ppm

sulphate: maximum 150 ppm

pH-value at 20 °C: 6.5 - 8.5

PLEASE NOTE

Enquiries about existing analyses of the

drinking water can be made at the mu-

nicipal authorities. If the quality of the

drinking water is insufficient, mix the lo-

cally available drinking water with fully

dematerialized water or distillate or

condensate until the analysis values as

stipulated above have been achieved.

- 38 vol.-% anti-freeze agent

WARNING

Use only anti-freeze agents with corro-

sion-preventive additives for engine

cooling systems that have been ap-

proved in the CHP module manufactur-

er’s instructions for the operating 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 glycol 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 running

water with the lids spread apart and seek medical

advice thereafter.

Control of the coolant and its renewal

● Check the concentration every quarter year with a

density spindle or a refractometer.

● Never allow the anti-freeze concentration to drop

below 38 vol.-%.

● Always compensate losses of coolant with a mix-

ture of water and 38 vol.-% anti-freeze.

•

CAUTION

Do not use containers designated for

drinking water or foodstuffs

● The entire coolant must be exchanged after 2

years at the latest.

● Treat coolant as well as corrosion and/or anti-

freeze agents as special refuse when disposing

them.

● When disposing disused coolant observe the regu-

lations of the local authorities.

Preparations

VITOBLOC 200 Operating instructions for the natural gas-fuelled CHP module 15

6130329 GB

Approved anti-freeze agents

approval granted to

product designation

Agip Deutschland AG

Agip Antifreeze Plus

Agip Schmiertechnik

Agip/Autol Langzeitfrostschutz

Aral AG

Aral Kühlerfrostschutz A

Aral Kühlerschutz Extra Aral

Kühlerschutz D

Avia-Mineralöl AG

Avia Frostschutz

Avia Frostschutz APN

BASF AG

Glysantin G 03

Glysantin G 48

Glysantin mit Protect Plus

BASF/USA

BASF/USA BC Antifreeze G 9313

Bucher & Cie. AG/Switzerland

Frostschutz Motorex

Caltex Services Ltd.

Caltex CX Engine Coolant

DEA Mineral oil AG

DEA Kühlerschutz

Deutsche Shell Chemie GmbH

GlycoShell

DOW Chemical Europe S.A.

DOW Gefrierschutzmittel D 824-13F

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 Super

Mobil Oil AG

Frostschutz 500

Frostschutz 500 Plus

ÖMV AG

ÖMV Frostschutzmittel

Ravensberger

Ravenol Alu-Kühlerfrostschutz

Shell Aseol AG/Switzerland

Aseol Antifreeze 26-30

Aseol FN 26-33

Shell Austria AG

Glycoshell AF 511

Texaco Technology Europe/Ghent

Texaco Frostschutz NF (EXT 6024)

Total Deutschland GmbH

Total Multiprotect OZO Frostschutz S

Total OZO Frostschutz S

YACCO/France

Antigel Yacco

Table 6 Anti-freeze agents containing corrosion-preventive additives for the engine cooling system of a CHP module

Preparations

16 Operating instructions for the natural gas-fuelled CHP module VITOBLOC 200

6130329 GB

2.1.4 Heating water

Quality regulations for hot water in conformity

with VDI Guideline 2035

The current edition of the manufacturer’s data and

VDI Guideline 2035 (Guidelines for Preventing Dam-

age from Corrosion and Stone Formation in Warm

Water Heating Plants) are definitive for the quality of the

hot water.

The chloride content should not be in excess of 30 mg/l

and the quality of the heating water should satisfy the

requirements of VDI 2035.

VDI 2035 makes requirements of the quality of the hot

water depending upon the overall heating output and

specific plant content.

CAUTION

You can calculate the specific plant vol-

ume in several heat generators with the

smallest single heat performance (see

VDI 2035 for greater detail).

total heating perfor-

mance

total hardness

in KW

in °dH

at <20 l/kW

minimum boiler heating

surface

in °dH

at >20 l/kW <50 l/kW mini-

mum boiler heating surface

in °dH

at >50 l/kW

minimum boiler heating

surface

<50 kW

no requirements or

<16.8°dH

11.2°dH

0.11°dH

>50 kW <200 kW

11.2°dH

8.4°dH

0.11°dH

>200 kw <600 kW

8.4°dH

0.11°dH

>600 kW

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. Therefore,

the probability of damage from corrosion in metallic

materials is low in hot water which is low in oxygen.

Possible sources of oxygen input are:

● low-pressure formation in the heating system

● air inclusion with filling and supplemental water

● oxygen input through the heating water coming

directly into contact with air (an open system)

● oxygen diffusion via permeable components such

as seals, plastic pipes, membranes and hoses

● the oxygen content of the filling and supplemental

water

● expansion tank for boilers that are too small

Chemical additives to the heating water

There is normally not any corrosion in warm water

heaters that are correctly designed, installed and oper-

ated. This is why additives can generally be dispensed

with.

CAUTION

Do not use any chemical additives in the

heating water without obtaining a clear-

ance certificate from the manufacturer of

the chemicals with reference to the de-

sign of the heating plant and materials

used.

Preparations

VITOBLOC 200 Operating instructions for the natural gas-fuelled CHP module 17

6130329 GB

2.2 Filling Fuels

2.2.1 Disassembling/Assembling the

Sound Hood

CAUTION

Only ever use the supplied original cab-

inet spanner to avoid damage to the

locks.

Always remember the following when opening and

closing the locks:

Closing:

Raise the sound hood plate and press against the

corresponding frame.

Caution: There is the danger of breakage if the sound

hood plate drops. This is why it is necessary to wear

protective clothing/shoes.

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 op-

posite one another)

Opening:

Raise the sound hood plate and press against the

corresponding frame.

Caution: There is the danger of breakage if the sound

hood plate drops. This is why it is necessary to wear

protective clothing/shoes.

The lock is closed in the initial position

(the dot marks on the lock are opposite

one another)

Press on the sound-absorbing hood

while turning the spanner 90°

(the dot marks on the lock are now 90°

to one another)

Turn the spanner another 90°

(the dot marks on the lock are now 180°

to one another)

Preparations

18 Operating instructions for the natural gas-fuelled CHP module VITOBLOC 200

6130329 GB

2.2.2 Filling and venting the engine cooling system

Coolant with anti-freeze

Fill the cooling system with a mixture of potable tap

water and anti-freeze containing a corrosion-

preventive additive for engine cooling systems.

WARNING

Use only anti-freeze agents with corro-

sion-preventive additives for engine

cooling systems that have been ap-

proved in the CHP module manufactur-

er’s instructions for operating re-

sources. Please refer to section 2.3

“Coolants“ for a list of anti-freeze

agents with corrosion-preventive addi-

tives for engine cooling systems and

further information about the water

quality required.

Handling anti-freeze concentrate

WARNING

When handling anti-freeze concentrate

wear protective gloves and goggles

Please observe the safety data sheet

(which can be obtained from glycol

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

drinking water or foodstuffs.

● Mix the coolant in the required quantity and con-

centration.

WARNING

A minimum concentration of 30 vol.-%

of anti-freeze agent must always be ob-

served, since the corrosion protection

will not be ensured with less than the 30

vol.-% as required.

NOTE

Since the CHP module will be put up in

frost-free rooms (minimum temperature:

+10 °C), a higher anti-freeze concentra-

tion is not required. The cooling system

has been designed in such a way that a

coolant with a maximum of 30 vol.-% of

anti-freeze can remain in the system in

Central Europe also in summer, as long

as the cooling system as such functions

reliably.

Fill in quantities pursuant to the technical description

for the CHP module.

Preparations

VITOBLOC 200 Operating instructions for the natural gas-fuelled CHP module 19

6130329 GB

Filling the cooling system

• Connect the pressure hose of an electric pump

or of a hand pump with the intake (Fig. 1, item 1).

• Open the stop cock (Fig. 1, item 2) and fill in the

coolant slowly up to approx. 1 bar.

• Check the filling pressure at the manometer (Fig.

1, item 3). The pressure in the cold state has to

be in the range of 1.1-1.3 bar.

Venting the cooling system

• Remove 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 the cooling system

please make absolutely sure that no

flammable coolant is spilled on hot sur-

faces – danger of ignition.

Fig. 1 Intake for the engine coolant with stop cock and

manometer

Fig. 2 Vent connection for the engine cooling system at

the gas separator bypass

Preparations

20 Operating instructions for the natural gas-fuelled CHP module VITOBLOC 200

6130329 GB

2.2.3 Filling in engine lubrication oil

Fill in fresh engine lubrication oil

● into the engine and

● into the additional tank for fresh oil (reserve for

operating the automatic lubrication oil system).

WARNING

Use only engine oil for gas-fuelled en-

gines that has been approved in the

CHP module manufacturer’s operating

instructions (see sub-section 2.1.2

Fehler! Verweisquelle 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 special refuse. Change oil-

soaked clothing and shoes. Do not put oil-soaked

cloths into your pockets.

● Skin

Wash with water and soap or with special hand

cleaning paste and brush the relevant parts of the

body, if necessary.

● Eyes

Cover the eyes and seek medical advice immedi-

ately.

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Viessmann Vitobloc 200 EM-238/363 Operating Instructions Manual

Brand: Viessmann

Model: Vitobloc 200 EM-238/363

Type: Operating Instructions Manual

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Vitobloc 200 EM-530/660

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Viessmann Vitobloc 200 EM-238/363 Operating Instructions Manual

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