elco VARION C-POWER 30.0, VARION C-POWER 7.2, VARION C-POWER 25.0, VARION C-POWER 20.0, VARION C-POWER 11.0 Operation Manual
...
Operation manual
Combined heat and power unit
VARION® C-POWER S, M, M+
06.2019
Made in Germany
Contents
1. Document information. . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Validity. . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Supporting documents. . . . . . . . . . . . . . . . . 4
1.3 Safety instructions . . . . . . . . . . . . . . . . . . . 5
1.4 Explanation of symbols . . . . . . . . . . . . . . . . 5
2. Safety information ...........................6
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Authorised target groups . . . . . . . . . . . . . . . 6
2.2.1 Manufacturer ........................ 6
2.2.2 Operator ............................ 6
2.2.3 Trained personnel .................... 6
2.2.4 User ............................... 6
2.3 General safety instructions . . . . . . . . . . . . . . 7
3. Product information ..........................8
3.1 Functional principle . . . . . . . . . . . . . . . . . . 8
3.2 Registering with the energy provider . . . . . . . . . 8
3.3 Modes of operation . . . . . . . . . . . . . . . . . . 8
3.3.1 Ready for e-car charging button ........ 8
3.3.2 Summer operation ................... 8
3.3.3 Heat-optimised ...................... 8
3.3.4 Electricity-optimised .................. 8
3.3.5 Shutdown ........................... 8
3.4 Safety devices. . . . . . . . . . . . . . . . . . . . . . 9
3.5 Product variants . . . . . . . . . . . . . . . . . . . . 9
3.5.1 VARION® C-POWER S ................. 9
3.5.2 VARION® C-POWER M. . . . . . . . . . . . . . . . . 9
3.5.3 VARION® C-POWER M+ ............... 9
3.6 Product overview. . . . . . . . . . . . . . . . . . . 10
3.6.1 Generation unit ..................... 10
3.6.2 Control cabinet ..................... 10
3.6.3 Modem ............................ 10
3.6.4 Expansion tank connection block ...... 11
3.6.5 MSM adapter magnetic filter (“MSM
filter”) ............................. 11
3.7 Scope of supply . . . . . . . . . . . . . . . . . . . . 11
4. Storage ...................................12
5. Assembly ..................................13
5.1 Safety instructions for assembly . . . . . . . . . . 13
5.2 Installation location requirements . . . . . . . . . 13
5.2.1 Overview of the installation location ... 13
5.2.2 Premises ........................... 14
5.2.3 Heating system ..................... 15
5.2.4 Flue ............................... 15
5.2.5 Exhaust air duct ..................... 15
5.2.6 Supply air supply .................... 15
5.2.7 Gas supply ......................... 15
5.2.8 Water supply ....................... 16
5.2.9 Condensate drain ................... 16
5.2.10 Power supply ....................... 16
5.2.11 Reactive current compensation ........ 16
5.2.12 Mobile communications network ...... 16
5.3 Assembly steps . . . . . . . . . . . . . . . . . . . . 17
5.3.1 Preparing for assembly ............... 17
5.3.2 Unpacking the system ................ 17
5.3.3 Positioning the generation unit ........ 18
5.3.4 Screwing the control cabinet in position 19
5.3.5 Screwing the expansion tank
connection block in position 19
5.3.6 Connecting the generation unit ........ 19
5.3.7 Connecting the temperature sensors ... 23
5.3.8 Connecting the modem .............. 23
5.3.9 Connecting the control cabinet ........ 24
5.3.10 Checking the connections ............ 24
5.4 Test run . . . . . . . . . . . . . . . . . . . . . . . . 25
5.4.1 Opening the generation unit .......... 25
5.4.2 Preparing the expansion tank
connection block .................... 26
5.4.3 Replenishing the cooling water ........ 26
5.4.4 Starting the test run ................. 27
5.4.5 Checking the system ................. 27
5.4.6 Stopping the test run ................ 28
5.4.7 Closing the generation unit ........... 28
6. Commissioning .............................29
7. Operation .................................30
8. Cleaning ...................................31
9. Service repairs .............................32
9.1 Maintenance . . . . . . . . . . . . . . . . . . . . . 32
9.2 Fault resolution . . . . . . . . . . . . . . . . . . . . 32
9.3 Repair . . . . . . . . . . . . . . . . . . . . . . . . . 33
10. Disassembly ...............................34
11. Disposal ...................................35
11.1 Disposing of packaging. . . . . . . . . . . . . . . . 35
11.2 Disposing of the system . . . . . . . . . . . . . . . 35
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Operation manual VARION® C-POWER – S, M, M+ / 06.2019
12. Appendix ..................................36
12.1 Hydraulic diagrams . . . . . . . . . . . . . . . . . . 36
12.1.1 Heating system variant 1 –
1 VARION® C-POWER, 1 buffer tank,
peak load boiler connected directly to
buffer tank ......................... 37
12.1.2 Heating system variant 2 –
1 VARION® C-POWER, 2 buffer tanks,
peak load boiler connected directly to
buffer tank ......................... 38
12.1.3 Heating system variant 3 –
1 VARION® C-POWER, 1 buffer tank,
peak load boiler connected to buffer
tank via hydraulic separator ........... 39
12.1.4 Heating system variant 4 –
1 VARION® C-POWER, 2 buffer tanks,
peak load boiler connected to buffer
tank via hydraulic separator ........... 40
12.1.5 Heating system variant 5 –
2 VARION® C-POWER, 2 buffer tanks,
peak load boiler connected to buffer
tank via hydraulic separator ...........
12.2 Energy label . . . . . . . . . . . . . . . . . . . . . . 42
12.2.1
12.2.2 VARION® C-POWER M. . . . . . . . . . . . . . . . 42
12.2.3
12.3 EC declaration of conformity .
VARION® C-POWER S ................
VARION® C-POWER M+ ..............
. . . . . . . . . . .
41
42
42
43
Operation manual VARION® C-POWER – S, M, M+ / 06.2019
3
Document informaon
i
1. Document information
1.1 Validity
Original operation manual.
This manual is valid for the following products and
performance categories:
B VARION® C-POWER S
B VARION® C-POWER 5.0
B VARION® C-POWER 7.2
B VARION® C-POWER M
B VARION® C-POWER 11.0
B VARION® C-POWER 16.0
B VARION® C-POWER 20.0
B VARION® C-POWER M+
B VARION® C-POWER 25.0
B VARION® C-POWER 30.0
1.2 Supporting documents
i
Additional documents belong to this operation manual and
must be observed.
“ELCO/Control” operation manual
The “ELCO/Control” operation manual describes how
to control the system via the operational display and is
included in the scope of delivery.
Wiring diagrams
The wiring diagrams are located on the inside of the control
cabinet door.
Technical data
The document for technical data is included in the scope of
delivery.
Manuals for system components
The manuals for the supplied system components (e.g. MSM
filter, modem) are included in the scope of delivery.
Manuals for accessories
The manuals for optional accessories (e.g. flue gas silencer,
exhaust air kit) are provided with each product.
This document is valid for all products with a serial number
starting with “ID 2000” onwards.
The descriptions are identical for all products; any
differences are specifically highlighted.
All illustrations show the product “VARION® C-POWER S”.
In this manual, the word “system” is used to denote the
product.
This manual is protected by copyright law. Duplication,
reproduction and transmission is only permitted with the
permission of the manufacturer.
Subject to change without notice.
Maintenance manual
The maintenance manual describes specific tasks for
maintaining the system that must only be performed by the
manufacturer. The maintenance manual is not included in
the scope of delivery.
Forms
Various forms for exchanging information (e.g. commissioning
request, datasheet for the generation system) are included
with the delivery.
4
Operation manual VARION® C-POWER – S, M, M+ / 06.2019
Document informaon
i
1.3 Safety instructions
D DANGER!
Information highlighted with the word HAZARD warns
against a hazardous situation that will lead to death or
severe injury.
D WARNING!
Information highlighted with the word WARNING warns
against a hazardous situation that can lead to death or
severe injury.
D CAUTION!
Information highlighted with the word CAUTION warns
against a situation that can lead to minor or moderate
injuries.
1.4 Explanation of symbols
Text
A Required action
B List
Cross reference to another point in this document
D
Cross reference to other documents that must be
observed
Internet link
Ј
Illustrations
2.
B
D ATTENTION!
Information highlighted with the word ATTENTION
warns against a situation that can lead to material or
environmental damage.
1.
x
1. Numbered action sequence
A Part designations with upper case letters
x Dimensions with lower case letters or units in mm
Arrows indicating movement and direction
A
Operation manual VARION® C-POWER – S, M, M+ / 06.2019
5
Safety informaon
2. Safety information
2.1 Intended use
The system is a combined heat and power unit for
generating electricity and heat. The system is intended
exclusively for incorporation in heating circuits in buildings.
The system is designed for bivalent operation, i.e. it must
be combined with an additional heat source (“peak load
boiler”) in order to operate.
The system is designed for the following energy demand.
System Annual energy requirement
Electricity kWh Heat kWh
VARION®
C-POWER S
VARION®
C-POWER M
VARION®
C-POWER M+
The system is only permitted for use in a technically
sound condition once it has been commissioned by the
manufacturer or a specialist partner authorised by the
manufacturer.
Intended use also includes reading and following this
manual.
20,000 - 50,000 60,000 - 100,000
80,000 - 130,000 180,000 - 300,000
100,000 - 250,000 200,000 - 400,000
2.2.2 Operator
The operator is responsible for the building in which the
product is installed. The operator has the following duties:
B Fulfilling the requirements specified by the energy
provider (e.g. registration, approval, compensation).
B Meeting the installation location requirements.
B Training the user.
B Complying with statutory occupational health and safety
obligations.
B Complying with the valid safety, accident prevention and
environmental protection regulations.
B Providing and complying with the documentation.
B Ensuring that the product is always kept in a technically
sound condition.
B Storing the system when necessary.
2.2.3 Trained personnel
Trained personnel are responsible for the assembly,
maintenance, disassembly and disposal of the product.
The following points must be observed:
B All tasks must only be performed by qualified personnel
who have been trained by the manufacturer and who
are familiar with assembly technology, gas and water
installations, and current safety regulations.
B Special installation tasks (e.g. tasks involving the
building structure or the ventilation system) must only
be performed by the suitably qualified personnel of
specialist companies.
B Electrical installations must only be performed by
qualified, skilled electricians.
Only qualified personnel trained by the manufacturer have
access to the “Specialist” area of the “ELCO/Control” control
mechanism.
Any other use is considered contrary to intended use.
2.2 Authorised target groups
This manual is intended for various target groups that are
authorised for specific duties.
2.2.1 Manufacturer
The manufacturer, ELCO GmbH, supplies the product and
has the following duties:
B Training experts on assembly, maintenance, disassembly
and disposal.
B Commissioning the system.
Only the manufacturer has access to the “Experts” area of
the “ELCO/Control” control mechanism.
6
2.2.4 User
Users may perform operational and cleaning tasks on this
product. Obligations of the user:
B To be trained on the product by the operator.
B To be familiar with this manual.
Trained users have access to the non-protected areas of the
“ELCO/Control” control mechanism, but not to the “Experts”
and “Specialist” areas.
Operation manual VARION® C-POWER – S, M, M+ / 06.2019
Safety informaon
2.3 General safety instructions
D WARNING!
Hazard caused by failing to observe the manual.
This manual contains important information for handling the
system safely. Potential hazards are specifically highlighted.
Failing to observe such information can lead to death or
severe injuries.
A Read the manual carefully.
A Follow the safety instructions contained in this manual.
A Follow the safety instructions on the system
A Store the manual in an accessible place.
If you can smell gas, immediately proceed as follows:
B Close the gas valve.
B Do not generate any naked flames.
B Do not operate any electrical switches
(e.g. light switches, all-pole separating points).
B Do not use any electrical appliances in the
hazardous area (e.g. telephone).
B Ventilate the rooms.
B Inform the manufacturer, gas utility company or qualified
service company.
The manufacturer does not accept any liability or guarantee
for damage or loss in the following cases:
B Failing to observe this manual.
B Contrary-to-intended use.
B Improper handling.
B Use by unauthorised target groups.
B Failing to meet the installation location requirements.
B Using replacement parts that have not been authorised
by the manufacturer.
B Bypassing the system’s safety devices.
B Removing the system’s seals and sealants.
B Failing to comply with the maintenance intervals.
Additional safety instructions are provided in the respective
chapters of this manual.
“4. Storage” (page 12).
D
“5. Assembly” (page 13).
D
“6. Commissioning” (page 29).
D
“7. Operation” (page 30).
D
“8. Cleaning” (page 31).
D
“9. Service repairs” (page 32).
D
“10. Disassembly” (page 34).
D
“11. Disposal” (page 35).
D
Use of the system is prohibited in the following cases:
B If the system or individual components are damaged.
B If the system has been altered or modified without
authorisation.
B If the supply and return lines (e.g. gas, flue gas, water,
electricity, condensate drain) are altered or modified
without authorisation.
B If any safety devices are missing or inoperable.
“3.4 Safety devices” (page 9).
D
B During the construction phase of the building.
B If the system has been in storage for more than
16 weeks after delivery.
“9. Service repairs” (page 32).
D
B If the system has been decommissioned for more than
16 weeks.
B For children or individuals who are incapable of
assessing the hazards associated with operating the
system.
Operation manual VARION® C-POWER – S, M, M+ / 06.2019
7
Product informaon
3. Product information
3.1 Functional principle
The combustion of gas powers a high-performance
alternator that produces electricity.
The heat that is generated by this process is used for hot
water provision and heating.
This principle is referred to as combined-heat-and-power.
3.3 Modes of operation
The system can be operated in five modes of operation
(including shutdown). The modes of operation are set via
the operational display.
“ELCO/Control” operation manual.
3.3.1 Ready for e-car charging button
Special mode for charging electric
to produce electricity in this mode if the storage battery is
fully charged.
3.3.2 Summer operation
In summer operation mode, the system only operates at
minimum capacity. The system only starts if the storage
battery has insufficient charge.
3.3.3 Heat-optimised
The system starts if a temperature requirement has been
set. If the storage battery has reached a specific percentage
charge, the system begins to power down steplessly.
vehicles. It is still possible
The control mechanism manages and monitors the
combustion process in the generation unit. The system is
operated via the operational display on the control cabinet.
3.2 Registering with the energy provider
The energy provider must be informed about the installation
of the system. Obligations of the operator:
A Inform the energy provider about the system before it is
assembled.
A Fulfil the requirements specified by the energy provider
(e.g. registration, approval, compensation).
A Provide the energy provider with all the relevant system
data.
Technical data.
The electricity produced over and above the operator’s own
requirement can be fed into the energy provider’s local
electricity network in return for compensation. A suitable
application must be submitted to the energy provider for
this purpose.
3.3.4 Electricity-optimised
The system starts to operate according to a temperature
requirement. Once a specific storage battery charge has
been reached, the system aligns itself to the electricity
consumption of the building.
3.3.5 Shutdown
The system is in hibernation mode. The system does not
start according to temperature requirements.
8
Operation manual VARION® C-POWER – S, M, M+ / 06.2019
Product informaon
3.4 Safety devices
D WARNING!
Risk of burns, pinching or electric shock.
The safety devices are intended to ensure the system is
handled safely. Missing or faulty safety devices can lead to
hazardous situations.
A Ensure that the protection devices are not removed.
A Follow the safety instructions on the system.
A Only remove the covers if you are required and
authorised to do so.
The system is equipped with the following safety devices:
B Emergency stop switch
B Pressure-relief valve
B Protective covers
B Safety stickers
3.5 Product variants
3.5.1 VARION® C-POWER S
3.5.2 VARION® C-POWER M
B VARION® C-POWER 11.0
B VARION® C-POWER 16.0
B VARION® C-POWER 20.0
B VARION® C-POWER 5.0
B VARION® C-POWER 7.2
3.5.3 VARION® C-POWER M+
B VARION® C-POWER 25.0
B VARION® C-POWER 30.0
Operation manual VARION® C-POWER – S, M, M+ / 06.2019
9
Product informaon
3.6 Product overview
3.6.1 Generation unit
The generation unit contains the actual combined heat and
power unit with the combustion engine, the alternator unit
and the heat exchangers.
The generation unit is the core piece of equipment for
producing the electricity and heat.
H
A
B
I
C
J
D
E
K
F
G
L
3.6.2 Control cabinet
The control cabinet contains all the components required to
control the system.
A
B
E
B
F
C
G
D
A Housing
B Aeration and ventilation
C Control cabinet door
D Emergency stop switch
E Operational display
F Master switch
G Cable bushings
3.6.3 Modem
A “Buffer water supply line” connection
B “Flue gas” connection
C “Gas” connection
D “Condensate” connection
E “Buffer water return line” connection
F Control cabinet wiring harness
G Supply air intake grille
H Housing cover
I Expansion tank connection
J Type plate
K “Exhaust air” connection (room-air dependent)
L Hoop guard
The modem makes it possible to monitor the system
remotely and read data via the mobile communications
network.
A
C
B
D
A Antenna (slot “GSM Main”)
B Power supply
C GSM modem
D Connection cable (slot “LAN 1”)
10
Operation manual VARION® C-POWER – S, M, M+ / 06.2019
Product informaon
3.6.4 Expansion tank connection block
The expansion tank offsets temperature-related fluctuations
in volume within the motor circuit (primary circuit).
D
A
E
F
B
G
H
C
A Manometer
B Cap valve
C Expansion tank
D Self-bleeding device
E Pressure-relief valve
F Fill-and-drain valve (connection for replenishing "water-
glycol mixture 60:40")
G Connection to generation unit
H Drain valve
3.7 Scope of supply
A
B
C
D
E
F
H
I
J
K
L
3.6.5 MSM adapter magnetic filter (“MSM filter”)
The combination filter filters magnetite and suspended
solids out of the water in the heating system.
A
B
C
A
D
E
A Valve
B Filter head (with indication of the direction of flow)
C Lock nut
D Brass cup
E Filter cartridge
M
G
A Generation unit
B Control cabinet
C Expansion tank connection block
D MSM filter
E Valve
F Temperature sensor
G Modem
H Balance strips
I Rear cover
J Front cover
K Supply air intake grille
L Cooling medium ("water-glycol mixture 60:40")
M Square spanner
N Documentation (e.g. operation manual)
1
Includes 24 months of remote monitoring (effective from
commissioning; extension available subject to charge)
1
N
Operation manual VARION® C-POWER – S, M, M+ / 06.2019
11
Storage
4. Storage
The system is prepared by the manufacturer for operation
on delivery. The system must be put into operation within
16 weeks following delivery. If that is not possible, the
system must be put into storage.
Storage of the system by the operator.
“2.2.2 Operator” (page 6).
D
D ATTENTION!
Risk of damage caused by improper storage.
During long periods of downtime, lubricants and liquids
settle within the system. Frost and damp conditions can
damage parts of the system.
A Store the system in a frost-free, dry place.
A Arrange for the manufacturer to rust-proof the system if
it is to be kept out of operation for more than 16 weeks.
When taking the system out of storage, the next steps must
be discussed with the manufacturer.
A Contact the manufacturer.
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Operation manual VARION® C-POWER – S, M, M+ / 06.2019
Assembly
5. Assembly
5.1 Safety instructions for assembly
D WARNING!
Hazard caused by failing to observe the assembly
instructions.
Errors made when installing the system can cause serious
injuries or material damage to the system or the building.
This chapter contains important information regarding the
safe assembly of the system.
A Read this chapter carefully before assembling the
system.
A Follow the safety instructions.
A Carry out the assembly as described.
The assembly must only be performed by trained
personnel.
Electrical work must only be performed by qualified, skilled
electricians.
“2.2.3 Trained personnel” (page 6).
D
B The system must be undamaged and in a faultless
condition before assembly.
B Only use suitable fittings.
B Cables and lines must not be damaged, kinked or
crimped.
B Before assembling, ensure that the supply voltage has
been and remains disconnected.
The supply voltage is only reconnected when instructed
in the respective assembly step.
B The generation unit must be transported to
the installation location by means of a suitable
transportation device (e.g. lift truck).
If it is not possible to transport it to the installation
location (e.g. lack of space):
A Contact the manufacturer.
5.2 Installation location requirements
D WARNING!
Risk of suffocation, gas explosions or material damage
caused by incorrectly installing the system.
Failing to observe these requirements can lead to hazardous
situations when handling electricity or gas. This chapter
contains important information for preventing hazardous
situations.
A Ensure that all of the installation location requirements
are complied with.
5.2.1 Overview of the installation location
To operate the system, some equipment must be provided
on site. The following illustration shows examples of the
required components.
H
E
F
A
B
G
C
D
A Buffer tank
B Temperature sensor holding fixture
A Buffer water supply line
E Buffer water return line
E Reactive current compensation
F Modem
G Supply air opening
H Supply voltage
I Flue
J Flue gas silencer
K Condensate drain
L Gas supply
M Gas meter
N Gas flow monitor
K
I
J
L
M
N
Operation manual VARION® C-POWER – S, M, M+ / 06.2019
The heating system also includes the peak load boiler and
pipework system that connects the system via the buffer
tank.
13
Assembly
5.2.2 Premises
The premises must meet the following requirements:
B The installation location must comply with the effective
applicable laws and regulations for boiler rooms
(e.g. in Germany, the ordinance for heat-producing
appliances (Feuerstättenverordnung)).
B The substrate on which the generation unit is to be
installed must be flat, even, solid, dry and load-bearing.
B The ambient air temperature must be between
+5°C and +30°C.
B The system must be protected against frost and the
elements.
The following are not permitted:
B Installation on floating screed.
B Operation of tumble dryers in the same room.
B Storage of explosive or highly flammable materials
(e.g. paper, paints, petrol) within the installation
location.
B Use of aggressive substances (e.g. sprays, solvents,
chlorinated cleaning agents, paints, adhesives) in the
vicinity of the system.
If the system is installed in vaulted cellars or bare smoothwalled rooms (hard-walled), there is a risk of noise and
sound resonance.
Space requirement for VARION® C-POWER M
1480
643
708
> 1000
> 1000
1097
1233
> 1000
Space requirement for VARION® C-POWER M+
1659
> 1000
The system must be positioned so that the following
requirements are fulfilled:
B None of the system’s ventilation or extraction devices
may be blocked or closed.
B The emergency stop switch must always be accessible.
Space requirement for VARION® C-POWER S
1226
635
> 1000
> 1000
1097
> 1000
> 1000
1400
> 1000
781
> 1000
> 1000
> 1000
The minimum clearance to the generation unit (> 1,000 mm
on all sides) must be maintained.
14
Operation manual VARION® C-POWER – S, M, M+ / 06.2019
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