Viessmann VITOBLOC 200, EM-401/549, EM-363/498 Technical Description

5414 733 09/2009

Technical Description

VITOBLOC 200

Block-type thermal power plant – electricity and heat

from natural gas

Very efficient due to cogeneration

Total efficiency 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

Legal Notice

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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.

Table of Contents

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1 Introduction ....................................................................................... 4

1.1 Continuous output in parallel operation ....................................................................... 5

1.2 Stand-by operation .......................................................................................................... 5

1.3 Emissions of pollution .................................................................................................... 5

1.4 Energy balance sheet ..................................................................................................... 6

2 Product description .......................................................................... 7

2.1 Gas spark-ignition engine with accessories ................................................................ 7

2.2 Coupling ......................................................................................................................... 10

2.3 The three-phase synchronous alternator ................................................................... 10

2.4 Basic frame .................................................................................................................... 10

2.5 Piping ............................................................................................................................. 11

2.6 Heat transfer system ..................................................................................................... 11

2.7 Exhaust 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 module ................................................. 22

4.2 Technical data of a complete cogeneration module .................................................. 26

4.3 Dimensions, weights and colours .............................................................................. 30

4.4 Installation ..................................................................................................................... 31

4.5 Start-stop ratio ............................................................................................................... 31

4.6 Ecotax in Germany ........................................................................................................ 31

5 Important information on planning and operation ....................... 33

5.1 Malfunctions .................................................................................................................. 33

6 Index ................................................................................................. 34

Introduction

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1 Introduction

This block-type thermal power plant (cogeneration
module) is a complete turnkey unit with an air-cooled
synchronous alternator for generating a three-phase
current 400 V, 50 Hz and warm water at a
temperature level of forward feed/return of 85°/65° at

full load and a standard temperature spread of 20 K.
Each cogeneration module can be operated both
thermally and dependent on the electrical load in the
electrical load range of 50%-100% (corresponding to
60%-100% thermal output).

Basic scope of delivery - Series equipment

- Exhaust gas purification system for achieving

NOx and CO values in conformity with Technical
Instructions on Air 2002

- Switchgear, built into the cogeneration module to save

space. No added space needed and no added cabling

- DDC data transmission interface for transmitting

the cogeneration parameters to the building
process control technique as an RS 232
hardware module with 3924 R data protocol
(without RK512)

- Switchgear including alternator power circuit, control,

monitoring and auxiliary drive component and
microprocessing control system

- Documentation in conformity with DIN 6280 Part

14, 1 copy in paper form and 1 copy on data
medium (PDF) in German

- Self-sufficient lubricating oil 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 provided by the customer

- Low-harmonics three-phase synchronous alternator for

optional stand-by operation in a separate network

- Gas spark ignition engine from the factory

supplier. No gasified or self-developed engine

- Heat transfer medium built and tested according to the

Pressure Vessel Directive 97/23/EC.

- Gas controlled member in conformity with DVGW

and DIN 6280 Part 14, including the thermal shut­off valve and gas ball cock.

- Factory trial run with complete cogeneration (engine

alternator heat exchanger switching cabinet) in
conformity with DIN 6280, Part 15.

- History memory – electronic machine log for

complete recording of the most important
operating parameters .

- Protecting the exhaust gas heat exchanger from failure

due to poor hot-water quality, corrosion and cavitation
by integrating it into the internal engine cooling water
cycle.

- Design in conformity with the Gas Equipment

Directive 90/396/EEC and EU Machine Directive
with production in conformity with DIN ISO 9001.

- Calibrated current meter and elastic connections

contained in the scope of delivery.

Tab. 1 Basic scope of delivery for series equipment

Introduction

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1.1 Continuous output in parallel operation

Refer to pages 22-25, Tables 6 and 7 for outputs and
efficiency

The outputs and efficiency satisfy the requirements of
the standards ISO 3046/1 at 25° C air temperature,
100 kPa air pressure (up to 100 m installation height
above sea level),30% relative humidity and methane
number 80 and reactive factor cos phi = 1. The
tolerance for all efficiency, heat output and energy
applications is 5%.

All other data for the cogeneration module applies to
parallel operation. You are receiving the data for the
partial load range for the purpose of information
(although there is no guarantee corresponding to ISO
and DIN).

Only use natural gas fuel that is acceptable in
accordance with DVGW Directive G260, 2nd gas
family, group L. You can get all of the data needed for
other gas quantities and installation conditions at your
request.

Current characteristic number

The cogeneration module is a series product in
accordance with the Gas Equipment Directive without
heat dissipation equipment.

The current characteristic number is defined as the
quotient of the electrical output divided by the heat
output as per the AGFW FW308 worksheet. The figure
in Tables 6 and 7 (pages 22-25) is in the defined range
between 0.5 and 0.9 for internal combustion engine
cogeneration systems.

Primary energy 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 transformation, the lower the primary energy
factor.

Primary energy savings in accordance with the
EU Cogeneration Directive

The level of primary energy saved is the percentage
savings of fuels with combined power and heat
generation within a cogeneration process in relation
to the fuel heat consumed in reference systems of
non-combined power and heat generation.

The calculation formula is defined in Appendix III of
the EU Directive 2004/8/EG on promoting
cogeneration geared towards available heat needs.

1.2 Stand-by operation

Charged gas-fuelled engines are only suited for use
in stand-by operation to a limited extent due to their
characteristic torque curves (on request if
necessary).

The hot water return temperature may not be in
excess of 65° C either in stand-by operation or
parallel operation.

The stand-by operation function is not in connection
with operating an absorption refrigerating machine.

1.3 Emissions of pollution

The following emission values after the exhaust gas
purification system refer to dry exhaust gas at 5%
residual oxygen content.

Emission values

NOx content measured
as NO2

< 500 mg/Nm³

CO content

< 300 mg/Nm³

Formaldehyde CH2O

< 60 mg/Nm³

Tab. 2 Emission values after exhaust gas purification

Introduction

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1.4 Energy balance sheet

The energy balance sheet shows you a graph of the
energy flow of the cogeneration module.

The energy balance sheet illustrates the
transformation of primary energy (natural gas, 100%)
into electrical and thermal collectable energy. The
losses occurring with this transformation are also
shown.

The electrical collectable energy comes from the
combustion process in the spark-ignition engine and
is transformed into current 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 collectable
energy.

Energy balance sheets

EM-401/549 EM-363/498

Mixed cooling

externally 50°C internally 80°C

calorific value energy input

100 % 100 %

Mechanical energy

38.1 % 37.9 %

Thermal energy

61.9 % 62.1 %

Electrical collectable energy

38.1 % 37.8 %

Thermal collectable energy

54.6 % 51.9 %

Losses

7.3 % 10.3 %

Fig. 1 The energy balance sheet of the cogeneration module.

Product description

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2 Product description

The cogeneration module consists of a wide variety of
subassemblies and components that this chapter will
explain to you. The subassemblies and components
are part of the scope of delivery of the cogeneration
module.

2.1 Gas spark-ignition engine with

accessories

2.1.1 Gas spark-ignition engine

The gas spark-ignition engine is operated as an
internal combustion engine with turbocharging and
two-stage mixture cooling with an air ratio of lambda ≈

1.6.
A compressed oil jet cools the piston heads. The

exhaust gases are drained through a dry exhaust gas
collector pipe.

Components

The crankcase is cast in one piece together with the
cylinder block. The 2 parallel cylinder supports with
6 cylinders each (V arrangement) form the close of
the crankcase. The cylinder liners are wet-running,
replaceable and made of cast iron. The gearbox is
arranged on the flywheel side of the crankcase. It
includes the crankshaft seal and drive gears for the
camshaft and oil pump. The crankshaft made of
chromium-molybdenum steel is forged in the forging
die and nitride hardened. It is lodged at the end
and between the cylinders. The crank pins are
intended for lodging one connecting rod each.

The bearing shells are made of lead/bronze with a
lead/indium covering and they have a steel back. The
connecting rods are also forged of chromium­molybdenum 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 the crankcase. The cylinder
heads made of cast iron for each cylinder are
fastened onto the crankcase. They have cooling
ducts, holes drilled for holding the spark plugs and
one intake and exhaust valve per cylinder. The
valves mounted to be suspended have replaceable
valve bushings.

2.1.2 Engine lubricating oil system

The engine is lubricated via a pressure circulating
lubrication system.

The oil is pumped via gear-driven oil pump from the
oil sump through the oil cooler that is designed as an
oil/water ribbed tube cooler. The lubricating oil is
purified through an oil filter cartridge with a paper
insert in the main flow. From there, the filtered oil is
distributed over various oil channels.

The oil lubricates the crankshaft bearings, the
connecting rod bearings, the piston pins, the camshaft
bearings and the rocking arms. The gears are
lubricated in the gearbox with splash oil within the
crankcase. The crank space ventilation is connected
to the combustion air suction via oil screen.

Components

The engine lubricating oil system consists of the oil
sump, an oil pump, and oil filter with a paper insert
and various oil channels.

Special characteristics

The crank space ventilation is connected to the
combustion air suction via an oil screen.

Product description

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2.1.3 Engine cooling system

The engine is cooled with a closed water circuit.
The pump presses the cooling water into the

crankcase through the oil cooler. The cylinder pins
and cylinder heads are cooled with the built-in cooling
water ducts within the crankcase. The cooling water
leaves the engine again after flowing through the
water-cooled exhaust gas collector pipe.

Components

The engine cooling system consists of an electrically
driven pump, a safety excess pressure valve and a
membrane expansion vessel.

Special characteristics

Suitable action should be taken to protect the engine
from excessively low cooling water temperatures due
to the heating water return tempered at too low a level
or an excessively large heating water volume flow
such as return rise or hydraulic switching.
Consequential damage due to continuous operation
outside acceptable operating parameters is excluded
from the warranty.

2.1.4 Engine starter

The engine starter supports the starting process of the
gas spark-ignition engine.

The engage relay is used both for pushing the pinion
with tracking into the engine’s gear rim and closing
the contact bridge for switching on the main starter
current.

Single-track operation of the single-track gear is
formed so that the pushing motions of the engage
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 relay
and a single-track relay. The sliding-gear starting
engine has a voltage supply of 24 V with a power
consumption of 6.5 kW.

2.1.5 The battery starter system

The two batteries supply the electrical energy for starting
the engine to the engine starter and the ignition system
(24 V). The batteries also supply the electrical energy for
the monitoring and regulating equipment (24 V).

Components

The two batteries (lead batteries, 170 Ah, 2 x 12 V) are
maintenance-free and filled with liquid electrolytic.

Special characteristics

These batteries are supplied precharged dry and filled
when starting the cogeneration module.

2.1.6 Combustion air filter

The combustion air filter filters the combustion air fed
to the gas spark-ignition engine.

Components

The combustion air filter is a two-stage dry air filter
made of fully recyclable plastic with replaceable paper
filter cartridges. It is built into the feed air line (on the
filter output). The low pressure may not be any more
than 30 mbar in front of the gas mixer.

Special characteristics

The air filter has to be serviced according to the
specifications in the maintenance plan and applying
the specific conditions at the place of installation.

Product description

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2.1.7 The gas lane and gas-air mixer

The cogeneration module is supplied with gas through
a loosely supplied modular safety gas lane
(components approved in conformity with DVGW).

The gas lane should be located above the module in
the direct vicinity of the engine.

The gas-air mixer with the flanged butterfly valve
works according to the Venturi principle and mixes the
gas with the combustion air.

Components and functions

The gas lane is in the scope of delivery of the
cogeneration module in conformity with DIN 6280 Part
14 and consists of:

Precision gas filter (included in the delivery)

The precision gas filter protects downstream
equipment from soiling. The matted fleece filter mat
made of polypropylene offers a high level of
flowthrough output, a high degree of purification and
long service lives. The precision gas filter is mounted
outside of the module.

Elastic stainless steel hose line (included in the
delivery)

For decoupling the structure-borne noise between the
gas precision filter and ball cock with thermally
triggering blocking equipment.

The ball cock with thermally triggering blocking
equipment

A fusible cut-out arrests a closing body pretensed by
a compression spring. The fusible cut-out releases the
closing body when it reaches the triggering
temperature of 92°–100 °C. This closes into a closing
contour and forms a driving fit that is also maintained
when the compression spring loses its force due to
further temperature impact.

Gas-pressure guard for minimum pressure

The gas-pressure guard is engineered for the
application range in accordance with DIN 3398 Part 1
and Part 2 and designed for falling pressure.

Two magnetic valves

The two magnetic valves are engineered as group B
gas safety valves in accordance with DIN 3391/3394,
EN 161. The magnetic valves are made of spring­loaded valve discs and a screen to protect the valve
seat. The starting gas quantity and the volume flow
can be adjusted. The valve is closed without 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 the
block-type thermal power plant from starting. The
other gas valve continues to function without any
problems and reliably blocks the gas.

– Zero-pressure regulator for fully stabilising to
zero pressure after the gas lane

The zero-pressure regulator keeps the gas-air mixture
constant. The zero-pressure regulator is equipped
with a preliminary pressure equalisation membrane
for a high level of regulating accuracy with changing
preliminary pressures as well as with a zero close.

Linear actuator

The linear actuator functions according to the rotary
slide valve principle for linear flowthrough to adjust the
gas-air mixture for lambda regulation.

Elastic stainless steel hose line

The elastic stainless steel hose line is in the
cogeneration module.

Gas-air mixture with a butterfly valve
Special characteristics

The gas flow pressure has to be 25–50 mbar at the
transfer point from the block-type thermal power plant
to the gas regulation lane.

2.1.8 Ignition system

The ignition system supports the starting process of
the gas spark-ignition engine.

It only ignites through a camshaft pick-up during the
intake cycle. The angular ignition spacing
irregularities of each of the cylinders are realised via
holes drilled on the camshaft wheel.

Components

The ignition system is designed as a contactless
electronic capacitor discharge ignition system based
on the camshaft.

It consists of ignition coils (one coil per cylinder),
electrical ignition distribution, the revolution
transducer for the camshaft, silicon ignition cables,
spark plug sockets and the high-performance
industrial spark plugs for stationary gas-fuelled
engines.

Special characteristics

The ignition system can be adjusted for the point in
time of ignition when operating the inputs and outputs
for external adjustment of the point in time of ignition.
The safety equipment can also be turned off.

Product description

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2.2 Coupling

The coupling (flange coupling) connects the gas spark­ignition engine with the three-phase synchronous
alternator.

Components

The flange coupling is made from silicone rubber, is
highly elastic and can be attached axially. It allows a
connection between the gas spark-ignition engine and
the three-phase synchronous alternator that is elastic to
torsion. The disc-shaped rubber body stressed for the
torque-to-bore volume ratio dampens the torsional
oscillation which makes it possible to compensate for
defects in axial alignment.

The rubber disc elements are directly start vulcanised
onto a hub body on the inner diameter. There is cam
meshing for the coupling flange on the scope of the
element which creates a positive locking plug-and­socket connection in operation that is almost free of
play.

2.3 The three-phase synchronous

alternator

The three-phase synchronous alternator generates
electrical power with the aid of its rotational movement.

The three-phase synchronous alternator is driven by
the gas spark-ignition engine through a coupling. It is
flanged onto the gas spark-ignition engine via an
intermediate casing.

Components

The three-phase synchronous alternator is equipped with
automatic cos-φ regulation for operating between φ =0.8
inductive –1.0, with an adjustable static unit, electronic
voltage regulation with a low speed guard and an
additional permanent magnet exciting machine.

The standard 2/3 chorded stator winding allows low­harmonic 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 satisfies the requirements in
accordance with VDE 0530, DIN 6280 Part 3 and the
quality standard ISO 9002.

2.4 Basic frame

The basic frame carries the cogeneration module (the
gas spark-ignition engine, the three-phase
synchronous alternator, the exhaust gas heat transfer
unit, the lubricating oil system and the optional noise
protection elements The cogeneration switching
cabinet and ventilator group can be disassembled for
installation. Beams can be loosened in the upper zone
and on the side in the lower zone so that larger
building components with hoisting equipment or
ceiling cranes can be lifted without any obstacles in
inspection work.

Components

The basic frame consists of a hollow-profile
construction of solid normal steel that is rigid to
twisting. The hydraulic interfaces for the gas, exhaust
gas, condensate, hot water and aggregate ventilation
are brought out on what are known as the “connecting
side” ready to be connected for the extensions
provided by the customer. The other three sides are
freely accessible to operation and maintenance.
Rubber elements are mounted on the basic frame that
takes the ventilating engine/alternator unit. The basic
frame is installed on Sylomer strips on the floor
without any fixed anchoring.

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2.5 Piping

The piping is premounted in the factory. It connects
the most important elements of the block-type thermal
power aggregate (cooling water heat transfer unit,
exhaust gas heat transfer unit and engine). These
elements are completely piped on the cooling water,
heating and exhaust gas side and insulated wherever
necessary.

Components

All pipe connections have metal compensators and
flexible hose connections to decouple vibrations and
they are engineered as flange or flat-sealing screwed
connections. Lines conducting water are engineered
in normal steel and the pipelines conducting exhaust
gas are engineered in stainless steel.

2.6 Heat transfer system

The heat transfer system consists of the exhaust gas
heat transfer unit and the cooling water heat transfer
unit. This heat transfer unit takes advantage of the
waste heat from the engine and the exhaust gas via
heat transition.

Special characteristics

The heat exchangers are dimensioned in conformity
with the Pressure Vessel Directive 97/23/EEC and the
pipelines are insulated wherever necessary.

2.6.1 The exhaust gas heat transfer unit

The exhaust gas heat transfer unit transfers the waste
heat from the exhaust gases of the gas spark-ignition
engine into the water cycle.

Components

The exhaust gas heat transfer unit has welded-in tube
bottoms made of stainless steel 1.4571 and a straight
tube bundle (for optimum cleaning).

The intake chamber is made of stainless steel 1.4828
and the output chamber is made of stainless steel

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 that it is protected from thermal tension
due to insufficient heating water quality.

2.6.2 Cooling water transfer unit (Plate
transfer heat unit )

The soldered plate transfer heat unit transfers the
waste heat from the gas spark-ignition engine and
exhaust gas into the water cycle.

Components

The plate transfer heat unit is made of a package of
plates that is soldered with 99.99% copper in the
vacuum process.

Every second plate is rotated 180° on the plane which
forms two flow spaces separated from one another
where media (engine cooling water and heating
water) is conducted in the counterflow. The stamping
of the plates causes a highly turbulent flowthrough
that allows highly effective heat transfer even at low
volume flows.

Special characteristics

The heat transfer unit is designed without a frame for
mounting the pipelines and the material for the plates
is stainless steel 1.4404 (AISI316).

2.6.3 Mixed cooling

Mixed cooling is done in two stages.
Both stages are integrated into the internal engine

cooling circuit in the EM-363/498 model.
The high-temperature stage is only integrated into the

engine cooling water cycle in the EM-401/549 model.
The low-temperature stage should be separately
supplied with external cooling water.

IMPORTANT

The system pressure in the low­temperature stage may not be in
excess of 2 bar. Otherwise, the
customer should use a heat exchanger
to separate the hydraulic system.

Product description

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2.7 Exhaust gas purification system

After purifying the exhaust gas, it is conducted
through the exhaust gas heat transfer unit that is
mounted in the frame in a lying position.

An oxidation catalyst (oxidising CO and CnHm)
reduces the pollution emissions of the exhaust gas.

Components

The active catalytic coating is applied to heat resistant
steel. The monolithic metallic substrate consists of
stainless steel ferritic sheeting with walls 0.04 mm
thick. The casing is made of stainless steel with high
temperature-resistance. The exhaust gas output
flange is mounted on the connecting side of the
cogeneration module.

Special characteristics

The operating temperature of the catalyst is limited to
less than 700° C to avoid early ageing.

The catalyst is integrated into the exhaust gas line
after the engine to be service-friendly and the lambda
probe for lambda≈1.6 operation is installed
immediately after the engine output in the exhaust gas
system of the cogeneration module.

2.8 Lubricating oil supply system

Each cogeneration module has equipment for
monitoring the lubricating oil level. You can observe
and check the oil level with the inspection glass. You
can check the minimum and maximum levels with an
alarm contact via electrical level control. The oil
consumption is covered from a lubricating oil storage
tank with a volume designed for ≥ one maintenance
interval.

The quantity of used oil can be drained from the
cogeneration module with a free slope. It is collected
and disposed of in a used oil drum. The fresh oil is
generally filled with 20-litre tins.

Components

The lubricating oil supply system consists of a
lubricating oil level guard, inspection glass 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, the fresh oil tank and the
engine cooling water for reasons of safety. This
means that it satisfies the requirements of the
Wasserhaushaltsgesetz (German Water Resources
Act).

2.9 OPTIONAL Sound insulation hood

and exhaust ventilator cowl

The lining of the cogeneration module consists of the
noise insulation hood and elements for the
engine/alternator unit and the linings of the heat
exchanger unit. The exhaust ventilator cowl ventilates
the cogeneration module.

Components

The sound insulation elements consist of steel
sheeting lined with combination elements made of
composite foam (200 kg/m³) and highly absorptive
soft foam with an additional surface skin. The coating
is 25 µm thin and it is largely resistant to benzene and
engine oil splashing and easy to clean. The surface
sealing protects from mechanical damage and has a
high level of durability. Fire properties in accordance
with FMVSS 302 or DIN 75200.

The combustion air suction is on the roof lining
outside of the noise hood.

Fresh air is suctioned on the side of the aggregate
sound lining.

The hood’s frequency medium for dampening noise is
approximately 20 dB. The subsequent heavy canvas
connection is contained in the scope of delivery.

Special characteristics

The load-bearing construction can be disassembled
for inspection to work with suitable hoisting gear
without obstructions.

The lining of the cogeneration module can be easily
removed for assembly work.

2 exhaust ventilator cowls have a maximum of 500 Pa
pressing for stable operating properties at higher air
inlet temperatures up to approximately 35 ° C.

Product description

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2.10 Series-production accessories

2.10.1 Set of elastic connections

Elastic connections are used for optimum structure­borne noise decoupling to the pipe connections of the
cogeneration module.

Components

● 1 exhaust gas axial compensator – rated width DN

200, flange PN 10, licensed in accordance with
DVGW

● 2 heating ring corrugated hose lines – rated width

DN 80, flange PN 10, rated length NL 1000, with lot
flange PN 10, made of steel

● 2 heating ring corrugated hose lines – rated width

1“ , flange PN 10, rated length NL 1000 for mixture
cooling with the EM-363/498 model.

● 1 gas axial compensator - NW DN 65 PN 6,

bellows made of stainless steel 1.4571, several
layers, with screwed connections made of
malleable iron, 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 office on the premises
of the manufacturer. Calibration valid 8
years. No separate expert opinion or
certificate is necessary pursuant to the
German calibration regulation, although
the meter manufacturer has to comply
with the statutory regulations.

Supply

Installation into the module switching cabinet

2.11 Monitoring equipment

Monitored by transmitters for oil pressure, cooling
water temperature, exhaust gas temperature, heating
water temperature, speed and transmitters for
minimum cooling water pressure, minimum
lubricating oil level and safety temperature limiter,
including the cabling to the switching cabinet.

Product description

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2.11.1 Vitobloc 200 EM-401/549

Fig. 2 The Vitobloc 200 EM-401/549 model monitoring equipment with a separate low-temperature circuit;

(optional items 80 and 83)
The customer should provide hydraulic separation
when the system pressure in the mixed cooling water circuit (17+18) is in excess of 2 bar.

Overall legend:

1 cogeneration module (scope of

delivery)

2 provided by the customer
10 deflagration guard (biogas)
11 safety valve (heating water)
12 heating water pump
13 return temperature controller
14 Heating water return
15 heating water forward feed
16 power current 400 V, 50 Hz
17 mixed cooling water forward feed
18 mixed cooling water return
19 mixed cooling water pump
21 safety valve (motor cooling water)
22 oil cooler
23 cooling water pump
24 membrane expansion unit
25 cooling water heat exchanger
26 dirt trap
27 shut-off valve
31 exhaust gas heat exchanger
32 sound absorber
33 condensate water output
34 exhaust gas output
35 catalyst
41 lambda regulating valve
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-air mixer
67 alternator
68 exhaust gas collection line
69 engine
70 speed controller and butterfly valve
71 turbocharger
72 intercooler (1st stage)
73 intercooler (2

nd

stage)

74 blow-off valve for low-temperature
circuit

80 exhaust ventilator cowl
81 exhaust air
82 additional air
83 sound-absorbing hood

Measuring points

EIA alternator-display monitoring
ES alternator output control
LS level control
LZA minimum level control
P pressure
PC pressure regulator
PI pressure indicator
PO visual pressure indicator
PZA- minimum pressure shut-off
PZA+ maximum pressure shut-off
SC speed controller
STB safety temperature limiter
SZA- underspeed
T temperature
TA exhaust air temperature before

the ventilator

TC temperature controller
TI temperature indicator
TZA+ alternator winding temperature

monitoring

XC lambda probe

* Provided loose for assembly by the

customer

** optional equipment

Product description

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2.11.2 Vitobloc 200 EM-363/498

Fig. 3 Vitobloc 200 EM-363/498 monitoring equipment model; (optional items 80 and 83)

Overall legend:

1 cogeneration module (scope of delivery)
2 provided by the customer
10 deflagration guard (biogas)
11 safety valve (heating water)
12 heating water pump
13 return temperature controller
14 Heating water return
15 heating water forward feed
16 power current 400 V, 50 Hz
17 mixed cooling water forward feed
18 mixed cooling water return
19 mixed cooling water pump
21 safety valve (motor cooling water)
22 oil cooler
23 cooling water pump
24 membrane expansion unit
25 cooling water heat exchanger
26 dirt trap
27 shut-off valve
31 exhaust gas heat exchanger
32 sound absorber
33 condensate water output
34 exhaust gas output
35 catalyst
41 lambda regulating valve
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-air mixer
67 alternator
68 exhaust gas collection line
69 engine
70 speed controller and butterfly valve
71 turbocharger
72 intercooler (1st stage)
73 intercooler (2

nd

stage)

74 blow-off valve for low-temperature circuit
80 exhaust ventilator cowl
81 exhaust air
82 additional air
83 sound-absorbing hood

Measuring points

EIA alternator-display monitoring
ES alternator output control
LS level control
LZA minimum level control
P pressure
PC pressure regulator
PI pressure indicator
PO visual pressure indicator
PZA- minimum pressure shut-off
PZA+ maximum pressure shut-off
SC speed controller
STB safety temperature limiter
SZA- underspeed
T temperature
TA exhaust air temperature before the

ventilator

TC temperature controller
TI temperature indicator
TZA+ alternator winding temperature

monitoring

XC lambda probe

* Provided loose for assembly by the

customer

** optional equipment

Product description

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2.12 Switching cabinet

The switching cabinet is mounted on the cogeneration
module. All the following components including
cabling are in the cogeneration module.

2.12.1 Brief description

Alternator power circuit

4-pole power circuit with thermal/magnetic trigger, manual operation
Alternator contact
Set of current transformers
calibrated kWh current meter including transformer

Control, monitoring and auxiliary drive component

Synchronisation and mains monitoring
Control system and relay for the KW pump, starter, exhaust ventilator cowl and gas lane
Output regulation for warm running, constant/sliding value with ramp function when starting and stopping speed and

output regulation with the electronic speed regulator functioning with an electrical actuator and mixed butterfly 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 for EVU, parametering and manual operation
Potential-free inputs for remote start, constant/sliding value regulation and substitute network start
History memory for recording the minimum/maximum analogous values for streamlining operation
Fault memory for undeletable recording of complete chains of faults with operating parameters for systematic fault

analysis
DDC interface via RS 232 with 3964R protocol (RK 512 should be put together by the customer as per the

hardware/software provided by the customer) – other interfaces on request
Operating and centralised fault indication with potential-free contacts
Option of remote data monitoring

Tab. 3 The components of the switching cabinet

Product description

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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

Product description

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2.13 Check-list for stand-by operation

The following items should be discussed with the
manufacturer of the block-type thermal power plant
and resolved when planning the systems of the block­type thermal power plant in stand-by operation or
systems in accordance with VDE 0108.

● The operating mode of the substitute network

system?
At least one single-line diagram should be
submitted for resolution. The switches to be
triggered by the block-type thermal power plant
should be stated or marked in the plan.

● What loads have to be supplied?

A list of the highest-performance consumers giving
the outputs and currents. Then the manufacturer of
the block-type thermal power plant defines the
acceptable load connection. It might be necessary
for the customer to provide a load-shedding switch
after consultation.

● Protective measure: The customer should check

the selectivity of the fuses.

● The acceptable hot-water return temperature with

block-type thermal power systems for stand-by
operation is no more than 65° C in parallel and
stand-by operation. That means that these block­type thermal power systems are not only suited to
supplying absorption refrigerating machines.

● The main gas magnetic valve, the network section

switch and the corresponding open-circuit shunt
release have to have a battery-buffered voltage
supply.
230 V supply voltage for the main gas magnetic
valve or network section switch is not permitted.
The main gas magnetic valve and the drive of the
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 systems provided by
the customer such as heating or ventilation may
make the block-type thermal power plant switch off
if there is a mains failure due to such things as a
lack of heat reduction. In this case, the higher­level regulation should be equipped with a
separate uninterruptible power supply.

● Stand-by operation should be tested immediately

after starting up the block-type thermal power plant
with everyone involved. If this is not possible, it will
be necessary to have a second date that will be
charged according to expenditures.

● Sprinkler pump supply is subject to the more

stringent VdS regulations so that is cannot be
assured with the normal design of a block-type
thermal power plant.

● The appropriate process control technique (such

as multi-module management) should be provided
with active-power load distribution if several
cogeneration modules are used in stand-by
operation.

● We do not recommend switching the block-type

thermal power plant up to any emergency-power
diesel alternator because the gas and diesel
engines have different regulating characteristics.
The basic prerequisite would be that the
emergency-power diesel alternator is
correspondingly equipped for parallel operation
with other power alternators (such as regulating
alternator voltage or digital inputs for active-power
load distribution on the control system of the diesel
alternator).

Service and maintenance

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3 Service and maintenance

There are what is known as consequential costs
“connected to operation” for the cogeneration module
in the form of inspection, service and maintenance.

The cogeneration module is exposed to many factors
such as wear and tear, ageing, corrosion and
thermal/mechanical loads as a result of its intended
operation. DIN 31051 designates this as wear. The
design of the component parts of the cogeneration
module gives them a wear reservoir that guarantees
reliable operation for the cogeneration module in
accordance with the operating conditions up to the
impairment of their functionality. Afterwards, these
parts should be replaced according to specific wear
and limited-time components.

Definition of "wear parts" according to DIN 31051

Wear parts are parts that are unavoidably subject to
wear due to operation and that are intended to be
replaced. They essentially include spark plugs and
air/oil filters. This 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 cylinder heads,
bearing shells, catalysts and heat transfer units. They
are replaced at longer intervals depending upon the
results of inspections. This is where we talk of
maintenance.

Having authorised personnel correctly service the
cogeneration module is very important for its warranty
and for it to function without any problems. Only
original parts and the operating resources (such as
lubricating oil) approved by the manufacturer of the
block-type thermal power plant may be used. The
operator is responsible for guaranteeing and
complying with the regulations for operating
resources.

IMPORTANT

Service should be carried out at least
once a year and the cooling water
should be changed no later than every
2 years.

NOTE

The expected service life of the
cogeneration module is no less than 10
years if it is regularly serviced and
maintained.

Service and maintenance

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3.1 Service and maintenance list

service level service work

A

tighten the cylinder head screws (only at 400 operating hours)

A/B/C

oil change

A/B/C

replace oil filter

A/B/C

check battery state and charge voltage / or fill distilled water

A/B/C

check the air filter and change wherever necessary

A/B/C

measure the valve play or adjust wherever necessary

A/B/C

check the cooling water pressure and vent wherever necessary

A/B/C

check or clean the condensate drain / check the neutralisation

A/B/C

check the butterfly valve and rod assembly and lubricate wherever necessary

A/B/C

measure the ignition cables and replace wherever necessary and check the spark plugs

A/B/C

check the point in time of ignition

A/B/C

check the spark failure limit

A/B/C

record or print out 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

change the spark plugs (from 1,000 operating hours)

B/C

check antifrost concentration and refill

B/C

check compression

B/C

check the alternator air suction and clean wherever necessary

B/C

test the reverse performance monitoring

B/C

check the gas lane for sealing and check the gas filter

B/C

test the overspeed shut-off

B/C

test the excess exhaust gas temperature shut-off

B/C

test the excess cooling water temperature shut-off

B/C

test the minimum oil pressure shut-off

B/C

check/clean pick-up

B/C

change the lambda probe

B/C

clean the gas mixer

C

change the cooling water (within 24 months)

C

check the crankshaft space ventilation and change wherever necessary

Tab. 4 Service List

Service and maintenance

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maintenance level maintenance work

i1/i2/i3/i4

check and clean exhaust gas heat exchanger

i1/i2/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 Maintenance list

Technical Data

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4 Technical Data

All subsequent planning and operating data refer to
a cogeneration module.

You can find detailed instructions on planning and
design in the "Natural Gas Block-Type Thermal Power
Plant Series – Project Management."

4.1 Operating parameters for the cogeneration module

4.1.1 Vitobloc 200 EM-401/549

Operating parameters for the cogeneration module

V

itobloc 200 EM-401/549

Continuous operation1) in parallel
operation

50%

load

75%
load

100%

load
electrical output cannot be overloaded kW 200 300 401
heat output of high temperature tolerance 5% kW 316 423 549
heat output of low temperature tolerance 5% kW 6 11 26
fuel usage tolerance 5% kW 609 831 1,053
current characteristic value in accordance with AGFW FW308 (electrical

output/thermal output)

0.73

Primary energy factor ENEV 2007 fPE 0.71
primary energy savings PEE in accordance with Directive 2004/8/EG support

for cogeneration

% 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 energy (heat) NT forward/return temperature ° C 42/45

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 ltr. 200
cooling water ltr. 140
heating water ltr. 75
gas connecting pressure 3) mbar 25 - 50
Heat generation (heating)
return temperature in front of the module min./max. ° C 60/65
standard temperature difference return/forward feed k 20
heating water volume flow standard m³/h 23.5
maximum acceptable operating pressure at high

temperature

bar 16

maximum acceptable operating pressure at low
temperature

bar 2

pressure loss at standard flowthrough in the HT module standard bar 0.8
pressure loss at standard flowthrough in the NT module standard bar 0.5

Technical Data

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Pollution emissions 4) in accordance with the Technical Instruction for Air 2002

NOx content measured as NO2 mg/Nm³ < 500
CO content mg/Nm³ < 300
formaldehyde CH2O mg/Nm³ < 60

Sound intensity level 1 free field meter away in accordance with DIN 45635
(tolerance to the specified values 3 dB(A))
exhaust air noise measured 1 meter after the channel

machine

6)

without sound hood dB (A) 91
with optional sound hood dB (A)

exhaust ventilator cowl

5)6)

without sound absorber dB (A)

exhaust gas7)

without sound absorber dB (A) 73
with sound absorber dB (A)

Combustion air and ventilation

module’s radiating heat without connecting line kW 39
installation room ventilation additional air volume flow m³/h >13,000
targeted exhaust air volume

flow

m³/h 13,000

maximum exhaust air

volume flow

m³/h 14,000

combustion air volume flow at 25 °C and 1,000 mbar m³/h 1,700
additional air temperature min./max. ° C 10/25
temperature difference additional air/exhaust air k < 20
pressing of the built-in exhaust

ventilator cowl

max. Pa 500

Exhaust gas

exhaust gas volume flow, moist at 120 °C m³/h 1,750
exhaust gas mass flow, moist kg/h 2,200
exhaust gas volume flow, dry 0 % O2 (0 °C; 1012 mbar) Nm³/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 operation; data for other installation conditions on request

2) cooling water pump, ventilator, battery charger, control transformer and mixed cooler pump

3) Gas connecting pressure is in accordance with DVGW-TRGI 1986/96 of the gas flowing pressure at the beginning of the module’s gas regulating
route

4) Emission figures after the catalyst with reference to dry exhaust gas; briefer service and exchange intervals for the catalyst should be considered

for the operation in accordance with the ½ values of the Technical Instruction for Air (with reference to CO)

5) at 500 Pa pressing, thermostat stage 100%

6) It contains the exhaust ventilator cowl and sound-absorbing hood for the Vitobloc 200 EM-401/549 and Vitobloc 200 EM-363/498 modules.

7) insert damping of the secondary exhaust gas sound absorber on request

Tab. 6 Operating parameters for the entire Vitobloc 200 EM-401/549 cogeneration module

Technical Data

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4.1.2 Vitobloc 200 EM-363/498

Operating parameters for the cogeneration module

V

itobloc 200 EM-363/498

Continuous operation 1) in parallel operation

50%

load

75%
load

100%

load
electrical output cannot be overloaded kW 181 271 363
heat output tolerance 5% kW 302 404 498
fuel usage tolerance 5% kW 549 756 960
current characteristic value in accordance with AGFW FW308 (electrical

output/thermal output)

0.73

Primary energy factor ENEV 2007 fPE 0.71
primary energy savings PEE in accordance with Directive 2004/8/EC support

for cogeneration

% 24.6

efficiency in parallel operation

electrical efficiency % 33.0 35.9 37.8
heat efficiency % 55.0 53.0 51.9
total 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 ltr. 200
cooling water ltr. 140
heating water ltr. 75
gas connecting pressure 3) mbar 25 - 50

Heat generation (heating)

return temperature in front of the module min./max. ° C 60/65
standard temperature difference return/forward feed k 20
heating water volume flow standard m³/h 22
maximum acceptable operating pressure bar 16
pressure loss at standard flowthrough in the module standard bar 0,5

Pollution emissions 4) in conformity with the Technical Instruction for Air 2002

NOx content measured as NO2 mg/Nm³ < 500
CO content mg/Nm³ < 300
formaldehyde CH2O mg/Nm³ < 60

Technical Data

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Sound intensity level 1 free field meter away in accordance with DIN 45635
(tolerance to the specified values 3 dB(A))
exhaust air noise measured 1 meter after the channel

Machine

6)

without sound hood dB (A) 91
with optional sound hood dB (A)

exhaust ventilator
cowl

5)6)

without sound absorber dB (A)

exhaust gas 7)

without sound absorber dB (A) 73
with sound absorber dB (A)

Combustion air and ventilation

module’s radiating heat without connecting line kW 38
installation room ventilation additional air volume flow m³/h >13,000
targeted exhaust air volume

flow

m³/h 13,000

maximum exhaust air

volume flow

m³/h 14,000

combustion air volume flow at 25 °C and 1,000 mbar m³/h 1,630
additional air temperature min./max. ° C 10/25
temperature difference additional air/exhaust air k < 20
pressing of the built-in exhaust ventilator

cowl

max. Pa 500

Exhaust gas

exhaust gas volume flow, moist at 120 °C m³/h 1,800
exhaust gas mass flow, moist kg/h 2,250
exhaust gas volume flow, dry 0 % O2 (0 °C; 1012 mbar) Nm³/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, ventilator, battery charger, control transformer and mixed cooler pump

3) Gas connecting pressure is in accordance with DVGW-TRGI 1986/96 of the gas flowing pressure at the beginning of the module’s gas regulating
route

4) Emission figures after the catalyst with reference to dry exhaust gas; briefer service and exchange intervals for the catalyst should be considered

for the operation in accordance with the ½ values of the Technical Instruction for Air (with reference to CO)

5) at 500 Pa pressing, thermostat stage 100%

6) It contains the exhaust ventilator cowl and sound-absorbing hood for the Vitobloc 200 EM-401/549 and Vitobloc 200 EM-363/498 modules.

7) insert damping of the secondary exhaust gas sound absorber on request

Tab. 7 Operating parameters for the entire Vitobloc 200 EM-363/498 cogeneration module

Technical Data

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4.2 Technical data of a complete cogeneration module

4.2.1 Vitobloc 200 EM-401/549

Technical data for the cogeneration module

V

itobloc 200 EM-401/549

engine with accessories

gas spark-ignition engine manufacturer MAN
engine model E 2842 LE 322
functioning 4-stroke
number of cylinders/arrangement 12 / V arrangement
bore/stroke mm 128/142
displacement ltr. 21.93
speed min

-

1

1,500
mean piston speed m/s 7.1
compression ratio 12 : 1
mean effective pressure bar 15.32
standard output1) cannot be overloaded kW 420
specifications full load consumption tolerance 5% kWh/kWh

mech

2.57
gas consumption for instance, at Hi = 10 kWh/m³ Nm³/h 102.8
lubricating oil quantity in the oilpan ltr. 90
lubricating oil consumption (mean) g/h approx. 130
engine weight (about) kg 1,415

Heat exchanger system for the engine cooling system (engin e blo ck and lubricating oil)

heat output tolerance 5% kW 236
cooling water temperature intake/output ° C 80 / 85.8
cooling water volume flow m³/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 system for high temperature (turbocharger)

heat output tolerance 5% kW 56
cooling water temperature intake/output ° C 80 / 82.8
cooling water volume flow m3/h 17.5

Mixed cooling low temperature (turbocharger)

heat output tolerance 5% kW 16
cooling water temperature intake/output ° C 42 / 45
cooling water volume flow m3/h 4.6

Plate heat exchanger

heat output kW 530
cooling water temperature intake/output ° C 88.6 / 80
heating water temperature intake/output ° C 65 / 85
pressure loss bar 0.6
Material of plates 1.4404

Rated widths

exhaust gas connection (AA) from the cogeneration module and pipe connection DN 200 / PN 10
condensation water connection (AKO) and pipe connection pipe ( 22 x 2.0
heating water forward/return (V/R) and pipe connection flange DN 80 / PN 16
gas connection (GAS) and pipe connection flange DN 65 / PN 16

Technical Data

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5414 733 09/2009

Alternator

model output kVA 550
three-phase current voltage/frequency V / Hz 400/50
speed min

-

1

1,500
efficiency at the rated output of the module and cos φ = 1 % 96.0
rated current A 793
continuous short-circuit current A 3-5 times the rated current
maximum acceptable load

application

A 200

stator circuit-breaker star
ambient temperature max. ° C 40
protection class IP 23

Time constants in seconds

open circuit transient Td'o sec. 1,858
short-circuited circuit transient Td' sec. 0.1
short-circuited circuit subtransient Td'’ sec. 0.01
with short-circuited field Ta sec. 0.015

Cabling to the cogeneration terminal box

NSHV protection (recommended) A 1,000

Minimum required design for correctly connecting the cogeneration system

2)

network connection to the NSNV, system-tie field or transformer

H07 RNF 5 x 3 x 185 mm²

remote selection for heat operation 100% output provided by the customer

Ölflex 12 x 1.5 mm²

feedback (potential-free contact) module "ready"
feedback (potential-free contact) module "operation"
feedback (potential-free contact) module "malfunction"

heating water pump dialling3) (potential-free contact)
heating-water regulating valve (return rise)

Ölflex 4 x 0.75 mm²

mixed cooling water control valve

Ölflex 4 x 0.75 mm²

heating water pump 230 V /10 A 3)

Ölflex 3 x 1.5 mm²

mixed cooling water pump

Ölflex 3 x 1.5 mm²

additional PT 100 sensor in the overall heating water return
to the optional module selection and deselection

Ölflex 2 x 1.5 mm²

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 mm²

system-tie circuit-breaker feedback is on

(signal from the NSHV or from the system-tie field)

Ölflex 5 x 1.5 mm²

system-tie circuit-breaker feedback is of

f

(signal from the NSHV or from the system-tie field)

select stand-by operation4)

Ölflex 3 x 1.5 mm²

switch-on command for the system-tie circuit-breaker NK switch release
(potential-free contact)

Ölflex 3 x 1.5 mm²

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 operation; data for other installation conditions at request

2) This cable list constitutes the minimum design needed for correctly connecting a block-type thermal power plant (only used as a guideline) The

electrical company doing the work has the responsibility for correct cabling which should be carried out according to the local requirements and
relevant VDE and EVU regulations.

3) The heating water pump in 230 V design can be clamped directly. The customer has to provide the power circuit with a pump design of 400 V.

The control equipment should be chosen to be potential-free from the module control system.

4) External control engineering makes the selection for stand-by operation after the customer’s load shedding. The selection can be made

automatically inside of the module, but without monitoring load shedding.

Tab. 8 Technical specifications for the complete Vitobloc 200 EM-401/549 cogeneration module

Technical Data

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4.2.2 Vitobloc 200 EM-363/498

Technical data for the cogeneration module Vitobloc 200 EM-363/498
engine with accessories

gas spark-ignition engine manufacturer MAN
engine model E 2842 LE 322
functioning 4-stroke
number of cylinders/arrangement 12 / V arrangement
bore/stroke mm 128/142
displacement ltr. 21.93
speed min

-

1

1.500
mean piston speed m/s 7.1
compression ratio 12 : 1
mean effective pressure bar 13.87
standard output1) cannot be overloaded kW 380
specifications full load consumption tolerance 5% kWh/kWh

mech

2.59
gas consumption for instance, at Hi = 10

kWh/m³

Nm³/h 93.4

lubricating oil quantity in the oilpan ltr. 90
lubricating oil consumption (mean) g/h approx. 110
engine weight (about) kg 1,415

Heat exchanger system for the engine cooling system (engine block and lubricating oil)

heat output tolerance 5% kW 231
cooling water temperature intake/output ° C 80 / 85
cooling water volume flow m³/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 1.4571
material of the water cooling jacket ST 50

Mixed cooling (turbocharger)

heat output tolerance 5% kW 53
cooling water temperature intake/output ° C 80 / 82.8
cooling water volume flow m3/h 18.1

Plate heat exchanger

heat output kW 497
cooling water temperature intake/output ° C 87.6 / 80
heating water temperature intake/output ° C 65 / 85
pressure loss bar 0.4
Material of plates 1.4404

Rated widths

exhaust gas connection (AA) from the cogeneration module and
pipe connection

DN 200 / PN10

condensation water connection (AKO) and pipe connection pipe ø 22 x 2.0
heating water forward/return (V/R) and pipe connection flange DN 80 / PN 16
gas connection (GAS) and pipe

connection

flange DN 65 / PN 16

Technical Data

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Alternator

model output kVA 550
three-phase current voltage/frequency V / Hz 400/50
speed min

-

1

1,500
efficiency at the rated output of the module and cos φ = 1 % 96.0
rated current A 793
continuous short-circuit current A 3-5 times the rated current
maximum acceptable load application A 200
stator circuit-breaker star
ambient temperature max. ° C 40
protection class IP 23

Time constants in seconds

open circuit transient Td'o sec. 1,858
short-circuited circuit transient Td' sec. 0.1
short-circuited circuit subtransient Td'’ sec. 0.01
with short-circuited field Ta sec. 0.015

Cabling to the cogeneration terminal box

NSHV protection (recommended) A 1,000

Minimum required design for correctly connecting the cogeneration system

2)

network connection to the NSNV, system-tie field or transformer

H07 RNF 5 x 3 x 185 mm²

remote selection for "heat operation" 100% output provided by the customer

Ölflex 12 x 1.5 mm²

feedback (potential-free contact) module "ready"
feedback (potential-free contact) module "operation"
feedback (potential-free contact) module "malfunction"

heating water pump dialling3) (potential-free contact)
heating-water regulating valve (return rise)

Ölflex 4 x 0.75 mm²

mixed cooling water control valve

Ölflex 4 x 0.75 mm²

heating water pump 230 V /10 A 3)

Ölflex 3 x 1.5 mm²

mixed cooling water pump

Ölflex 3 x 1.5 mm²

additional PT 100 sensor in the overall heating water return
to the optional module selection and deselection

Ölflex 2 x 1.5 mm²

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 mm²

system-tie circuit-breaker feedback is on

(signal from the NSHV or from the system-tie field)

Ölflex 5 x 1.5 mm²

system-tie circuit-breaker feedback is of

f

(signal from the NSHV or from the system-tie field)

select stand-by operation4)

Ölflex 3 x 1.5 mm²

switch-on command for the system-tie "circuit-breaker NK switch release"
(potential-free contact)

Ölflex 3 x 1.5 mm²

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 operation; data for other installation conditions at request

2) This cable list constitutes the minimum design needed for correctly connecting a block-type thermal power plant (only used as a guideline) The

electrical company doing the work has the responsibility for correct cabling which should be carried out according to the local requirements and
relevant VDE and EVU regulations.

3) The heating water pump in 230 V design can be clamped directly. The customer has to provide the power circuit with a pump design of 400 V.

The control equipment should be chosen to be potential-free from the module control system.

4) External control engineering makes the selection for stand-by operation after the customer’s load shedding. The selection can be made

automatically inside of the module, but without monitoring load shedding.

Tab. 9 Technical specifications for the complete Vitobloc 200 EM-363/498 cogeneration module

Technical Data

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4.3 Dimensions, weights and colours

Dimensions of the cogeneration module Frame dimensions

including sound-

absorbing hood

and exhaust ventilator

cowl 1)

length including switching cabinet mm 3,980 4,650
width mm 1,600 1,650
height mm 2,000 2,020

The weight of the cogeneration module

empty weight (about) kg 6,300
operational weight (about) kg 6,800

Colours

engine and alternator light grey (RAL 7035)
frame anthracite grey (RAL 7016)
switching cabinet Vitosilver
sound-absorbing hood Vitosilver

connections design standard size

AA

exhaust gas 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-401/549 and Vitobloc 200 EM-363/498
cogeneration modules

2) only available in the Vitobloc 200 EM-401/549 model with the external mixed cooling water connection

Tab. 10 Dimensions, weights, colours and connections

Fig. 6 The dimensions and connections of the Vitobloc 200 EM-401/549 and Vitobloc 200 EM-363/498 cogeneration modules

(dimensions in mm);
The ventilator box already mounted on the back side can be disassembled for mounting the module.

Technical Data

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4.4 Installation

You can find detailed instructions on design in the
"Natural Gas Block-Type Thermal Power Plant Series
– Project Management" and in the relevant assembly
instructions.

You have to bear the items below in mind for installing
the cogeneration module:

- A blocked clearance as per page 30, Figure 7 in

the installation plan should be kept for operating
and servicing.

- These dimensions are needed to a simple pipe

length of 10 meters; otherwise, it will be
necessary to make a separate calculation.

- We recommend dimensioning the gas

connecting lines for the block-type thermal power
plant to use this lane as buffer storage. This can
be used to intercept fluctuations in pressure with
boiler circuits.

- We recommend using a calibrated gas meter

with a G160 design.

- The optional exhaust air ventilator box can be

disassembled for installing the cogeneration
module. Please let us know before delivery.

- It should not drop below the dewpoint in the

exhaust gas system. Any condensate
accumulating should be continually drained. A
water reservoir should be provided on the
condensate output.
We recommend separate exhaust gas
conduction for every cogeneration module with
multiple module systems. If you use a collecting
exhaust gas line, it is necessary to reliably
prevent the exhaust gas from flowing back into
any 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 EM­401/549 model for the low-temperature mixed
cooling circuit.

- Condensate flows out of the cogeneration

module when starting in the cold state.
Neutralisation is not necessary due to exhaust
gas purification in accordance with ATV A251
(Nov. 1998). A water reservoir (siphon loop)
should be provided with an effective water
column height corresponding to the exhaust gas
system pressure (a maximum of 150 mm WS) to
keep the exhaust gas from flowing out through
the condensate drain.

- The exhaust gas condensate should be disposed

of in accordance with applicable regulations.

4.5 Start-stop ratio

The module should be at least 120 min in operation
per start (approximately 2:1 ratio of the number of
operating hours to the starts).
Early wear and tear in the starting equipment from
shorter times is caused by operation and is not a
defect.

4.6 Ecotax in Germany

You have to register your block-type thermal power
plant with your main customs office before starting
it up in Germany so that your block-type thermal
power plant can be exempted from the petroleum
(natural gas) and electricity tax. This provides a
substantial improvement of 10%-35% in economic
efficiency. Metering equipment may be required for
this.

NOTE

All electricity generated in Germany via
cogeneration has been supported since
January of 2009 (2009 Cogeneration
Law).

Technical Data

32 ESS Energie Systeme & Service GmbH VITOBLOC 200 EM-401/549 / EM-363/498

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Fig. 7 Sample installation plans – description without fittings and safety equipment (dimensions in mm )

Vitobloc 200

EM-18/36

EM-50/81

EM-70/115

EM-140/207

EM-199/263
EM-199/293

EM-238/363

EM-401/549
EM-363/498

A 1,000 mm 1,000 mm 1,000 mm 1,000 mm 1,000 mm 1,000 mm

B 1,200 mm 1,400 mm 1,600 mm 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 4,650 mm

Tab. 11 Installation dimensions

Fig. 8 Block-type thermal power plant with the base

Minimum base dimensions
Vitobloc 200 EM-401/549
Vitobloc 200 EM-363/498

L 4,000 mm
W 1,600 mm
H 150 mm

Important information on planning and operation

VITOBLOC 200 EM-401/549 / EM-363/498 ESS Energie Systeme & Service GmbH 33

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5 Important information on planning and operation

5.1 Malfunctions

Malfunctions or consequential damage due to
unacceptable operating conditions are neither
covered by the warranty nor any service contract.
Your operational safety will be boosted if you comply
with the items below:

Design

● avoid clocking on-off operation and provide buffer

memory.
The ratio of operating hours to starts has to be at
least greater that 2 (in other words, at least two
hours of operation per start). The larger the ratio of
operating hours: starts, the better.

Installation space

● Provide exhaust gas and exhaust air dampers in

sound-critical objects and always allow for elastic
connections (i.e., compensators).

● Make sure that the exhaust gas and exhaust air

lines are correctly dimensioned and conducted
(because of pressure losses, rated widths and flow
roaring).

● Make sure that it is installed on the loosely

supplied Sylomer strips for structure-borne noise
decoupling.

● Do not install in the same room as a NH3

refrigerating machine.

Heating

● guarantee constants and sufficient heating water

volume flow

● prevent emergency shutdown due to excessive

heating water return temperatures The hot water
return temperature may not be in excess of 65° C
either in stand-by operation or in parallel operation.

● Any return temperature increasing mechanism

should be installed as near to the cogeneration
module as possible.

● Provide optional heat quantity meters in the return

temperature increasing mechanism to ascertain the
heat energy generated.

● The stand-by operation function does not apply in

connection with operating an absorption
refrigerating machine.

Exhaust gas

● Sufficiently dimension the exhaust gas cross-

section (no more than 10 m/s of the flow speed).

● Use a suitable qualification approval exhaust gas

pipe (with a wall thickness of at least 1 mm made
of stainless steel and connections pressure­resistant 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.

● Provide sufficient fresh air supply and reliably carry

off warm exhaust air.

● Provide separate air inlet suction in the swimming

pool (if the air contains chlorine).

Fuel

● Maintain gas flow pressure of 25-50 mbar and a

methane number ≥ 80.

● Overdimension the inlet as a pressure buffer.

● Optional gas quantity meters generally measure

the operational cubic meters. These readings
should be converted into normal cubic meters (z
Number) in accordance with the guidelines of
DVGW-TRGI G 600.

Electro

● The block-type thermal power plant generates

electric power at 400 V. For reasons of safety, it
has sensitive electrical nozzle protection
equipment that reacts to asynchronous network
loads in the customer’s network in accordance with
the regulations. Safety shutdowns are not a
malfunction of the block-type thermal power plant.

● If the electrical loads in stand-by operation are

incorrectly dimensioned, this may cause
emergency shutdown due to overloading (inductive
or capacitive starting currents are as much as 20
times the rated current, which can overload the
block-type thermal power plant).

● Always avoid shutting down under full load since

the component parts are subject to maximum
mechanical loads.

● The cogeneration modules have to be connected

to the equipotential bonding rail provided by the
customer via an earthing cable.

Service + Operating resources

● regular service and care by qualified personnel.

We recommend signing a service contract.

● Clean up drip leaks, dispose of old oil correctly and

regularly check the exhaust gas condensate lines
to see if they are in good working order.

● Disconnect the batteries if there are longer

interruptions to operations when shutting down the
module and preserve the module when it is shut
down for longer than 24 hours.

Index

34 ESS Energie Systeme & Service GmbH VITOBLOC 200 EM-401/549 / EM-363/498

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6 Index

A

Alternator power circuit .......................................... 16

B

Basic circuit diagram .............................................. 17

Basic frame ............................................................ 10

C

Colours ................................................................... 30

Cooling water transfer unit ..................................... 11

Coupling ................................................................. 10

D

Design .................................................................... 33

Dimensions ............................................................ 30

E

Electro .................................................................... 33

Emission values ....................................................... 5

Emissions of pollution .............................................. 5

Energy balance sheet .............................................. 6

Exhaust gas ........................................................... 33

Exhaust gas front silencer ...................................... 12

Exhaust gas purification 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

Service ................................................................... 33

Service and repair .................................................. 19

Sound insulation hood ............................................ 12

Stand-by operation ................................................... 5

Switching cabinet ................................................... 16

T

Technical Data ....................................................... 22

Three-phase synchronous alternator ..................... 10

V

Ventilation .............................................................. 33

W

Weights .................................................................. 30

Z

z-number ................................................................ 33

Notes

VITOBLOC 200 EM-401/549 / EM-363/498 ESS Energie Systeme & Service GmbH 35

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36 ESS Energie Systeme & Service GmbH VITOBLOC 200 EM-401/549 / EM-363/498

5414 733 09/2009

ENERGY

• gas-fuelled engine

systems

• cogeneration

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

[e-mail]
www.ess-landsberg.de

799 000 016