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
2 ESS Energie Systeme & Service GmbH VITOBLOC 200 EM-401/549 / EM-363/498
5414 733 09/2009
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
4 ESS Energie Systeme & Service GmbH VITOBLOC 200 EM-401/549 / EM-363/498
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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.
Product description
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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.
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