elco VARION C-POWER 50.0 User manual

Made in Germany
Operating manual
Combined heat and power unit
VARION® C-POWER 50.0
09.2019

2Operating manual VARION® C-POWER 50.0 / 09.2019
Contents
1. Document information. . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Validity. . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Supporting documents. . . . . . . . . . . . . . . . . 4
1.3 Safety instructions . . . . . . . . . . . . . . . . . . . 5
1.4 Explanation of symbols . . . . . . . . . . . . . . . . 5
2. Safety information ...........................6
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Authorised target groups . . . . . . . . . . . . . . . 6
2.2.1 Manufacturer........................ 6
2.2.2 Operator............................ 6
2.2.3 Trained personnel .................... 6
2.2.4 User ............................... 6
2.3 General safety instructions . . . . . . . . . . . . . . 7
3. Product information..........................8
3.1 Functional principle . . . . . . . . . . . . . . . . . . 8
3.2 Registering with the energy provider . . . . . . . . . 8
3.3 Modes of operation . . . . . . . . . . . . . . . . . . 8
3.3.1 Ready for e-car charging button ........ 8
3.3.2 Summer operation ................... 8
3.3.3 Heat-optimised ...................... 8
3.3.4 Electricity-optimised .................. 8
3.3.5 Shutdown........................... 8
3.4 Product variants . . . . . . . . . . . . . . . . . . . . 9
3.5 Product overview . . . . . . . . . . . . . . . . . . . . 9
3.5.1 Generation unit ...................... 9
3.5.2 Control cabinet ..................... 10
3.5.3 Modem............................ 10
3.5.4 Calorific value heat exchanger (only
with variant “VARION® C-POWER 50.0
Calorific value”) ..................... 11
3.6 Safety devices. . . . . . . . . . . . . . . . . . . . . 11
3.7 Scope of supply . . . . . . . . . . . . . . . . . . . . 11
4. Storage ...................................12
5. Assembly..................................13
5.1 Safety instructions for assembly . . . . . . . . . . 13
5.2 Installation location requirements . . . . . . . . . 13
5.2.1 Overview of the installation location ... 13
5.2.2 Installation room .................... 14
5.2.3 Heating system ..................... 15
5.2.4 Flue gas routing ..................... 15
5.2.5 Exhaust air duct..................... 15
5.2.6 Supply air supply .................... 15
5.2.7 Gas supply ......................... 15
5.2.8 Water supply ....................... 16
5.2.9 Condensate drain ................... 16
5.2.10 Power supply ....................... 16
5.2.11 Mobile communications network ...... 16
5.3 Assembly steps . . . . . . . . . . . . . . . . . . . . 17
5.3.1 Preparing for assembly ............... 17
5.3.2 Unpacking the system................ 17
5.3.3 Positioning the generation unit ........ 18
5.3.4 Screwing the control cabinet in position 18
5.3.5 Connecting the generation unit
(VARION® C-POWER 50.0 Standard,
VARION® C-POWER 50.0
High temperature)................... 19
5.3.6 Connecting the generation unit
(VARION® C-POWER 50.0 Calorific value) 22
5.3.7 Connecting the temperature sensors ... 26
5.3.8 Connecting the modem .............. 27
5.3.9 Connecting the battery............... 27
5.3.10 Connecting the control cabinet ........ 28
5.3.11 Checking the connections ............ 29
6. Commissioning .............................30
7. Operation .................................31
8. Cleaning...................................32
9. Service repairs .............................33
9.1 Maintenance . . . . . . . . . . . . . . . . . . . . . 33
9.2 Fault resolution . . . . . . . . . . . . . . . . . . . . 33
9.3 Repair . . . . . . . . . . . . . . . . . . . . . . . . . 34
10. Disassembly ...............................35
11. Disposal...................................36
11.1 Disposing of packaging. . . . . . . . . . . . . . . . 36
11.2 Disposing of the system . . . . . . . . . . . . . . . 36

3
Operating manual VARION® C-POWER 50.0 / 09.2019
12. Appendix..................................37
12.1 Technical data. . . . . . . . . . . . . . . . . . . . . 37
12.2 Hydraulic diagrams . . . . . . . . . . . . . . . . . . 37
12.2.1 Heating system variant 1 –
1 VARION® C-POWER, 1 buffer tank,
peak load boiler connected to buffer
tank via hydraulic separator........... 38
12.2.2 Heating system variant 2 –
1 VARION® C-POWER, 2 buffer tanks,
peak load boiler connected to buffer
tank via hydraulic separator........... 39
12.2.3 Heating system variant 3 –
2 VARION® C-POWER, 2 buffer tanks,
peak load boiler connected to buffer
tank via hydraulic separator........... 40

4Operating manual VARION® C-POWER 50.0 / 09.2019
Document informaon
i
1. Document information
i
1.1 Validity
Original operation manual.
This manual is valid for the following products:
BVARION® C-POWER 50.0 Standard
BVARION® C-POWER 50.0 High temperature
BVARION® C-POWER 50.0 Calorific value
The descriptions are identical for all products; any
differences are specifically highlighted.
The illustrations show the product
“VARION® C-POWER 50.0 Standard”.
In this manual, the word “system” is used to denote
the product.
This manual is protected by copyright law. Duplication,
reproduction and transmission is only permitted with the
permission of the manufacturer.
Subject to change without notice.
1.2 Supporting documents
Additional documents belong to this operation manual and
must be observed.
System documentation
The documentation valid for the delivered system
(e.g. technical data, maintenance plan) is included in the
scope of delivery.
“ELCO/Control” operation manual
The “ELCO/Control” operation manual describes how
to control the system via the operational display and is
included in the scope of delivery.
Wiring diagrams
The wiring diagrams are located on the inside of the control
cabinet door.
Manuals for system components
The manuals for the supplied system components
(e.g. modem) are included in the scope of delivery.
Manuals for accessories
The manuals for optional accessories (e.g. flue gas silencer,
exhaust air kit) are provided with each product.
Maintenance manual
The maintenance manual describes specific tasks for
maintaining the system that must only be performed by the
manufacturer. The maintenance manual is not included in
the scope of delivery.
Further documents and information (e.g. forms,
planning notes, technical drawings) are available on the
manufacturer's website.
Јwww.elco.net

5
Operating manual VARION® C-POWER 50.0 / 09.2019
Document informaon i
1.3 Safety instructions
DDANGER!
Information highlighted with the word DANGER warns
against a hazardous situation that will lead to death or
severe injury.
DWARNING!
Information highlighted with the word WARNING warns
against a hazardous situation that can lead to death or
severe injury.
DCAUTION!
Information highlighted with the word CAUTION warns
against a situation that can lead to minor or moderate
injuries.
DATTENTION!
Information highlighted with the word ATTENTION
warns against a situation that can lead to material or
environmental damage.
1.4 Explanation of symbols
Text
ARequired action
BList
DCross reference to another point in this document
Cross reference to other documents that must be
observed
ЈInternet link
Illustrations
A
2.
B
1.
x
1. Numbered action sequence
APart designations with upper case letters
xDimensions with lower case letters or units in mm
Arrows indicating movement and direction

6Operating manual VARION® C-POWER 50.0 / 09.2019
Safety informaon
2. Safety information
2.1 Intended use
The system is a combined heat and power unit for
generating electricity and heat. The system is intended
exclusively for incorporation in heating circuits in buildings.
The system is designed for bivalent operation, i.e. it must
be combined with an additional heat source (“peak load
boiler”) in order to operate.
The system is designed for the following energy demand.
System Annual energy requirement
Electricity kWh Heat kWh
VARION®
C-POWER 50.0
Standard
275,000 750,000
VARION®
C-POWER 50.0
High temperature
275,000 750,000
VARION®
C-POWER 50.0
Calorific value
275,000 750,000
The system is only permitted for use in a technically
sound condition once it has been commissioned by the
manufacturer or a specialist partner authorised by the
manufacturer.
Intended use also includes reading and following this
manual.
Any other use is considered contrary to intended use.
2.2 Authorised target groups
This manual is intended for various target groups that are
authorised for specific duties.
2.2.1 Manufacturer
The manufacturer, ELCO GmbH, supplies the product and
has the following duties:
BTraining experts on assembly, maintenance, disassembly
and disposal.
BCommissioning the system.
Only the manufacturer has access to the “Experts” area of
the “ELCO/Control” control mechanism.
2.2.2 Operator
The operator is responsible for the building in which the
product is installed. The operator has the following duties:
BFulfilling the requirements specified by the energy
provider (e.g. registration, approval, compensation).
BMeeting the installation location requirements.
BTraining the user.
BComplying with statutory occupational health and safety
obligations.
BComplying with the valid safety, accident prevention and
environmental protection regulations.
BProviding and complying with the documentation.
BEnsuring that the product is always kept in a technically
sound condition.
BStoring the system when necessary.
2.2.3 Trained personnel
Trained personnel are responsible for the assembly,
maintenance, disassembly and disposal of the product.
The following points must be observed:
BAll tasks must only be performed by qualified personnel
who have been trained by the manufacturer and who
are familiar with assembly technology, gas and water
installations, and current safety regulations.
BSpecial installation tasks (e.g. tasks involving the
building structure or the ventilation system) must only
be performed by the suitably qualified personnel of
specialist companies.
BElectrical installations must only be performed by
qualified, skilled electricians.
Only qualified personnel trained by the manufacturer have
access to the “Specialist” area of the “ELCO/Control” control
mechanism.
2.2.4 User
Users may perform operational and cleaning tasks on this
product. Obligations of the user:
BTo be trained on the product by the operator.
BTo be familiar with this manual.
Trained users have access to the non-protected areas of the
“ELCO/Control” control mechanism, but not to the “Experts”
and “Specialist” areas.

7
Operating manual VARION® C-POWER 50.0 / 09.2019
Safety informaon
2.3 General safety instructions
DWARNING!
Hazard caused by failing to observe the manual.
This manual contains important information for handling the
system safely. Potential hazards are specifically highlighted.
Failing to observe such information can lead to death or
severe injuries.
ARead the manual carefully.
AFollow the safety instructions contained in this manual.
AFollow the safety instructions on the system
AStore the manual in an accessible place.
If you can smell gas, immediately proceed as follows:
BClose the gas valve.
BDo not generate any naked flames.
BDo not operate any electrical switches
(e.g. light switches, all-pole separating points).
BDo not use any electrical appliances in the
hazardous area (e.g. telephone).
BVentilate the rooms.
BInform the manufacturer, gas utility company or qualified
service company.
Use of the system is prohibited in the following cases:
BIf the system or individual components are damaged.
BIf the system has been altered or modified without
authorisation.
BIf the supply and return lines (e.g. gas, flue gas, exhaust
air, water, electricity, drain) are altered or modified
without authorisation.
BIf any safety devices are missing or inoperable.
D“3.6 Safety devices” (page 11).
BDuring the construction phase of the building.
BIf the system has been in storage for more than
5 months after delivery.
D“4. Storage” (page 12).
BIf the system has been decommissioned for more than
5 months.
BFor children or individuals who are incapable of
assessing the hazards associated with operating the
system.
The manufacturer does not accept any liability or guarantee
for damage or loss in the following cases:
BFailing to observe this manual.
BContrary-to-intended use.
BImproper handling.
BUse by unauthorised target groups.
BFailing to meet the installation location requirements.
BUsing replacement parts that have not been authorised
by the manufacturer.
BBypassing the system’s safety devices.
BRemoving the system’s seals and sealants.
BFailing to comply with the maintenance intervals.
Additional safety instructions are provided in the respective
chapters of this manual.
D“5. Assembly” (page 13).
D“6. Commissioning” (page 30).
D“7. Operation” (page 31).
D“8. Cleaning” (page 32).
D“4. Storage” (page 12).
D“9. Service repairs” (page 33).
D“10. Disassembly” (page 35).
D“11. Disposal” (page 36).

8Operating manual VARION® C-POWER 50.0 / 09.2019
Product informaon
3. Product information
3.1 Functional principle
The combustion of gas in an industrial gas engine powers a
high-performance alternator that produces electricity.
The heat that is generated by this process is used for hot
water provision and heating.
This principle is referred to as combined-heat-and-power.
The control mechanism manages and monitors the
combustion process in the generation unit. The system is
operated via the operational display on the control cabinet.
3.2 Registering with the energy provider
The energy provider must be informed about the installation
of the system. Obligations of the operator:
AInform the energy provider about the system before it is
assembled.
AFulfil the requirements specified by the energy provider
(e.g. registration, approval, compensation).
AProvide the energy provider with all the relevant system
data.
D“12.1 Technical data” (page 37).
The electricity produced over and above the operator’s own
requirement can be fed into the energy provider’s local
electricity network in return for compensation. A suitable
application must be submitted to the energy provider for
this purpose.
3.3 Modes of operation
The system can be operated in five modes of operation
(including shutdown). The modes of operation are set via
the operational display.
“ELCO/Control” operation manual.
3.3.1 Ready for e-car charging button
Special mode for charging electric vehicles. It is still possible
to produce electricity in this mode when the storage battery
has reached the maximum value.
3.3.2 Summer operation
In summer operation mode, the system only operates at
minimum capacity. The system only starts if the storage
battery has insufficient charge.
3.3.3 Heat-optimised
The system starts if a temperature requirement has been
set. If the storage battery has reached a specific percentage
charge, the system begins to power down steplessly.
3.3.4 Electricity-optimised
The system starts to operate according to a temperature
requirement. Once a specific storage battery charge has
been reached, the system aligns itself to the electricity
consumption of the building.
3.3.5 Shutdown
The system is in hibernation mode. The system does not
start according to temperature requirements.

9
Operating manual VARION® C-POWER 50.0 / 09.2019
Product informaon
3.4 Product variants
BVARION® C-POWER 50.0 Standard
BVARION® C-POWER 50.0 High temperature
BVARION® C-POWER 50.0 Calorific value
3.5 Product overview
3.5.1 Generation unit
The generation unit contains the actual combined heat and
power unit with the combustion engine, the alternator unit
and the heat exchangers.
The generation unit is the core piece of equipment for
producing the electricity and heat.
J
H
B
C
A
D
E
F
G
I
A “Exhaust air” connection (room-air dependent)
B Ventilation
C Type plate
D Connection cable for calorific value heat exchanger 1
E Secondary pump
F Primary pump
G Control cabinet wiring harness
H Housing cover
I Connection cabinet
J Hoop guard
1only with variant "VARION® C-POWER 50.0 Calorific value"

10 Operating manual VARION® C-POWER 50.0 / 09.2019
Product informaon
Connections (VARION® C-POWER 50.0 Standard,
VARION® C-POWER 50.0 High temperature)
A
B
C
D
E
F
A “Flue gas” connection
B “Condensate” connection
C “GAS” connection
D “Combustion air” intake
E “Buffer water return line” connection
F “Buffer water supply line” connection
Connections (VARION® C-POWER 50.0 Calorific value)
A
B
C
D
E
F
A “Flue gas” connection
B “Condensate” connection
C “GAS” connection
D “Combustion air” intake
E “Buffer water return line” connection
F “Buffer water supply line” connection
3.5.2 Control cabinet
The control cabinet contains all the components required to
control the system.
A
G
F
B
H
B
E
C
D
A Housing
B Aeration and ventilation
C Control cabinet door
D Emergency stop reset
E Emergency stop switch
F Operational display
G Master switch
H Cable bushings
3.5.3 Modem
The modem makes it possible to monitor the system
remotely and read data via the mobile communications
network.
E
C
A
D
B
A Antenna (slot “mobile”)
B Antenna (slot “mobile”)
C Power supply
D LTE modem
E Connection cable (slot “LAN 1”)

11
Operating manual VARION® C-POWER 50.0 / 09.2019
Product informaon
3.5.4 Calorific value heat exchanger (only with variant
“VARION® C-POWER 50.0 Calorific value”)
The calorific value heat exchanger uses the heat contained
in the flue gas for additional heat recovery.
B
C
D
E
F
A
A “Flue gas” connection (outlet)
B “Buffer water return line” connection (inlet)
C “Condensate” connection
D “Flue gas” connection (inlet)
E Connection cable for generator unit
F “Buffer water return line” connection (outlet)
3.6 Safety devices
DWARNING!
Risk of burns, pinching or electric shock.
The safety devices are intended to ensure the system is
handled safely. Missing or faulty safety devices can lead to
hazardous situations.
AEnsure that the protection devices are not removed.
AFollow the safety instructions on the system.
AOnly remove the covers if you are required and
authorised to do so.
The system is equipped with the following safety devices:
BEmergency stop switch
BPressure-relief valve
BProtective covers
BSafety stickers
3.7 Scope of supply
A
B
M
G
F
H
I
K
L
C
D
J
E
A Generation unit
B Control cabinet
C Calorific value heat exchanger 1
D Connecting pipes with axial compensator 1
E Line from generation unit to calorific value heat
exchanger 1
F Siphon
G Temperature sensor
H Balance strips
I Modem 2
J Battery box with two batteries 24 V
K Cooling medium (water-glycol mixture 60:40")
L Square spanner
M Documentation (e.g. operation manual)
1only with variant "VARION® C-POWER 50.0 Calorific value"
2Includes 24 months of remote monitoring (effective from
commissioning; extension available subject to charge)

12 Operating manual VARION® C-POWER 50.0 / 09.2019
Storage
4. Storage
The system is prepared by the manufacturer for operation
on delivery. The system must be put into operation within
5 months following delivery. If that is not possible, the
system must be preserved.
Storage of the system by the operator.
D“2.2.2 Operator” (page 6).
DATTENTION!
Risk of damage caused by improper storage.
During long periods of downtime, lubricants and liquids
settle within the system. Frost and damp conditions can
damage parts of the system.
AStore the system in a frost-free, dry place.
AArrange for the manufacturer to rust-proof the system if
it is to be kept out of operation for more than 5 months.
The shelf life of the preservative is 12 months.
When taking the system out of storage, the next steps must
be discussed with the manufacturer.
AContact the manufacturer.

13
Operating manual VARION® C-POWER 50.0 / 09.2019
Assembly
5. Assembly
5.1 Safety instructions for assembly
DWARNING!
Hazard caused by failing to observe the assembly
instructions.
Errors made when installing the system can cause serious
injuries or material damage to the system or the building.
This chapter contains important information regarding the
safe assembly of the system.
ARead this chapter carefully before assembling the
system.
AFollow the safety instructions.
ACarry out the assembly as described.
The assembly must only be performed by trained
personnel.
Electrical work must only be performed by qualified,
skilled electricians.
D“2.2.3 Trained personnel” (page 6).
BThe system must be undamaged and in a faultless
condition before assembly.
BOnly use suitable fittings.
BCables and lines must not be damaged, kinked or
crimped.
BBefore assembling, ensure that the supply voltage has
been and remains disconnected.
The supply voltage is only reconnected when instructed
in the respective assembly step.
BThe generation unit must be transported to
the installation location by means of a suitable
transportation device (e.g. lift truck).
If it is not possible to transport it to the installation
location (e.g. lack of space):
AContact the manufacturer.
5.2 Installation location requirements
DWARNING!
Risk of suffocation, gas explosions or material damage
caused by incorrectly installing the system.
Failing to observe these requirements can lead to hazardous
situations when handling electricity, gas or hot water.
This chapter contains important information for preventing
hazardous situations.
AEnsure that all of the installation location requirements
are complied with.
5.2.1 Overview of the installation location
To operate the system, some equipment must be provided
on site. The following illustration shows examples of the
required components.
A
B
I
J
L
M
N
G
C
D
F
H
E
K
A Buffer tank
B Temperature sensor holding fixture
C Buffer water supply line
D Buffer water return line
E KMS filter (optionally available)
F Modem
G Supply voltage
H Supply air opening
I Flue gas routing
J Flue gas silencer
K Condensate drain
L Gas supply
M Gas meter
N Gas flow monitor
The heating system also includes the peak load boiler and
pipework system that connects the system via the buffer
tank.

14 Operating manual VARION® C-POWER 50.0 / 09.2019
Assembly
5.2.2 Installation room
The installation room must meet the following
requirements:
BThe installation room must comply with the effective
applicable laws and regulations for boiler rooms
(e.g. in Germany, the ordinance for heat-producing
appliances (Feuerstättenverordnung)).
BThe substrate on which the generation unit is to be
installed must be flat, even, solid, dry and load-bearing.
BThe ambient temperature must be between
+5 °C and +30 °C.
BThe room height must be at least 2,400 mm from the
installation surface.
BThe system must be protected against frost and the
elements.
The following are not permitted:
BInstallation on floating screed.
BOperation of tumble dryers in the same room.
BStorage of explosive or highly flammable materials
(e.g. paper, paints, petrol) within the installation
location.
BUse of aggressive substances (e.g. sprays, solvents,
chlorinated cleaning agents, paints, adhesives) in the
vicinity of the system.
If the system is installed in vaulted cellars or bare smooth-
walled rooms (hard-walled), there is a risk of noise and
sound resonance.
The system must be positioned so that the following
requirements are fulfilled:
BNone of the system’s ventilation or extraction devices
may be blocked or closed.
BThe emergency stop switch must always be accessible.
Space requirement (VARION® C-POWER 50.0 Standard,
VARION® C-POWER 50.0 High temperature)
> 700 > 700
> 700
> 700
2587
822
1756
Space requirement (VARION® C-POWER 50.0 Calorific value)
> 700
> 700
> 700
> 700
3806
969
1781
The minimum distance (> 700 mm on all sides) must be
maintained.
Minimum distance for maintenance work:
B600 mm free space above the system.
B300 mm free space next to the control cabinet.
If the minimum distances are not maintained:
AContact the manufacturer.

15
Operating manual VARION® C-POWER 50.0 / 09.2019
Assembly
5.2.3 Heating system
The structural elements of the building’s heating system
primarily comprise the peak load boiler, the buffer tank,
and the pipework system and radiators.
The peak load boiler supplies the required residual heat if
the heating energy requirement exceeds the capacity of the
system (e.g. in extremely cold weather).
For the system to operate, a buffer tank is required, which
must comply with the following requirements:
BThe buffer tank must have holding fixtures for the
temperature sensors.
BThe buffer tank must have shut-off devices fitted on the
connections to the system.
BThe buffer tank must be designed to meet the system
specifications:
minimum 50 litres per kW thermal for
installations > 10 kWth
These specifications are technical minimum conditions.
Regional or national funding guidelines (e.g. in accordance
with BAFA in Germany) may differ and must be checked.
The dimensioning of the pipework system must be designed
to meet the following requirements:
BMaximum heat requirement of the building.
BMaximum thermal capacity of the system.
5.2.4 Flue gas routing
For the system to operate, the building must have a flue,
which must comply with the following requirements:
BThe local laws and regulations must be complied with
(e.g. in Germany, the building regulations).
BThe flue gas routing must comply with the local
regulations (e.g. in Germany, DIN 18160).
BThe flue gases must be removed via a flue.
BAs a fundamental rule, the flue must extract the flue
gases via the roof.
BThe dimensions for the flue gas ducting and flue must be
calculated on an individual basis.
BThe gradient of the horizontal section must be min. 5 cm
per metre.
BThe flue must be inspected and approved for operation
(e.g. by a master chimney sweep).
BA flue gas silencer must be fitted in the flue gas routing.
The flue gas silencer (optionally available) must be
installed near the generation unit.
BThe flue gas routing must have a water-filled siphon at
its lowest point.
5.2.5 Exhaust air duct
DWARNING!
Risk of suffocation due to improper use of exhaust air.
The exhaust air must not be used for heating purposes.
Poisonous gases may be produced inside the generation unit
that can lead to death by suffocation.
AEnsure that the exhaust air from the generation unit is
guided outside.
AMake sure that the exhaust air and flue gas are always
extracted separately to each other.
AEnsure that the supply air is not contaminated by the
exhaust air.
Additional devices with exhaust air (e.g. washer-dryers)
may only be installed subject to consultation with a suitable
specialist or chimney sweep.
5.2.6 Supply air supply
Sufficient supply air must be supplied for the combustion
process and the ambient temperature:
BThe total requirement of the heating system (e.g. for the
peak load boiler) must be born in mind.
BThe supply air supply must meet the system
specification.
D“12.1 Technical data” (page 37).
BThe supply air must not be supplied via a concentric pipe
if the inner pipe is used for flue gas routing.
BIf the ambient temperature in the installation room is
permanently above 30 °C, additional air exchange is
required.
5.2.7 Gas supply
For the system to operate, a gas supply is required that must
comply with the following requirements:
BThe gas supply must comply with the established
regulations (e.g. in Germany, TRGI).
BThe system specifications (e.g. type and composition of
the gas) must be complied with.
D“12.1 Technical data” (page 37).
BThe building’s system must be fitted with a gas flow
monitor, gas meter and a gas filter.
BThe gas flow monitor must meet the system
specifications.
D“12.1 Technical data” (page 37).
BConnection via a gas appliance outlet is never permitted.

16 Operating manual VARION® C-POWER 50.0 / 09.2019
Assembly
5.2.8 Water supply
DATTENTION!
Risk of damage caused by poor water quality.
Too high a proportion of suspended solids and magnetite
along with the incorrect water hardness can damage the
generation unit or shorten its service life.
ACheck the water quality regularly.
BThe water quality must comply with the specifications of
the applicable standards and Directives
(e.g. in Germany, VDI Regulation 2035).
BThe heating system water must be free from mechanical
impurities.
BThe hardness of the water must be < 0.11 °dH.
BConductivity < 100 µS/cm.
BPH value > 8.2 and < 9.0.
5.2.9 Condensate drain
For the system to operate, the building must have a
condensate drain, which must comply with the following
requirements:
BThe condensate drain must be depressurised.
BThe inner diameter of the condensate drain must not be
reduced.
BA neutralization device is recommended for each system
to collect condensate containing oil.
BThe siphon must be made of corrosion-resistant, acid-
resistant material (e.g. plastic or stainless steel).
BThe siphon must be regularly filled with water to prevent
it from drying out.
BThe siphon must also be filled with water during an
interruption of operation.
BThe local water disposal regulations must be considered.
5.2.10 Power supply
For the system to operate, the building requires a
connection to the electricity supply that must comply with
the following requirements:
BThe specifications and technical connection conditions
of the energy provider must be taken into consideration
(e.g. electricity meter).
BThe start-up power and cable lengths must be taken into
account when calculating the cable cross-sections.
BThe supply voltage must meet the system specifications.
D“12.1 Technical data” (page 37).
5.2.11 Mobile communications network
Remote monitoring via the modem requires access to the
mobile communications network. The modem must be
accessible. The position of the modem has an influence on
the reception quality.
The reception quality may be improved as required by
means of the following accessory (optionally available):
BExternal antenna (distance max. 15 m)
BPatch cable (max. 100 m long)

17
Operating manual VARION® C-POWER 50.0 / 09.2019
Assembly
5.3 Assembly steps
Brief overview:
5.3.1 Preparing for assembly
5.3.2 Unpacking the system
5.3.3 Positioning the generation unit
5.3.4 Screwing the control cabinet in position
5.3.5 Connecting the generation unit
(VARION® C-POWER 50.0 Standard,
VARION® C-POWER 50.0 High temperature)
5.3.6 Connecting the generation unit
(VARION® C-POWER 50.0 Calorific value)
5.3.7 Connecting the temperature sensors
5.3.8 Connecting the modem
5.3.9 Connecting the battery
5.3.10 Connecting the control cabinet
5.3.11 Checking the connections
5.3.1 Preparing for assembly
AFamiliarise yourself with the assembly situation and the
documentation.
BSystem
BSystem components
BSafety devices
BAccessories
BInstallation location
BOperation manual and supporting documents
AGather together the required tools and materials.
AKeep the assembly area clear of objects than may get in
the way or be damaged.
ACheck that all of the installation location requirements
have been fulfilled.
D“5.2 Installation location requirements” (page 13).
AEnsure that the supply voltage has been and remains
disconnected. Only connect the supply voltage when
instructed in the respective assembly step.
If accessories (e.g. flue gas silencer, exhaust air kit) are
required for the assembly process:
AEnsure that the accessory is correctly assembled and
ready for connection.
AEnsure that the lines from the accessories have been laid
correctly and are accessible.
Manuals for accessories.
5.3.2 Unpacking the system
DATTENTION!
Risk of damage caused by improper handling.
The system may be damaged during unpacking or
transportation.
ADo not cut through the protective packaging.
AKeep objects that might damage the system away from it
(e.g. tools).
ARemove the packaging material from the system.
ARemove the parts included in the scope of delivery from
on top of the generation unit.
ACheck the system and all the parts it contains for
damage.
ACheck the scope of delivery according to the delivery
note for completeness.
If parts are missing or damaged:
AContact the manufacturer.
ARemove the packaging material from the installation
location.
D“11.1 Disposing of packaging” (page 36).

18 Operating manual VARION® C-POWER 50.0 / 09.2019
Assembly
5.3.3 Positioning the generation unit
DATTENTION!
Risk of damage to the generation unit caused by improper
transportation.
In narrow transportation routes, it may be necessary to
disassemble parts of the generation unit in order to move
the device into the installation location. Disassembly for
transport may only be carried out by the manufacturer.
AContact the manufacturer.
ASelect a suitable installation location.
D“5.2 Installation location requirements” (page 13).
APosition the balance strips.
APlace the generation unit on the balance strips.
AEnsure that the generation unit stands level.
5.3.4 Screwing the control cabinet in position
AOpen the control cabinet.
AMark the drill hole positions on the wall.
ADrill the holes for the screws.
AScrew the control cabinet onto the wall.
AObserve the minimum distances.
D“5.2.2 Installation room” (page 14).

19
Operating manual VARION® C-POWER 50.0 / 09.2019
Assembly
5.3.5 Connecting the generation unit
(VARION® C-POWER 50.0 Standard,
VARION® C-POWER 50.0 High temperature)
When connecting the system to the heating system it is
necessary to follow the appropriate hydraulic diagram.
D“12.2 Hydraulic diagrams” (page 37).
Always match the connections to the identifiers on the
generation unit.
Pay attention the to connection sizes and type when
connecting the lines.
Generation unit connection sizes
Connection Connection size and type
Buffer water return line 2” male thread
Buffer water supply line 2” male thread
Condensate 3/4” male thread
Flue gas – in front of silencer DN 80
Flue gas – after silencer DN 100
Exhaust air DN 200
Gas 1” female thread
DATTENTION!
Risk of damage caused by improper connection of lines.
Fixed supply lines will transfer vibrations to the building.
Vibrations may damage the supply lines.
AOnly use flexible lines for all the lines connected to the
generation unit.
APay close attention when matching the lines and
connections.
Buffer water return line
AConnect the line to the return line of the buffer tank.
AConnect the line to the “Buffer water return line”
connection on the generation unit.
Buffer water supply line
AConnect the line to the supply line of the buffer tank.
AConnect the line to the “Buffer water supply line”
connection on the generation unit.

20 Operating manual VARION® C-POWER 50.0 / 09.2019
Assembly
Condensate
The line for the condensate water must be corrosion
resistant.
The line must have a sufficient gradient between the
generation unit and the drain.
AConnect the siphon to the “Condensate” connection on
the generation unit.
AConnect the line to the siphon.
AConnect the line to the condensate drain.
Flue gas
384
The line must be laid with a sufficient gradient to the
generation unit.
AMake sure that a suitable flue gas silencer (optionally
available) is present:
BIn the flue gas routing.
BIn close proximity to the generation unit.
BWith horizontal installation with correct discharge of
the condensate water.
AConnect the axial expansion joint (optionally available)
to the “flue gas” connection of the generation unit.
Alternatively, a hose compensator (optionally available)
can also be used.
AConnect the line to the axial compensator.
AConnect the line to the flue gas silencer on both sides.
AFasten the line.
AEnsure that the line is not interrupted (e.g. that it does
not slip out of vertically installed parts).
AEnsure that the connection piece (optionally available)
cannot vibrate out of place.
Flue gas silencer instructions.