Viessmann VITOBLOC 200 User manual

5841436 GB 09/2019 Please retain for future use
Installation instructions
for contractors
VITOBLOC 200
Type EM-530/660 version SCR Part no. 7727282
Type EM-530/660 version SCR-ready Part no. 7727283
CHP unit for operation with natural gas

Company details
2 Installation instructions VITOBLOC 200 EM-530/660 version SCR
5841436 GB
This appliance meets all basic
requirements of the applicable standards
and guidelines. Conformity has been
verified. All associated documents and the
original Declaration of Conformity are
available from the manufacturer.
NOTE!
The Vitobloc 200 CHP unit is not suitable
for 60 Hz operation. It is therefore not
available for the American and Canadian
markets in particular.
Service partner
Viessmann Kraft-Wärme-Kopplung GmbH
D-86899 Landsberg am Lech
Tel.: [phone]
Fax: [phone]
Email: [email protected]
www.viessmann.de
These instructions are protected by copyright. All rights
derived from this copyright are reserved (even when only
excerpts are used), unless a contractual agreement is
reached in this regard.
Viessmann Werke GmbH & Co. KG reserves the right to
change the product described herein at any time and
without notice, in line with technological advances, unless
contractually specified otherwise
Original document

Table of contents
VITOBLOC 200 EM-530/660 version SCR Installation instructions 3
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1Introduction......................................................................................4
1.1 Structure of the safety instructions..............................................................................4
1.2 Depiction of safety instructions ...................................................................................4
1.3 Safety symbols..............................................................................................................5
1.4 Trademarks....................................................................................................................5
2Intended use.....................................................................................6
3Safety................................................................................................7
3.1 Legal disclaimer ............................................................................................................7
3.2 Safety equipment...........................................................................................................7
3.3 Personnel.......................................................................................................................8
3.4 General safety regulations............................................................................................9
3.5 Special safety regulations...........................................................................................10
3.6 Information regarding particular types of hazard......................................................11
4Product description.......................................................................14
4.1 Overview ......................................................................................................................14
4.2 Materials provided as standard..................................................................................15
5Transport, storage and siting .......................................................16
5.1 Transport......................................................................................................................16
5.2 Storage.........................................................................................................................17
5.3 Siting ............................................................................................................................17
6Installation at the installation site.................................................21
6.1 Ventilation provided by operator................................................................................21
6.2 Heating connection .....................................................................................................22
6.3 Gas connection............................................................................................................23
6.4 Exhaust gas connection..............................................................................................25
6.5 Condensate drain ........................................................................................................26
6.6 Connection of AdBlue™ and compressed air ...........................................................27
6.7 Fitting/removing noise attenuating elements............................................................28
6.8 Electrical connection...................................................................................................29
7Commissioning..............................................................................31
8Control and operation ...................................................................31
9Information regarding service and maintenance.........................31
10 Appendix ........................................................................................32
10.1 Engine lubricating oil ..................................................................................................32
10.2 Coolant.........................................................................................................................32
10.3 Permissible types of antifreeze ..................................................................................32
10.4 Heating water...............................................................................................................33
10.5 Gas quality...................................................................................................................34
10.6 AdBlueTM.......................................................................................................................34
10.7 Compressed air ...........................................................................................................34
10.8 Type testing in accordance with EU Gas Appliances Regulation............................35

Introduction
4 Installation instructions VITOBLOC 200 EM-530/660 version SCR
5841436 GB
1 Introduction
This document applies to the combined heat and
power (CHP) unit Vitobloc 200 EM-530/660 (versions
SCR and SCR-ready) –also referred to below as the
"machine". This document must always be kept within
easy reach of the system.
Constant development may result in minor changes to
the illustrations, functional steps and specifications.
Viessmann Werke GmbH & Co. KG expressly
disassociates itself from all content of all linked
websites and does not consider such content its own.
This declaration applies to all external links and
references to the internet specified within this
document.
1.1 Structure of the safety instructions
Safety instructions each consist of 5 elements.
Fig. 1 Safety instructions structure
1 Keyword
2 Type and source of hazard
3 Potential consequences of the hazard
4 Avoidance of the hazard
5 Hazard symbol
1.2 Depiction of safety instructions
The safety instructions in this documentation are
important for safety and must be observed.
DANGER
Meaning
Designates an imminent danger
If the situation is not avoided, it will
result in death or serious, irreversible
injury.
WARNING
Meaning
Designates a potentially dangerous
situation
If the situation is not avoided, it will
result in death or serious, irreversible
injury.
CAUTION
Meaning
Designates a potentially dangerous
situation
If the situation is not avoided, it may
result in slight or minor, reversible
injury.
PLEASE NOTE
Meaning
Designates a potentially harmful
situation
If the situation is not avoided, the
machine or an object in its vicinity may
be damaged.
1
2
3
4
5

Introduction
VITOBLOC 200 EM-530/660 version SCR Installation instructions 5
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1.3 Safety symbols
The following signs (safety symbols) are attached to
the machine or must be affixed on/in the plant room
by the operator:
1.3.1 Prohibition signs
Access for unauthorised persons
forbidden!
Areas identified in this way may only
be accessed by people who have
been expressly authorised to do so,
e.g. in connection with work to be
performed there. Access is prohibited
for all other people.
Fire, naked flames and smoking
forbidden!
Identifies danger zones in which fire,
naked flames and smoking are
prohibited.
Access prohibited for persons with
active implants!
(e.g. cardiac pacemakers)
Identifies danger zones that must not
be accessed by persons with active
implants.
Access prohibited for persons with
passive implants!
(e.g. artificial joints)
Identifies danger zones that must not
be accessed by persons with metal
implants.
1.3.2 Warning signs
Warning of dangerous electrical
voltage!
Means "stop" before entering danger
zones containing live parts.
Warning of hot surfaces!
Means "stop" before entering danger
zones that may contain hot surfaces.
1.3.3 Command signs
Wear safety shoes!
Prescribes that protective footwear
must be worn during transportation
and installation.
Use ear defenders!
Requires ear defenders to be worn
during work in the installation room
while the CHP unit is in operation
1.4 Trademarks
Reference is made in this document to various
registered trademarks that are not specifically
identified as such within the text. The absence of any
identification does not necessarily mean that the
corresponding product name is free of third party
rights.

Intended use
6 Installation instructions VITOBLOC 200 EM-530/660 version SCR
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2 Intended use
The operator of the Vitobloc 200 EM-530/660 CHP
unit (versions SCR and SCR-ready) must observe the
relevant country-specific laws and regulations.
Target group
This document is intended solely for use by
contractors; see chapter 3.3 Personnel.
Application
The Vitobloc 200 EM-530/660 CHP unit (versions
SCR and SCR-ready) is intended exclusively for the
generation of three-phase current 400 V, 50 Hz and
DHW in natural gas mode.
It is only intended for industrial and commercial
applications.
Any use that differs from or goes beyond this is
considered inappropriate. The manufacturer rejects all
liability for any losses arising from such inappropriate
use. The operator alone bears the associated risks.
Intended use also includes observance of these
instructions and compliance with the inspection and
servicing conditions.
Incorrect use
All applications deviating from the intended use are
deemed to be impermissible incorrect use. This
includes:
●Application areas not listed under "Application".
●Use of operating fluids that do not correspond to
the manufacturer's specifications.
●Use outside the permissible technical operating
limits.
●Use in areas at risk of explosion.
●Use outdoors.
●Bypassing of safety equipment.
●Operation as an emergency generator.
●Operation in permanent island mode.
●Use only for heat generation if power is not drawn
off simultaneously.
●Siting in the same room as a boiler system with
atmospheric burner or an NH3refrigeration unit
with an interconnected air supply.
EC Declaration of Conformity and Declaration of
Incorporation
This CHP unit is considered a complete machine as
referred to in the EC Machinery Directive.
The machine complies with the EC Machinery
Directive. This has been established by means of a
conformity assessment process.
Declaration of Conformity
The Declaration of Conformity is the basis for the
system's CE designation. The CHP unit may only be
operated in accordance with country-specific
legislation, regulations and standards.
The controller has a CE designation in accordance
with the EMC Directive and the Low Voltage Directive.

Safety
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3 Safety
3.1 Legal disclaimer
The CHP unit is built in accordance with the latest
engineering standards and recognised safety
regulations. Nevertheless, impermissible use can still
result in risk to life and limb or to machine impairment
and other material losses.
Only use the CHP unit if it is in perfect technical
condition, in accordance with its intended use, and if
you are aware of all safety and risk-relevant factors.
Only use it with due regard to the operating
instructions. Faults that may have a detrimental
impact on safety must be corrected without delay.
Use of prescribed and/or approved operating fluids in
line with the specification is a prerequisite for the
recognition of warranty claims.
Operation of the CHP unit at levels exceeding the
limits invalidates the warranty. The manufacturer
accepts no liability for faults and/or damage
(corrosion, contamination, wear) caused by gases or
materials that were not known and agreed to at the
time the contract was concluded.
Safety information
Information concerning safety cannot be interpreted
against Viessmann Werke GmbH & Co. KG. Even if
all safety instructions are followed, there is no
guarantee that the CHP unit will not cause any injuries
or damage.
No modifications may be made to the CHP unit
without the approval of Viessmann Werke GmbH &
Co. KG. Additional components not included in the
standard delivery may be integrated into the system.
The operator is responsible for any damage to the
CHP unit or other material assets caused by such
components.
DANGER
Impermissible modifications to the
machine!
Risk to life, serious personal injury
resulting in irreversible damage
Never perform any modifications or
alterations to the machine without
permission.
3.2 Safety equipment
The installer protects the CHP unit from unauthorised
access by installing it in a locked plant room. The
installer is also responsible for ensuring that all safety
equipment is fully installed and fully functional.
Furthermore, the installer is responsible for attaching
the safety symbols.
DANGER
Missing or non-functional safety
equipment!
Risk to life, serious personal injury
resulting in irreversible damage
NEVER remove or disable safety
equipment.

Safety
8 Installation instructions VITOBLOC 200 EM-530/660 version SCR
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3.3 Personnel
All personnel working on the CHP unit must be
trained in its use. They must also have read and
understood the documentation, including the chapter
concerning safety. We recommend that this is
confirmed with their signature.
The term "personnel" includes the installer, the
operator and the user of the machine.
PLEASE NOTE
Failure to observe the installation
instructions!
Serious material damage to the
machine and its surroundings
The specifications in the installation
instructions must be observed.
Siting, replacement, adjustment,
servicing and maintenance may only be
carried out by personnel with specific
training on the relevant component of
the machine.
Installer (e.g. specialist company)
The installer must integrate the CHP unit safely into a
system.
DANGER
Missing or non-functional safety
equipment!
Risk to life, serious personal injury
resulting in irreversible damage
NEVER remove or disable safety
equipment.
PLEASE NOTE
Installation, control and operation by
unauthorised or unqualified persons!
Serious material damage to the
machine and its surroundings
No unauthorised persons are permitted
within the working area.
Only employ qualified, trained
personnel.
The installer is responsible for the following tasks:
●Installing the CHP unit.
●Connecting the CHP unit.
●Installing the prescribed safety and protective
equipment.
●Attaching the necessary safety symbols.
●Displaying the Declaration of Conformity for the
system.
●Preparing the operating instructions for the
system.
●Training the operator/user. The operator/user
must sign to confirm they have participated in this
training.
Installation personnel
The responsibilities of the installation and
commissioning personnel must be defined.
The personnel must meet the following requirements:
●They must have read and understood all the
documentation, including the chapter concerning
safety.
●They must be trained and instructed in the work to
be performed.
●They must use the personal protective equipment.
●Only qualified personnel may carry out work on
the machine. Qualified personnel are people who
can assess the work to be performed and identify
potential risks based on their technical training
and experience as well as their knowledge of
applicable standards.
●Depending on country-specific legislation,
regulations and standards, the installer may need
to adapt these conditions.
Operator
The operator of the CHP unit is responsible for it
being used as intended. The operator must ensure
safe, technically flawless operation of the machine as
well as define and comply with all safety regulations
for the personnel.
The operator is responsible for compliance with
country-specific legislation, regulations and
standards.

Safety
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3.4 General safety regulations
Only use the CHP unit if it is in perfect technical
condition in accordance with its intended use, and if
you are aware of all safety-relevant factors. Incorrect
handling may result in personal injury and material
damage.
In the event of any defects or faults being identified
with regard to operational safety or operational
reliability, the CHP unit must be shut down
immediately or not started up in the first place.
DANGER
Incorrect handling of the machine with
regard to operational reliability!
Risk to life, serious personal injury
resulting in irreversible damage
Refrain from all unsafe working methods.
Do not carry out any modifications,
additions or alterations to the machine
which may adversely affect safety.
Take measures to ensure safe, fully
functional operation.
Only operate the machine if all protective
and safety equipment is fully functional.
Comply with the safety regulations.
PLEASE NOTE
Unauthorised modification to
programmable control systems!
Serious material damage to the
machine and its surroundings
No unauthorised persons are permitted
within the machine's working area.
Only qualified, trained personnel may
operate the machine.
●In the event of malfunctions, shut down and
secure the machine immediately! Correct all faults
immediately.
●Spare parts must meet the technical requirements
stipulated by the manufacturer. This is always
guaranteed in the case of original spare parts.
●Appropriate workshop equipment is essential for
carrying out the installation work.
●The location of fire extinguishers and how they are
used must be made known!
●Observe the fire alarm and firefighting procedures.

Safety
10 Installation instructions VITOBLOC 200 EM-530/660 version SCR
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3.5 Special safety regulations
3.5.1 Siting and storage
PLEASE NOTE
Incorrect siting or storage!
Material damage due to corrosion
Protect the machine and its parts from
rust.
Prevent the formation of condensation.
3.5.2 Assembly work and installation
●Adhere to the settings prescribed in the installation
instructions! Only qualified personnel may perform
such work.
●For all work involved in operating or setting up the
machine and its safety equipment, observe the
start-up and shutdown procedures described in
the operating instructions!
●When replacing larger assemblies, attach them
carefully to lifting gear and secure them in such a
way that no risk can arise from this. Only use
appropriate, technically flawless lifting gear and
lifting accessories with sufficient load bearing
capacity! Do not stand or work under suspended
loads!
●Only entrust experienced personnel with the
fastening of loads and instruction of crane drivers!
The person providing guidance must remain within
sight of or in voice contact with the operator.
●When performing overhead installation work,
always use the intended or other safe climbing
aids and working platforms. Do not use machine
parts as climbing aids! Wear safety harnesses
when carrying out servicing work at a height!
●Always retighten any threaded connections that
have been loosened during installation work.
●If any safety equipment needs to be removed
during installation, it must be inspected
immediately after completing the installation work.
●Ensure the safe and environmentally responsible
disposal of operating fluids and fuels!
●Installation of the machine and its peripheral
connection systems may only be carried out by
authorised personnel from a specialist company,
who have been instructed in these tasks by the
manufacturer.
●Work on parts carrying gas must be carried out by
a licensed specialist.
●The applicable engineering standards as well as
all building and statutory regulations apply to the
practical execution of this work.
●Design the safety equipment in accordance with
all locally applicable regulations.
●Observe the accident prevention regulations.
3.5.3 Commissioning
●Observe start-up and shutdown procedures,
machine ramp-up and control displays!
●Before switching on/commissioning the machine,
ensure that no-one can be put at risk by the
machine starting up.
●Before commissioning the machine, check all
safety equipment and other protective devices for
completeness and correct function. Check all
machine parts for the presence of any foreign
bodies.
●Before commissioning, it is essential to check that
the operating fluids comply with the
manufacturer's specifications.
●No unauthorised people or objects are permitted
within the danger zone during commissioning.
PLEASE NOTE
Unsuitable operating fluids!
Serious material damage to the
machine
Gases and combustion air must meet
the manufacturer's specifications in
accordance with chapter 10.5.