Viessmann VITOBLOC 200 Parts list manual

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
VITOBLOC 200 EM-401/549 / EM-363/498 ESS Energie Systeme & Service GmbH 3
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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
5414 733 09/2009
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 shut-
off 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 chromium-
molybdenum 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 spring-
loaded 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 spark-
ignition 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-and-
socket 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-φregulation 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 low-
harmonic 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 low-
temperature 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 structure-
borne 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 (2nd 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 (2nd 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 block-
type 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 block-
type 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 higher-
level 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