Viessmann VITOBLOC 200 Parts list manual

5368 451 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 model EM-50/81
Block-type thermal power plant for natural
gas operation
in accordance with the requirements of the EU
Gas Equipment Directive and EU Machine
Directive
Electrical power 50 kW
Thermal output 81 kW
Fuel input 145 kW

Legal Notice
2 ESS Energie Systeme & Service GmbH VITOBLOC 200 EM-50/81
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This equipment satisfies the basic
requirements of the appropriate
standards and directives. Its conformity
has been demonstrated. These
documents and the original conformity
declaration are stored on the premises
of the manufacturer.
Important general instructions for application
Only use this technical equipment as intended and
complying 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 the
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.

Introduction
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1Introduction.......................................................................................4
1.1Continuous output in parallel operation.......................................................................5
1.2Emissions of pollution....................................................................................................5
1.3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 and exhaust gas front silencer ...........................12
2.8Lubricating oil supply system......................................................................................12
2.9Sound insulation hood and exhaust ventilator cowl ................................................12
2.10Series-production accessories....................................................................................13
2.11Monitoring equipment...................................................................................................14
2.12Switching cabinet..........................................................................................................15
2.13Check-list for stand-by operation................................................................................17
3Service and maintenance...............................................................18
3.1Service and maintenance list.......................................................................................19
4Technical Data.................................................................................21
4.1Operating parameters for the cogeneration module .................................................21
4.2Technical data of a complete cogeneration module..................................................23
4.3Dimensions, Weights and Colours.............................................................................25
4.4Installation .....................................................................................................................26
4.5Start-stop ratio...............................................................................................................26
4.6Ecotax in Germany........................................................................................................26
5Important information on planning and operation.......................28
5.1Malfunctions ..................................................................................................................28
6Index.................................................................................................29
7Conformity declaration...................................................................30
8Brief instructions ............................................................................31

Introduction
4 ESS Energie Systeme & Service GmbH VITOBLOC 200 EM-50/81
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1 Introduction
This block-type thermal power plant (cogeneration
module) is a complete turnkey unit with an air-cooled
synchronous alternator for generating three-phase
current 400 V, 50 Hz and warm water at a temperature
level of forward feed/return of 90°/70° 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 and stainless steel
exhaust gas front silencer for achieving NOx values in
accordance with Technical Instructions on Air 2002
(when new NOx < 125 mg/m³, CO < 150 mg/m³) and
reducing the exhaust gas alarm.
- Sound-absorbing hood for installing in sound-critical
zones such as hospitals, schools and similar
institutions.
- Fresh-air suction through the exhaust air fan with
maximum additional pressing of 250 Pa for the
exhaust air duct.
- 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 accordance 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 the 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. Maximum
operating pressure for the heating system 16 bar.
- Gas controlled member in accordance 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
accordance 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 accordance with the Gas Equipment
Directive 90/396/EEC and EU Machine Directive with
production in accordance 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 <0}

Introduction
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1.1 Continuous output in parallel
operation
Refer to page 21, Table 6 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 mean 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 on
request.
Current characteristic number
This cogeneration module is a series product with the
product number (CE-0433BT0002) 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 Table 6 (page 21) 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/EC on promoting
cogeneration geared towards available heat needs.
Stand-by operation
The cogeneration modules can also be used as
stand-by aggregates if the electricity grid fails in
stand-by operation if the customer’s main low-voltage
distribution is appropriately designed.
If there is a power failure when the block-type thermal
power plant is shut down, the first cogeneration
module can be started and automatically enabled as a
stand-by rail within 15 seconds.
Output will be reduced 10% to have sufficient regular
reserves in stand-by operation. The consumers
approved for stand-by power should be enabled in
stages (40% – 40% – 10%).
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.
1.2 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< 125 mg/Nm³
CO content* < 150 mg/Nm³
< 137 mg/kWh
Formaldehyde CH2O < 60 mg/Nm³
Emission values in accordance with ½ Technical Instruction on Air
Tab. 2 Emission values after exhaust gas purification

Introduction
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1.3 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 it
transformed into current through 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.
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
This gas spark-ignition engine is operated as an
internal combustion engine (aspirating engine) without
turbocharging and at an air ratio of lambda = 1.
A compressed oil jet cools the piston heads. The
exhaust gases are drained through a water-cooled
exhaust gas collector pipe.
Components
The crankcase is cast in one piece together with the
cylinder block. The cylinder support with 4 cylinders
arranged in line forms 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.
2.1.1 Engine lubricating oil system
The engine is lubricated with 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 oil screen.

Product description
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2.1.2 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.
2.1.3 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.
2.1.4 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, 110 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.
2.1.5 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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2.1.6 The gas lane and gas-air mixer
The cogeneration module is supplied with gas through
a modular safety gas lane (components approved in
accordance with DVGW).
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 cogeneration module in
accordance 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 current.
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.
Sealing should only be checked from 1,200 kW of
heat output in accordance with EN 746-2 whereas
DIN 33831-2 only recommends it from 390 kW. It can
be supplied as an option if requested.
2.1.7 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 is launched with
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 with 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 in 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 bears the cogeneration module (gas
spark-ignition engine, three-phase synchronous
alternator, cooling water pump, cooling water
expansion vessel, heat exchanger, exhaust gas front
silencer, exhaust gas purification, lubricating oil
supply system, switchgear and noise protection
elements). Beams can be loosened in the upper zone
and one the side in the lower zone to lift larger
building components with hoisting equipment of
ceiling cranes without being obstructed 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 module 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 the ground on four height-
adjustable elastomer buffers without fixed anchoring.