Viessmann VITOBLOC 200 User manual

5780067 GB 10/2017 Please store this document in a safe place.
Assembly instructions
for the specialist
VITOBLOC 200
model BM-366/437
Part no. 7639780
Block-type thermal power plant for biogas operation

Legal notice
2 Assembly instructions VITOBLOC 200 BM-366/437
5780067 GB
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.
NOTE
The Vitobloc 200 cogeneration module is
not suited to 60 Hz operation which means
that it is in particular not available to the
American and Canadian market.
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 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.
[email protected]
phone: +49+8191+9279-0

Table of Contents
VITOBLOC 200 BM-366/437 Assembly instructions 3
5780067 GB
1Directives, norms.............................................................................4
1.1 Working at the block-type thermal power plant..........................................................4
1.2 General safety and installation instructions............................................................... 4
1.3 MRL risk notice.............................................................................................................4
1.4 Remaining hazards with the use of the combined heat and power plant ................. 6
1.5 Important provisions, guidelines, norms and directives............................................7
2Specifications...................................................................................9
2.1 Cogeneration module operating parameters.............................................................. 9
2.2 Operating parameters of a complete cogeneration module .................................... 11
2.3 Dimensions, weights and finishes............................................................................. 13
3Transportation................................................................................14
3.1 Unload by fork truck................................................................................................... 14
3.2 Block-type thermal power plant storage conditions ................................................ 14
3.3 Cranage ....................................................................................................................... 15
3.4 Setting up.................................................................................................................... 16
3.5 Removing the transport securing devices................................................................ 17
4Installation......................................................................................18
4.1 Qualification of personnel.......................................................................................... 18
4.2 Scope of delivery ........................................................................................................ 18
4.3 Requirements on the technical room ........................................................................ 19
4.4 Peripheral connections of the cogeneration module (flowchart)............................ 20
4.5 Peripheral ventilation and exhaust............................................................................ 21
4.6 Heating connection..................................................................................................... 22
4.7 Gas connection........................................................................................................... 23
4.8 Exhaust gas connection............................................................................................. 24
4.9 Condensate drainage.................................................................................................. 25
4.10 Electrical connection.................................................................................................. 26
4.11 Installation of the noise cover (if part of the supply)............................................... 27
5Notification of readiness for start-up............................................28
6Declaration of conformity according to Machine Directive.........34

Directives, norms
4 Assembly instructions VITOBLOC 200 BM-366/437
5780067 GB
1 Directives, norms
1.1 Working at the block-type thermal power plant
CAUTION
The assembly, the connections for fuel
and exhaust, the electric power
connection, first start-up as well as
maintenance and repair shall be carried
out by specialist firms with personnel
instructed and authorized for these
tasks by the block-type thermal power
plant manufacturer. All work at gas
equipment shall only be undertaken by
a specialist for gas systems.
All work shall comply with the
applicable technical rules and the
requirements of the building inspection
and the laws. All safety devices must
comply with local requirements. All
accident prevention rules shall be
observed. It is forbidden to remove any
safety device, jumper it or render it
ineffective.
LIABILITY
The supplier's warranty will be void if
safety information is ignored and safety
instructions are not observed. The use
of prescribed and permitted operating
materials shall be confirmed to the party
granting warranty in writing and is a
precondition for the acceptance of
defect claims.
NOTE
Illustrations and descriptions in these
operating instructions may deviate from
the cogeneration module delivered to
you in certain respects due to changes
of the specifications.
INSTRUCTION
The construction and operation of the
Block-type thermal power plant and the
work package in relation with it are
based on the following:
–Statutory regulations
–Technical directives documenting
the state of the art in engineering:
EN, DIN, VDE, VDI, DVGW
directives, emission control act
–Accident prevention regulations of
the professional associations and
the Factory Act
–Regulations of the local power
supply companies and local
administrational authorities
1.2 General safety and installation
instructions
●Use the cogeneration module only for the purpose
for which the manufacturer has intended it.
●Operate the cogeneration module only when the
housing and the cables and lines are intact and not
damaged.
●Make sure that no unauthorized persons can
access the cogeneration module. It is possible that
risks are not identified by unauthorized persons.
●Do not operate the cogeneration module in a moist
or wet environment.
●The cogeneration module should only be
maintained and repaired by skilled personnel
familiar with the associated risks and the applicable
provisions.
1.3 MRL risk notice
The combined heat and power plant module
generates electricity and heat. A gas/gasoline engine
powers a 3-phase synchronous alternator. The table
below provides information on possible risks which
can occur during usual or reasonably foreseeable use
during installation and maintenance of the plant. This
is the reason why only instructed specialist personnel
are allowed to operate and maintain the plant.

Directives, norms
VITOBLOC 200 BM-366/437 Assembly instructions 5
5780067 GB
GPSG (Product Safety Act) Article 5(1)1a:
What risks should be observed during usual or
reasonably foreseeable use?
Source of risk:
Dangerous activity:
Response:
Switchgear:
Injection switch
Alternator contactor
Power cables
Removal of covers
Reaching under a cover with your arm
Terminal connection
Dangerous electric shock
Terminal X1 / 7,8,9
External voltage!
When terminals are connected, the
terminal can be live with voltage even if
the injection switch is off
Dangerous electric shock
Contactors and relays
Manual operation of relays or contactors
Undefined circuits with substantial
damage
( engine / alternator)
Risk of short circuit, with possible
electric shock
Alternator:
Power and control
connections
Removal of the covers on the terminal
box
Touching the terminals and control
p.c.b.s
Dangerous electric shock
Covers and ventilation panels
Removal of covers
or reaching under a cover with your arm
Putting objects in the ventilation
openings
Dangerous electric shock
Risk of damage
Mechanical damage at the alternator
Engine:
Engine block
Oil pan
Cooling water lines
Touching the engine when it is hot
Opening of shutoff or drain valves
Risk of burning
Scalding due to outflow of cooling
water
Oil test fitting (quick acting
closure)
Actuating the ball closure
Scalding due to outflow of engine oil
Rotating parts of the engine
Touching
Risk of damage
Ignition:
Ignition coils
Ignition cable
Plug connectors
Disconnection of ignition cables
Pulling of plug connectors
Dangerous electric shock (high
voltage)
Engine damage
Battery:
Battery poles
Removing pole caps
Placing metal objects on poles
Short circuit with risk of burning
Explosion hazard
Battery fluid
Opening the battery compartments
Risk of chemical burns
Observe battery safety instructions.
Fan:
Rotating fan wheel
Opening the covers,
Putting the hand in the fan wheel
Risk of damage
Gas lines:
Bolted joints of gas lines
Test fitting
Opening of bolted connections
Opening the test fitting
Gas escape
Explosion hazard
Exhaust lines:
Exhaust lines
Measuring port
Opening of exhaust flanges
Opening the measuring port
Touching unprotected exhaust pipes
Touching unprotected measuring port
Exhaust escape
Risk of poisoning
Risk of burning
Tab. 1 Block-type thermal power plant hazards

Directives, norms
6 Assembly instructions VITOBLOC 200 BM-366/437
5780067 GB
1.4 Remaining hazards with the use of the combined heat and power plant
What active dangers does the block-type thermal
power plant involve for the operators?
Regardless of the use of a combined heat and power
plant, all applicable instructions for the safe
transportation and the applicable instructions relating
to the technical installation (power, gas, heating,
ventilation) should be observed.
Despite all safety precautions, the following hazards
can remain in connection with the use of a combined
heat and power plant.
Hazard analysis acc. to DIN EN 12100:
What remaining active hazards are posed by
the CHP to the operators?
Manufacturing/works trial run Transporting Storing Assembling Installing Starting up
Programming at control panel
Using/operating Cleaning (cold CHP) Fault finding Maintaining Shutting down Dismantling Disposing
Mechanical hazard 1 1 1
Electrical hazard 1 1 1 1
Heat hazard 2 2 2 2 2 2
Noise hazard 2 2
Vibration hazards
Radiation hazard 2 2 2 2 2 2
Hazards due to materials and substances 2 2 2 2 2 2 2 2
Hazards due to ignorance of ergonomic principles
Hazards due to slipping, stumbling, falling
Hazard combinations
Hazards in connection with the site environment
Hazards due to accidental starting and unexpected cranking
Hazards due to shutting down / emergency stop
Hazards due to changes of rotational speed
Hazards due to power failure
Hazards due to failure of the control loop
Hazards due to fracture during operation 1 1 1 1 1 1 1
Hazards due to service in potebtially explosive atmosphere
1 High remaining hazard - Ignoring safety instructions can be fatal.
2 Remaining hazard - Ignoring safety instructions can cause damage to health.
Tab. 2 Remaining hazard analysis acc. to DIN EN 12100
Mechanical hazards
Mechanical hazards occur if protective covers must
be removed for finding faults or making repairs. This
includes essentially the grids covering the fan box and
the toothed belt covers of some models.
This work must only be performed by specially trained
technicians.
Electrical hazards
Electrical hazards occur if protective covers must be
removed for finding faults during start-up (works test)
or for maintenance or repair. This includes essentially
the cover of the alternator terminal box, or switches
and protective covers in the switchboard, e.g., for
adjusting the setting of the synchronizer or measuring
the alternator voltage or the mains voltage.
Wear suitable protective clothing for work on the
ignition system because a defective ignition cable can
cause electric shock.
This work must only be performed by specially trained
technicians.

Directives, norms
VITOBLOC 200 BM-366/437 Assembly instructions 7
5780067 GB
Hazards due to heat
During operation, the combustion engine in the block-
type thermal power plant and the downstream heat
generation components and the exhaust line become
very hot; the temperature can reach several hundred
degrees centigrade at exposed points. All pipelines
and components are insulated as far as possible.
However, some points are accessible freely for
service and installation. These can become hot in
operation and are not protected against accidental
touching, e.g., the measuring fitting for exhaust gas
back pressure.
If a fault develops, the safety pressure limiter can trip
and discharge hot cooling water. This can involve the
risk of scalding.
Hazard due to noise
Use suitable hearing protection when working on the
cogeneration module during operation with open
noise cover, e.g., during fault finding or repairs.
Hazard due to radiation
Electromagnetic fields emanating from generators in
the block-type thermal power station can temporarily
disturb any heart pacemaker in its immediate vicinity.
The signs of a potential disturbance might be
dizziness, palpitations or an irregular pulse. The heart
pacemaker functions normally as soon as the person
wearing it moves away from the generator.
Hazards due to materials and substances
Like a car, the block-type thermal power plant is
started by batteries. The batteries are filled with
battery acid. Battery acid has caustic effect. Avoid
skin contact and observe the applicable safety
instructions.
The same is true of cooling water containing glycol
and the lubrication oil of the engine. Wash the parts of
your body in contact with these substances with
copious amounts of water and apply body care agent.
Waste gas might escape uncontrollably if there are
leaks in the waste gas system (causing the hazard of
carbon monoxide poisoning). However, it is normally
conducted outside by the extract ventilator cowl
through an extract air duct. Therefore it is important to
watch out for leaks when carrying out service work on
the open machine and to ensure that the sound-
absorbing hood is closed during operation.
Hazards due to breakage in operation
Particular care is required when the CGP module is
lifted by crane; observe the crane hook and the
transport lugs.
Breakage can cause leaks in overheated
components. Hot engine oil, heating or cooling water
can gush out. For example, hoses can burst or test
fittings break away.
It cannot be excluded that - like in cars - the engine
can break and fragments be ejected in very rare
cases.
If parts of the exhaust system break or corrode, toxic
carbon monoxide can escape. In this case, switch off
(shut down) the block-type thermal power plant
immediately and start the ventilation.
Hazards due to operation in potentially explosive
atmosphere
It is permitted to set up, operate, maintain and run the
cogeneration module in a potentially explosive
atmosphere (ATEX zone) only if one of the two
following fundamental conditions exists:
1. Constant mechanical ventilation (exhaust) of the
technical room prevents a potentially explosive
mixture.
2. The gas supply line is fitted with a gas warning
system and a sufficient number of sensors at
strategic points.
In this case, when the gas concentration is at the
lower alarm limit, the mechanical room
ventilation (exhaust) is switched on, the
cogeneration module can be switched off and
the gas main solenoid receives a closing signal.
The personal protection equipment comprises:
Hearing protection (work on the running block-type
thermal power plant with open noise cover)
Protective gloves and goggles when handling battery
acid, glycol or engine lubricating oil
1.5 Important provisions, guidelines, norms and directives
Provision
Designation
2009/142/EC (7. GPSGV)
EU directive relating to appliances burning gaseous fuels
2014/68/EU (14. GPSGV)
EU pressure vessel directive
2006/42/EC (9. GPSGV)
EU machine directive
2014/35/EU (1. GPSGV)
EU low voltage directive
2014/30/EU (EMVG)
EU electromagnetic compatibility directive
DIN EN 60204-1 (VDE 0113-1)
Safety of machinery –Electrical equipment of machines
Part 1: General requirements
DIN EN ISO 12100
Safety of machinery –Fundamental terminology, general design principles

Directives, norms
8 Assembly instructions VITOBLOC 200 BM-366/437
5780067 GB
Provision
Designation
DIN EN ISO 14121-1
Safety of machinery –Risk assessment –Part 1: Technical principles
DIN EN 13857
Safety of machinery –Safety distances to prevent danger zones being reached
DIN 1340
Gaseous fuels and other gases –types, components, use
DIN 1940
Internal combustion engines –Reciprocating engines: Terminology, symbols,
units
ISO 3046-1
Reciprocating internal combustion engines –Requirements Part 1:
Specifications of output, fuel and lubricant consumption and testing methods
DIN 4109
Sound insulation in building construction –Requirements and proof
DIN EN 13384
Exhaust systems –Thermal and fluid dynamic calculation methods
DIN EN 12828
Heating systems in buildings –Design for water-based heating systems
DIN 4753
Water heaters and water heating systems for drinking and process water
DIN 6280
Current generating sets with reciprocating internal combustion engines –
Combined heat and power plants with reciprocating internal combustion
engines
Part 14: Fundamentals, requirements and components, design and
maintenance
Part 15: Tests
DIN ISO 8528-1
Reciprocating internal combustion engine-driven current generating sets
Part 1 –Application, ratings and design
DIN 18380
VOB Construction tendering and contract regulations –part C:
General technical Terms of Contract for construction work (ATV);
Heating systems and central water heating systems
DIN 51857
Gaseous fuels and other gases –Calculation of calorific value, heating value,
density, specific gravity and Wobbe index of gases and gas mixtures
DIN EN 50110-1 (VDE 0105-1)
Operation of electrical installations
DIN EN 50110-2 (VDE 0105-2)
Operation of electrical installations (national annexes)
VDE 0105-100
Operation of electrical installations Part 100: General requirements
DIN EN 50178 (VDE 0160)
Electronic equipment for operation in power installations
VDE 0100
Construction of power installations of nominal voltages up to 1000 V
DIN EN 50156-1 (VDE 0116-1)
Electrical equipment for furnaces and ancillary equipment - Part 1:
Requirements for application design and installation
DIN EN 60034-1 (VDE 0530-1)
Rotating electrical machines - Part 1: Rating and performance
ASUE
block-type thermal power plant and methane number
ASUE
Approval procedure of block-type thermal power plant
UVV BGV A 3 (VBG4)
Accident prevention regulations for electrical plant and equipment
ATV-DVWK
Worksheet ATV-DVWK-A 251 Condensate from condensing boilers
BlmSchV
4th Regulation concerning the application of the German Immission Control Act
(Ordinance concerning installations subject to approval, 4. BlmSchV)
DVGW
Worksheet G 260 –Gas quality
DVGW
Worksheet G 600 –Technical rules for gas installations (TRGI 1986/1996)
FeuVo
Fire code of the Federal states
EnEV
Ordinance concerning energy saving thermal insulation and energy saving
technical equipment in buildings (Energy Saving Ordinance - EnEV)
TA Lärm
Technical guideline for noise
TA Luft
Technical guideline for clean air
VDEW
Directive concerning the operation of power generating sets in parallel with the
low-voltage network of the electricity supply company
VDI 2035
Sheet 1 –Avoidance of damage to hot water heating installations - scale
formation in drinking water heating and hot water heating installations
VDI 3985
Principles of planning, execution and acceptance of combined heat and power
generating plants with internal combustion engines
VDI 6025
Economic calculations for capital goods and plants
Tab. 3 Important regulations, directives, norms and guidelines for the construction and operation of a Block-type thermal power
plant

Specifications
VITOBLOC 200 BM-366/437 Assembly instructions 9
5780067 GB
2 Specifications
All planning and operating data below refer to one
cogeneration module in each case. Detailed information on the planning and execution is available in "Biogas block-type thermal power plant
series –Project management“.
2.1 Cogeneration module operating parameters
Operating parameters for the cogeneration module
Vitobloc 200 BM-366/437
Continuous operation 1) in parallel operation
50%
load
75%
load
100%
load
electrical output2)
cannot be overloaded
kW
183
275
366
heat output of high temperature 3)
tolerance 8%
kW
219
330
437
heat output of low temperature 3)
tolerance 8%
kW
8
12
16
fuel usage (at Hi = 6.5 kWh/m³)
tolerance 5%
kW
510
730
950
current characteristic value in accordance with AGFW FW308
(electrical output/thermal output)
0.81
utilisation ratio pursuant to the German Energy Taxation Law 4)
%
87.0
efficiency in parallel operation
electrical efficiency
%
35.9
37.6
38.5
heat efficiency high temperature
%
43.0
45.2
46.0
heat efficiency low temperature
%
1.1
1.6
1.7
total efficiency
%
80.0
84.4
86.2
Energy generation
electrical energy (three-phase)
voltage
V
400
frequency
Hz
50
internal electrical energy requirements5)
kW
7.5
heat energy (heat) HT
forward/return temperature
° C
85 / 65
heat energy (heat) NT
forward/return temperature
° C
35 / 38
Fuels and filling amounts
quality of fuel, lubricating oil, cooling water and heating water
refer to the current
operational regulations
filling quantity
lubricating oil
ltr.
60
added fresh oil tank
ltr.
200
cooling water
ltr.
140
heating water
ltr.
75
gas connecting pressure6)
mbar
20 - 50
Heat generation (heating)
return temperature in front of the module
min./max.
° C
60/65
standard temperature difference
return/forward feed
K
20
heating water volume flow
standard
m³/h
19.0
maximum acceptable operating pressure at high
temperature
bar
10
maximum acceptable operating pressure at low
temperature
bar
2
pressure loss at standard flowthrough in the HT module
standard
bar
0.8
pressure loss at standard flowthrough in the NT module
standard
bar
0.5

Specifications
10 Assembly instructions VITOBLOC 200 BM-366/437
5780067 GB
Tab. 4 Operating parameters of the complete cogeneration module Vitobloc 200 BM-366/437
Pollution emissions 7)
NOx content
measured as NO2
mg/Nm³
< 500
CO content
mg/Nm³
< 1,000
formaldehyde CH2O
mg/Nm³
< 60
Sound intensity level 1 free field meter away in accordance with DIN 45635
(tolerance to the specified values 3 dB(A))
exhaust gas8)
with 1 optional sound absorber
dB (A)
74
module
with sound insulation hood
dB (A)
81
without sound insulation hood
dB (A)
90
Combustion air and ventilation
module’s radiating heat
without connecting line
kW
approx. 39
installation room ventilation
nominal supply air volume flow
at 30°C additional air temperature
m³/h
13,361
nominal extract air volume flow
at 30°C additional air temperature
m³/h
11,600
residual pressure
at nominal extract air volume flow
Pa
250
supply air temperature
min./max.
° C
10/35 9)
Exhaust gas
exhaust gas volume flow, moist
at 150 °C
m³/h
1,622
exhaust gas mass flow, moist
kg/h
1,800
exhaust gas volume flow, dry
0 % O2(0 °C; 1012 mbar)
Nm³/h
1,901
maximum acceptable counterpressure
depending upon module
mbar
15
exhaust gas temperature
max.
° C
180
1) output data in accordance with ISO 3046 Part 1
(at 1,000 mbar of air pressure, air temperature 25° C, relative humidity 30% and cos φ =1)
All other data for the module apply to parallel operation; data for other installation conditions on request
2) The output power display is geared towards the generator counting arrow system, not the consumer counting arrow system. That means that the
output power is displayed with a positive sign, i.e. when the output power is delivered (feed).
3) Measured at a hot water return temperature of 65° C
4) The utilisation ratio pursuant to the German Energy Taxation Law is defined as a quotient of the sum of the thermal and mechanical power
generated to the sum of the energies used and auxiliary energies used.
5) cooling water pump, ventilator, battery charger and control transformer
6) Gas connecting pressure is in accordance with DVGW-TRGI 1986/96 of the gas flowing pressure at the beginning of the module’s gas regulating
route
7) Emission figures after the catalyst with reference to dry exhaust gas
8) We urgently recommend providing 2 consecutive exhaust gas sound absorbers when using the block-type thermal power station in residential
areas to comply with the demands of spaces requiring special protection
9) Ambient temperature no higher than 35°C and its average value over a period of 24 hours no higher than 30°C

Specifications
VITOBLOC 200 BM-366/437 Assembly instructions 11
5780067 GB
2.2 Operating parameters of a complete cogeneration module
Specifications of the cogeneration module
Vitobloc 200 BM-366/437
Engine with accessories
Gas Otto engine
Supplier
MAN
Engine type
K 2842 LE 322
Strokes
4-stroke
No. of cylinders/arrangement
12 / V arrangement
Bore/stroke
mm
128/142
Swept volume
Liters
21.93
Speed
min-1
1,500
Mean piston speed
m/s
7.1
Compression ratio
12 : 1
Mean effective pressure
bar
13.87
Standard output ¹)
cannot be overloaded
kW
380
Spec. full-load consumption
Tolerance 5 %
kWh/kWhmech
2.45
Gas consumption
e. g., at Hi = 6.5 kWh/m³
Nm³/h
146.15
Lubricating oil volume in pan
Liters
60
Lubricating oil consumption
(mean)
g/h
approx. 110
Engine weight
(abt.)
kg
1,415
Engine cooling heat exchanger system (engine block and lubricating oil)
Heat output
Tolerance 8 %
kW
205
Cooling water temperature
Inlet/outlet
° C
80 / 85.8
Cooling water flow
m³/h
37.6
Exhaust heat exchanger
Heat output
Tolerance 8 %
kW
194
Exhaust temperature
Inlet/outlet
° C
470 / < 150
Cooling water temperature
Inlet/outlet
° C
84.9 / 88.6
Pressure loss
Exhaust end
mbar
< 10
Pipe material
1,4571
Exhaust head material
Inlet
1,4828
Outlet
1,4571
Water jacket pipe material
ST 50
Mixture cooling, high temperature (turbo charger)
Heat output
Tolerance 8 %
kW
38
Cooling water temperature
Inlet/outlet
° C
80 / 82.8
Cooling water flow
min.
m³/h
17.5
Mixture cooling, low temperature (turbo charger)
Heat output
Tolerance 8 %
kW
16
Cooling water temperature
Inlet/outlet
° C
35 / 38
Cooling water flow
min.
m³/h
4.6
Plate heat exchanger
Heat output 2)
kW
421
Cooling water temperature
Inlet/outlet
°C
88.6 / 80
Heating water temperature
Inlet/outlet
°C
65 / 85
Pressure loss
bar
0.6
Plate material
1,4404
Nominal dimensions
Exhaust connection (AGA) from cogeneration module, pipe connection
DN 200 / PN10
Condensed water connection (KO), pipe connection
Pipe ø 22 x 2.0
Heating water flow/return (HV/HR), pipe connection
DN 80 / PN16
Gas connection (GAS), pipe connection
DN 80 / PN16

Specifications
12 Assembly instructions VITOBLOC 200 BM-366/437
5780067 GB
Synchronous alternator
generator type
LSA 47.2 M8
apparent power Sn
at cos phi = 0.8
kVA
500
three-phase current
voltage/frequency
V / Hz
400 / 50
speed
min-1
1,500
efficiency at the rated output of the module and cos φ = 13)
%
96.0
rated current
A
658
sub-transient short circuit current I"k-
initial - short alternating current according to DIN EN 60909-0
(VDE 0102)
A
5,594.5
maximum acceptable load application
A
200
stator circuit-breaker
star
protection class
IP 23
Cabling to the cogeneration terminal box
NSHV protection (recommended)
cos phi = 0.8
A
820
Minimum required design for correctly connecting the cogeneration system4)
network connection to the NSNV, system-tie field or
transformer
X1: L1,L2,L3, N PE
H07 RNF
5 x 2 x 240 mm²
remote selection for "heat operation" 100% output
provided by the customer
X1: terminal 40 / 41
Ölflex 12 x 1.5 mm²
feedback (potential-free contact) module "ready"
X5: terminal 1 / 2
feedback (potential-free contact) module "operation"
X5: terminal 3 / 4
feedback (potential-free contact) module "malfunction"
X5: terminal 5 / 6
heating water pump selection (potential-free contact)
X5: terminal 9 / 10
heating-water regulating valve (return rise)
X5: terminal 16 / 17 / 18 / PE
Oilflex 4 x 0.75mm²
Mixture cooling water control valve
X7: terminal 1 / 2 / 3 / PE
Oilflex 4 x 0.75mm²
Heating water pump 230 V or 400 V /10 A
X5: terminal 21 / N / PE (230V)
X5: terminal 33/34/35/PE (400V)
Oilflex 3 x 1.5mm²
Mixture cooling water pump
X5: terminal 36 / N / PE
Oilflex 3 x 1.5mm²
additional PT 100 sensor in the total heating water
return for optional module selection and deselection
X1: terminal 44 / 45
Ölflex 2 x 1.5 mm²
earthling cable from the module to the
potential-equalisation rail provided by the customer
earthing connection on the
module frame
dimensioning as per
customer’s conditions
Extended plant design with "stand-by operation"
network measuring voltage in front of the system-tie
circuit-breaker
X1: terminal 7 / 8 / 9 / N / PE
Ölflex 5 x 1.5 mm²
system-tie circuit-breaker feedback is on
(signal from the NSHV or from the system-tie field)
X1: terminal 12 / 13
Ölflex 5 x 1.5 mm²
system-tie circuit-breaker feedback is off
(signal from the NSHV or from the system-tie field)
X1: terminal 14 / 15
select stand-by operation5)
X1: terminal 38 / 39
Ölflex 3 x 1.5 mm²
switch-on command for the system-tie circuit-breaker
"NK switch release" (potential-free contact)
X5: terminal 7 / 8
Ölflex 3 x 1.5 mm²
1) output data in accordance with ISO 3046 Part 1
(at 1,000 mbar of air pressure, air temperature 25° C, relative humidity 30% and cos φ =1)
All other data for the module apply to parallel operation; data for other installation conditions on request
2) Measured at a hot water return temperature of 65° C
3) cos φ display value in the generator counting arrow system
4) This cable list constitutes the minimum design needed for correctly connecting a block-type thermal power plant (only used as a guideline) The
electrical company doing the work has the responsibility for correct cabling which should be carried out according to the local requirements and
relevant VDE and EVU regulations.
5) External control engineering makes the selection for stand-by operation after the customer’s load shedding. The selection can be made
automatically inside of the module, but without monitoring load shedding.
Tab. 5 Specifications of the complete cogeneration module Vitobloc 200 BM-366/437

Specifications
VITOBLOC 200 BM-366/437 Assembly instructions 13
5780067 GB
2.3 Dimensions, weights and finishes
Dimensions of the cogeneration module
Frame size
incl. noise cover
and extract fan1)
Length, incl. control cabinet
mm
3,983
4,708
Width
mm
1,600
1,650
Height
mm
2,000
2,026
Weight of the cogeneration module
Deadweight
(abt.)
kg
6,300
Operating weight
(abt.)
kg
6,800
Finishes
Engine, alternator
Light gray (RAL 7035)
Frame
Anthracite gray (RAL 7016)
Control cabinet
Silver
Noise cover
Silver
Connections
Design
Norm
Size
AGA
Exhaust outlet
Flange
EN 1092-1
DN 200 / PN 10
KO
Condensed water discharge
Pipe
DIN EN 10220
Ø 22 x 2.0
GAS
Gas inlet
Flange
EN 1092-1
DN 80 / PN 16 2)
HV/HR
Heating flow/return
Flange
EN 1092-1
DN 80 / PN 16
GV/GR
Mixture cooler flow/return
Pipe fitting
DIN EN 10226
R 1“
external thread
AL
Extract outlet
Flange
—
580 x 580 P20
1) The noise cover is available as an option for cogeneration modules Vitobloc 200 BM-366/437.
2) For minimum 20 mbar gas flow pressure and 5 kW/nm³ calorific value, other values on request
Tab. 6 Dimensions, weights, finishes and connections
Fig. 1 Dimensions and connections of cogeneration modules Vitobloc 200 BM-366/437 with optional noise cover
(all dimensions in mm); the fan box attached on the rear can be removed when the module is moved.

Transportation
14 Assembly instructions VITOBLOC 200 BM-366/437
5780067 GB
3 Transportation
NOTE
The cogeneration module is delivered
by heavy truck along sufficiently load-
bearing roads.
3.1 Unload by fork truck
CAUTION
Use suitable devices / fixtures to avoid
damage to the cogeneration module
during unloading and transportation by
fork truck.
Fig. 2 Unloading by fork truck
3.2 Block-type thermal power plant
storage conditions
The block-type thermal power plant should be
transported and stored protected from moisture (max.
rel. humidity: 70 %).
Do not expose the cogeneration module to air with
dust or halogens.

Transportation
VITOBLOC 200 BM-366/437 Assembly instructions 15
5780067 GB
3.3 Cranage
-Move the cogeneration module by crane
suspended on ropes which are attached to 4
additional transport lugs.
-It should be put into place when vertical (other
options on request).
CAUTION
Make sure that everybody leaves the
area under the module when it is
suspended on the crane hook. Maintain
the lifting equipment in good order.
NOTE
The optional transport lugs should be
screw-fitted at the sides of the base
frame (Fig. 3). Observe the minimum
frame dimensions.
CAUTION
Use suitable devices / fixtures to
prevent damage to the cogeneration
module during transportation by crane.
Do not attach the rope, pull at or
otherwise subject projecting parts to
load.
CAUTION
It should only be put into place with a
crane and ropes with a mounted sound-
absorbing hood, because it might
otherwise tip.
It is necessary to use a transport frame
when transporting and putting into
place a cogeneration module without a
sound-absorbing hood (can be hired
out against a deposit).
Fig. 3 Moving the cogeneration module by crane and
ropes, requires four additional transport lugs

Transportation
16 Assembly instructions VITOBLOC 200 BM-366/437
5780067 GB
3.4 Setting up
●The cogeneration module is installed on a raised
base without separate anchoring and placed on
sylomer strips (loose supply) for separation from
structure-borne noise.
CAUTION
Make sure that the foundation base has
the required height (≥ 150 mm) for
drainage of condensed water.
H
L
W
Base minimum dimensions
Vitobloc 200 BM-366/437
L 4,000 mm
W 1,600 mm
H 150 mm
Fig. 4 block-type thermal power plant with base
Switching
cabinet
side
380
1600
2660
3600
1600
540
Fig. 5 Locating plan for sylomer strips
•The scope of delivery includes:
10 green SR 55 sylomer strips
2 yellow SR 11 sylomer strips
(1,500 x 100 x 50 mm)
•blank required green:
7 x 1,500 mm long
2 x 1,400 mm long
1 x 600 mm long
1 x 300 mm long
•blank required yellow:
1 x 1,500 mm long
1 x 380 mm long
1 x 280 mm long

Transportation
VITOBLOC 200 BM-366/437 Assembly instructions 17
5780067 GB
G
G
Supply
air
Horizontal projection
H
I
Gas
Extract air
Condensate
Exhaust gas
Extract air
Condensate
D
C
AB
F
1m
Cut
E
Exhaust gas
Extract air
Gas
Heating water
Condensate
Heating water
Condensate
Supply
air
Fig. 6 Minimum distances in the technical room
(dimensions in mm)
A
1,000 mm
B
2,000 mm
C
7,000 mm
D
4,708 mm
E
2,070 mm
F
3,500 mm
G
1,500 mm
H
1,650 mm
I
4,650 mm
Tab. 7 Minimum distances in the technical room
3.5 Removing the transport securing
devices
●Remove the packaging and send it for recycling.
●Remove four transport securing devices at the
elastic supports of the engine and alternator
(Fig. 7)
Fig. 7 Remove four transport securing devices at the
elastic supports of the engine and alternator
CAUTION
Always remount the transport locking
device when the block-type thermal
power station is removed after final
shut-down. Otherwise, there is a risk
that the motor-generator unit will tear off
from the basic frame if not transported
vertically, which can endanger the
transport personnel.

Installation
18 Assembly instructions VITOBLOC 200 BM-366/437
5780067 GB
4 Installation
4.1 Qualification of personnel
DANGER!
Cogeneration modules, including all
peripheral connection systems must be
installed by a specialized firm
employing personnel instructed and
authorized for this kind of work by the
block-type thermal power plant supplier.
All work at gas equipment shall only be
undertaken by a specialist for gas
systems.
Specialized personnel, according to
VDMA 24186-0 are personnel
(mechanic, foreman, technician,
engineer) with the required vocational
qualification. Vocational qualification
includes at least complete training in an
industrial or trade occupation or higher-
level education in building services.
All work shall comply with the
applicable technical rules and the
requirements of the building inspection
and the laws.
All safety devices must comply with
local requirements.
All accident prevention rules shall be
observed.
4.2 Scope of delivery
-Module
-Optional equipment as ordered

Installation
VITOBLOC 200 BM-366/437 Assembly instructions 19
5780067 GB
4.3 Requirements on the technical room
The following minimum requirements must be met
before the cogeneration module is moved and installed
in the technical room:
-The place where the cogeneration module is
installed should be level and have sufficient load
bearing capacity.
-Provide sufficient space for carrying out
installation and maintenance work (Fig. 6).
-The technical room should have water supply and
a floor drain with oil barrier.
-A competent firm should check to see if extra
noise control measures are required.
-If the cogeneration module is installed after prior
dismantling, this must be done by supplier
personnel to ensure that warranty is not lost.
-The effects of external vibrations, e.g., transmitted
through the building, or electromagnetic radiation,
must be reduced to an absolute minimum and
documented at the time of start-up.
-The room where it will be erected should be made
pursuant to the applicable firing directive and
applicable construction law ordinances/
regulations. We recommend integrating the CHP
module into the fire protection strategy for safe
operation.
-To increase workplace safety for the operator we
recommend that you install a CO monitor in the
installation room.
CAUTION
Do not store or use flammable materials
or liquids near the Block-type thermal
power plant.
Do not smoke or use open fire or naked
flame during operation of the block-type
thermal power plant.
We recommend, similar to the
requirement of the old Heating Room
Directive, installing a fire extinguisher of
the appropriate size (at least 9 l) in the
technical room.
NOTE
The following signs shall be put up both
outside and inside the technical room:
Prohibition sign P 06
"No access for unauthorized persons“
Prohibition sign P 02
"Fire, naked light and smoking not
permitted“
Prohibition sign P 11
"No access for persons wearing a
pacemaker“

Installation
20 Assembly instructions VITOBLOC 200 BM-366/437
5780067 GB
4.4 Peripheral connections of the cogeneration module (flowchart)
cogeneration module (scope of delivery) performance provided by the customer
(recommendation)
XC
TA
SC
ES
TI
SZA-
EIA
TZA+
LZA-
STB
G
3~
P/T
PI
PI
PZA-
PI
PI
P/TP/T
13
82
31
21
83**
80**
81
25
22
67
52
61
63
65
64 66 69
24
23
TC
LS
51
PO 71
68
74
P
*
*
*
2
PC
PZA+
PN = 20..50 mbar
46
T
**
*
*
TITC
SDB
M
84
10
PZA-
PI
45 46
T
42
43
47
*
32 34 (AGA)
16
18 (GV)
TI PI
26 27
19
27
PZA
24 17 (GR)
= 2bar!
M
13
44 (GAS)
Z
PZA
TI PI
12 26 27 14 (HR)
15 (HV)
27
24
11
M
13
= 65°C!
48
33 (KO)
pH
36
M
28
28
29
29
M
70 72 73
Fig. 8 Monitoring devices of the Vitobloc 200 BM-366/437 version; (items 80 and 83 optional)
NOTE
Only use design-tested parts for the safety
equipment of the heat circuit connection.
Overall legend:
1 cogeneration module (scope of delivery)
2 gas lane (scope of deliver, provided loose)
3 provided by the customer (recommendation)
10 deflagration guard (biogas)
11 safety valve (heating water)
12 heating water pump
13 return temperature controller
14 heating water return (HR)
15 heating water forward feed (HV)
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
28 hot water - filling and draining tap
29 bleed valve
31 exhaust gas heat exchanger
32 sound absorber
33 condensate water output (KO)
34 exhaust gas output (AGA)
35 catalyst
36 neutralization
41 lambda regulating valve
42 magnetic valve
43 zero pressure regulator
44 gas connection (GAS)
45 gas filter
46 gas ball cock with thermal safety valve
47 sealing control
48 gas meter
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 safety valve for low-temperature circuit
80 extract ventilator cowl
81 extract air
82 additional air
83 sound-absorbing hood
84 One-way restrictor
Measuring points
EIA alternator-display monitoring
ES alternator output control
LS level control
LZA minimum level control
P pressure
PN gas flow pressure
PC pressure regulator
PI pressure indicator
PO visual pressure indicator
PZA- minimum pressure shut-off
PZA+ maximum pressure shut-off
SC speed controller
SDB safety pressure limiter
STB safety temperature limiter
SZA- underspeed
T temperature
TA extract air temperature before
the ventilator
TC temperature controller
TI temperature indicator
TZA+ alternator winding temperature
monitoring
* Provided loose for assembly by the
customer
** optional equipment