Viessmann Vitobloc 200 EM-50/81 User manual

6130329 GB 04/2019 To be kept carefully!
Operating instructions
for specialists
VITOBLOC 200
block-type thermal power plant module for natural gas operation
model EM-50/81 model EM-199/263 model EM-401/549
model EM-70/115 model EM-238/363 model EM-530/660
model EM-140/207 model EM-260/390

Legal notice
2 Operating instructions for the natural gas-fuelled CHP module VITOBLOC 200
6130329 GB
This equipment satisfies the basic require-
ments of the appropriate standards and di-
rectives. Its conformity has been demon-
strated. 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 com-
plying with the assembly instructions, operating instruc-
tions and service instructions. Only authorised profes-
sionals 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, acces-
sories 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.

Table of Contents
VITOBLOC 200 Operating instructions for the natural gas-fuelled CHP module 3
6130329 GB
1Instructions for operating the CHP.................................................4
1.1 Qualification of the personnel ......................................................................................4
1.2 Introduction into the unit’s functions and operation ..................................................4
1.3 Hazard warnings pursuant to the Machinery Directive...............................................4
1.4 Residual dangers from operating a combined heat and power plant........................6
1.5 Requirements concerning the technical room ............................................................8
1.6 Regulations for the prevention of accidents causing personal injury.......................9
2Preparations...................................................................................10
2.1 Consumables...............................................................................................................10
2.2 Filling Fuels..................................................................................................................17
3Commissioning..............................................................................24
3.1 Authorized personnel..................................................................................................24
3.2 Measuring and setting points for the commissioning ..............................................25
3.3 Commissioning instructions for the CHP module.....................................................28
4Programming .................................................................................32
4.1 Operator’s and indicator unit of the CHP module .....................................................32
4.2 CHP module control level 1: Display & change operating values...........................34
4.3 CHP module control level 2: Manual mode...............................................................36
4.4 CHP module control level 3: Display & change of parameters................................38
5Usage and operations ...................................................................43
5.1 Duties of the plant operator........................................................................................43
5.2 Remote monitoring with TeleControl LAN.................................................................44
5.3 Operations log for CHP modules................................................................................45
5.4 Requirements for optimal operation ..........................................................................46
5.5 Emergency...................................................................................................................47
6Cleaning .........................................................................................48
7Trouble-shooting ...........................................................................49
7.1 Fault messages from the CHP module that cannot be acknowledged ....................50
8Shutdown .......................................................................................54
8.1 Temporary shutdown ..................................................................................................54
8.2 Final shutdown (decommissioning)...........................................................................55

Instructions for operating the CHP
4 Operating instructions for the natural gas-fuelled CHP module VITOBLOC 200
6130329 GB
1Instructions for operating the CHP
1.1 Qualification of the personnel
The combined heat and power plant (CHP) has been
designed and built according to the state-of-the-art
and on the basis of the latest safety regulations. Spe-
cial attention has been paid to user friendliness. Op-
erating a CHP module and handling the required
operating resources should not cause any problems
at all, if the personnel is suitably trained and thinks
pro-actively.
Pursuant to VDMA 24186-0, skilled and specialist
staff (fitters, foremen, technicians, engineers etc.) is
personnel with the relevant professional qualification,
i.e. the completed vocational training in at least one
field of building service engineering or a higher quali-
fication.
In order to run the CHP module safely, efficiently as
well as in an environmentally-friendly and most opti-
mal way, only operating personnel will be admitted
who know these operating instructions precisely and
who have been duly familiarized with the plant opera-
tion.
LIABILITY
The manufacturer cannot be held liable,
if these safety instructions and any oth-
er instructions are disregarded.
CAUTION HIGH VOLTAGE.
DANGER TO LIFE.
Only suitably qualified personnel (elec-
tricians) are authorized to open the
module control panel or other electric
control & instrumentation (I&C) sys-
tems. Covers of the CHP module must
not be removed without having received
special instructions.
1.2 Introduction into the unit’s func-
tions and operation
The manufacturer shall familiarize the plant operator
or the personnel assigned to operate the plant with
the functions of the CHP module as well as how to
operate it and hand over the technical documents.
NOTE
Details of pictures or illustrations and
descriptions contained in these operat-
ing instructions may deviate from the
CHP module actually delivered as a re-
sult of ongoing technical developments.
1.3 Hazard warnings pursuant to the
Machinery Directive
The combined heat and power plant module has been
designed to generate power and heat at the same
time. In order to do so, an internal gas combustion
engine will drive a three-phase synchronous alterna-
tor. The table below contains information about poten-
tial risks in accordance with the relevant safety regula-
tions that may arise during the assembly and mainte-
nance work during usual or reasonably predictable
operations. Therefore, only skilled and specialist per-
sonnel who have been duly instructed are authorized
to operate the unit and carry out any maintenance
work.

Instructions for operating the CHP
VITOBLOC 200 Operating instructions for the natural gas-fuelled CHP module 5
6130329 GB
Article § 5(1)1a of the Equipment & Product Safety Act (GPSG):
What risks may arise during usual or reasonably predictable operations?
source of danger:
dangerous activity:
consequence:
switchgear:
feeder circuit-breaker
alternator contactor
power cable
removal of covers
reaching under the covers
connecting work at terminals
life-endangering electric shock
terminal X1/7,8,9
caution, external voltage.
terminals may still be live during connec-
tion work, although the feeder circuit-
breaker has been switched off
life-endangering electric shock
contactors and relays
relays or contactors being switched
manually
undefined circuits causing considera-
ble damage (to motor/alternator)
danger of short circuit and, possibly,
electric shock
alternator:
power and control connec-
tions
removing the cover sheets of the termi-
nal boxes
touching terminals and control PCBs
life-endangering electric shock
covers and cowl panels
removal of covers
or reaching under the covers
inserting objects into the ventilation slits
life-endangering electric shock
risk of injury
mechanical damage to the engine
alternator
engine:
engine block
oil pan
cooling water pipes
touching the hot machine
opening various shut-off or drain cocks
risk of burns
scalding from discharged cooling
water
oil test nipple (snap closing)
operating the check ball
scalding from discharged engine oil
rotating engine parts
touching
risk of injury
ignition:
ignition coils
ignition cables
spark plugs
loosening ignition cables
removing spark plugs
life-endangering electric shock (high
voltage)
damage to the engine
battery:
battery terminals
removing the terminal covers
placing metal objects on the terminals
short circuit and risk of burns
risk of explosion
battery acid
opening the battery chambers
risk of chemical burns
observe the battery safety instructions. (see chapter: 2.8)
fan:
rotating fan wheel
opening the covers,
reaching into the fan wheel
risk of injury
gas pipes:
screwed gas pipe connections
test nipples
opening various crewed connections
opening test nipples
gas leakage
risk of explosion
exhaust gas pipes:
exhaust gas pipes
adapter socket
opening various exhaust gas flanges
opening adapter sockets
touching un-insulated exhaust gas pipes
touching un-insulated adapter sockets
exhaust gas leakage
risk of poisoning
risk of burns
Table 1 CHP module hazard warnings

Instructions for operating the CHP
6 Operating instructions for the natural gas-fuelled CHP module VITOBLOC 200
6130329 GB
1.4 Residual dangers from operating a combined heat and power plant
What active risks are the operating personnel ex-
posed to from CHP module operations?
Irrespective of the actual conditions where a com-
bined heat and power plant will be installed, the rele-
vant fundamental safety regulations for the shipment
and the installation applicable to all trades (power,
gas, heating, ventilation) must be observed.
The following table makes reference to potential re-
sidual dangers which may still arise from the opera-
tion of a combined heat and power plant, even if the
relevant safety measures have been taken.
Risk analysis pursuant to DIN EN 12100:
What residual dangers is the operating
personnel exposed to when operating a CHP
production/test run transportation storage assembly installation commissioning
programming at the control panel
operations cleaning (CHP cold) trouble shooting maintenance de-commissioning disassembly disposal
Mechanical risks 1 1 1
Electrical risks 1 1 1 1
Thermal risks 2 2 2 2 2 2
Risks from noise 2 2
Risks from vibration
Risks from radiation 2 2 2 2 2 2
Risks from materials and substances 2 2 2 2 2 2 2 2
Risks from disregading ergonomic principles
Risks from skidding, stumbling and falling
Combinations of risks
Risks arising from the ambient conditions
Risks from unexpected starting, unexpected spinning
Risks from shutting-down the plant (emergency-off)
Risks from changing the speed
Risks from power supply cuts
Risks from a failure in the control circuitry
Risks from breakages during operation 1 1 1 1 1 1 1
Risks from operating the plant in an explosive environment
1 high residual risk –failure to observe the safety regulations may have fatal consequences.
2 residual risk –failure to observe the safety regulations may cause health damage.
Table 2 Risk analysis pursuant to DIN EN 12100
Mechanical risks
Mechanical risks will occur, when safety covers have
to be removed during trouble-shooting or while
maintenance measures are carried out. This concerns
largely the cover grilles of the fan box and the coup-
ling cover as well as the timing belt cover, depending
on the type of plant.
This work must only be carried out by suitably trained
and specialist personnel.
Electrical risks
Electrical risks will occur, when safety covers have to
be removed during the commissioning (factory trial
run), during trouble-shooting or while maintenance
measures are carried out. This concerns largely the
lid of the alternator’s terminal box or switches and
protective covers of the switchgear, e.g. when syn-
chronizing devices are adjusted or the alternator and
mains voltage is measured.
When working on the ignition system, suitable protec-
tive clothing must be worn, since electric shocks can
be transmitted from defective ignition cables.
This work must only be carried out by suitably trained
and specialist personnel.

Instructions for operating the CHP
VITOBLOC 200 Operating instructions for the natural gas-fuelled CHP module 7
6130329 GB
Thermal risks
The combustion engine in the CHP module as well as
the heat extraction components and the exhaust gas
piping downstream may get very hot for operational
reasons and develop temperatures of some hundred
degrees centigrade in exposed areas. The piping and
the components are insulated as far as possible.
However, some spots are freely accessible for instal-
lation and service purposes. They can get very hot
during operations and are not protected against unin-
tentional contact, e.g. measuring nipples for the ex-
haust gas counter pressure.
In the event of a breakdown, the pressure relief valve
can trip and discharge hot cooling water, which may
cause the risk of scalding.
Risks from noise
When working on the CHP module and the sound-
insulating lid is open during operations, e.g. during
trouble-shooting and while maintenance work is car-
ried out, the relevant ear protection must be worn.
Risks from 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 dizzi-
ness, palpitations or an irregular pulse. The heart
pacemaker functions normally as soon as the person
wearing it moves away from the generator.
Risks from materials and substances
Like a car, the CHP module will be started with batter-
ies. These batteries are filled with acid which has a
caustic effect. The contact of such acid with the skin
should therefore be avoided under any circumstances
and the relevant safety regulations are to be ob-
served.
The same applies to the glycol-containing cooling
water and the engine lubrication oil. Should you have
come in contact with such materials, wash the affect-
ed parts of the body thoroughly and treat them with
suitable body care products.
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.
Risks from breakage during operation
Exercise particular care and attention when lifting the
CHP modules on a crane hook or on their lifting eyes.
In the event of a breakage, thermally overloaded
components may develop leakages, so that hot en-
gine oil, but also heating or cooling water may get
discharged as a result of burst hoses or broken-off
measuring nipples.
It cannot be excluded under extremely rare circum-
stances that an engine breaks, as it can happen with
cars as well, so that fragments are catapulted through
the air.
Parts containing exhaust gas may get leaky and toxic
carbon dioxide may get discharged in the event of a
breakage/rupture or as a result of corrosion. Please
switch off (shut down) the CHP module immediately
and activate the ventilation.
The personal protective clothing includes
ear protection (when working with the sound-
insulating lid open during operations);
protective gloves and goggles, when handling battery
acid, glycol and engine lubrication oil.

Instructions for operating the CHP
8 Operating instructions for the natural gas-fuelled CHP module VITOBLOC 200
6130329 GB
1.5 Requirements concerning the technical room
CAUTION
Smoking and open fire are not permit-
ted. Flammable materials or liquids
must not be stored or used close to the
CHP module. Keep fire extinguishers
and other fire fighting equipment within
reach.
We recommend, similar to the require-
ment of the old Heating Room Directive,
installing a fire extinguisher of the ap-
propriate size (at least 9 l) in the tech-
nical room.
WARNING
In order to avoid breakdowns or dam-
age, the contamination of the combus-
tion air with halogen hydrocarbons (as
contained in spray cans, solvents,
cleaning agents, paint, adhesives etc.)
and excessive amounts of dust must be
excluded.
The technical room for the CHP module must be frost-
proof and well ventilated. The supply and extract air
openings must not be closed or their size be reduced.
The room temperature must not drop below +10 °C.
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 per-
mitted“
Prohibition sign P 11
“No access for persons wearing a
pacemaker“
CAUTION
Only a specialist firm with personnel
specifically trained in these fields of re-
sponsibility by the CHP module manu-
facturer is authorized to carry out the
assembly work, the initial commission-
ing as well as the maintenance and re-
pair work and to install the fuel, exhaust
gas as well as the power connections.
Any work on pipelines containing gas or
on live parts must be carried out by duly
authorized specialist firms.
LIABILITY
According to Article § 10 of the Energy
Saving Directive, the operator shall ar-
range for the plant’s cleaning and
maintenance, the latter on the basis of
a maintenance schedule. In the course
of such measures, the proper function-
ing of the entire plant shall be checked.
Any defects identified shall be rectified
immediately. During the warranty peri-
od, the maintenance shall be carried
out in line with the maintenance sched-
ule by duly authorized personnel.
NOTE
We recommend concluding a mainte-
nances contract with a company that
has been authorized to do such work by
the manufacturer.

Instructions for operating the CHP
VITOBLOC 200 Operating instructions for the natural gas-fuelled CHP module 9
6130329 GB
1.6 Regulations for the prevention of accidents causing personal injury
When installing the CHP module and before the commissioning:
●No persons must stay under loads suspended from
a crane hook. Keep the lifting gear in proper condi-
tions.
●Read the operating instructions carefully before the
commissioning of the CHP module.
●Affix the prohibition sign “No access for unauthor-
ized persons“ well visible at the entrance of the
technical room of stationary engines.
●Only suitably trained personnel are authorized to
operate the CHP module. Make sure during work
on the engine that it cannot be started by unauthor-
ized persons.
●Protect rotating machine parts (e.g. coupling, fan)
against accidental contact. Do not get too close to
any rotating parts, while the engine is running.
Wear tight-fitting garments.
●Use only proper tools for work.
●Do not touch an engine at operating temperature
with bare hands: There is a risk of burns. Protect
exhaust gas pipes against accidental contact. The
insulation must be made of fire-proof material that
is resistant to fuel and lubrication oil.
●Exhaust gas is toxic. Therefore, exhaust gas pipes
must not only be tight and stable, but also made of
a suitable material.
●Keep the ambience of the engine as well as step
ladders and stairs free from oil and grease, since
accidents as a result of skidding may have serious
consequences.
●Open the coolant circuit only after the engine has
cooled down. If it must be opened at the engine's
operating temperature, observe the instructions in
the chapter “Maintenance and care“ of the operat-
ing instructions.
●Neither open nor re-tighten pipelines and hoses
under pressure (lubrication oil circuit, coolant circuit
and possibly the hydraulic oil circuit): There is a
risk of injury caused by leaking liquids.
●As a matter of principle, smoking and open fire in
the engine room are not permitted. Please observe
the regulations for gas installations.
●Wear goggles when working with compressed air.
●Operating supplies (such as fuels and lubricants)
are flammable and constitute a health risk. They
must only be kept in containers that cannot be con-
fused with those for drinks.
●Please observe the manufacturer’s regulations for
handling batteries.
Caution: Battery acid is toxic and caustic. Bat-
tery gas is explosive.
●When working on the electric system, disconnect
the battery’s grounding cable first, so as to avoid a
short circuit.
●When carrying out welding work observe the “In-
formation bulletins for welders“.

Preparations
10 Operating instructions for the natural gas-fuelled CHP module VITOBLOC 200
6130329 GB
2Preparations
LIABILITY
Inform the warranty office in writing be-
fore commissioning the plant, when us-
ing the specified or approved operating
supplies (see assembly instructions in
the chapter „Notification about the
plant’s readiness for commissioning“),
as this is the prerequisite for having any
warranty claims acknowledged.
When being used improperly or not fort he intended
purpose, operating supplies will be an environmental
hazard. Do not let them penetrate the ground or flow
into the sewer system.
2.1 Consumables
2.1.1 Natural gas, the fuel
Gaseous fuels consist largely of methane, propane
and butane as well as traces of higher hydrocarbons
and inert components, such as carbon dioxide and
Nitrogen.
●The valid regulations applicable for gas installa-
tions must be observed.
●Smoking and open flames are not permitted.
●Leakages in the gas supply system pose a risk of
explosion and must be eliminated immediately.
●Fire extinguishers and other fire fighting equipment
must be kept within reach.
●Do not store any flammable materials in the engine
room.

Preparations
VITOBLOC 200 Operating instructions for the natural gas-fuelled CHP module 11
6130329 GB
Gas quality
WARNING
Natural gas and the combustion air
must not contain any phosphorus, ar-
senic, heavy metals or dust, and halo-
gens only in quantities up to the limits
stipulated.
The natural gas must be technically
free from mist, dust and liquids and
must not contain any substantial quan-
tities of corrosive components. The
methane number and the calorific val-
ue of the biogas must remain constant.
PLEASE NOTE
The methane number (not to be con-
fused with the methane content) is a
measurement for the knock susceptibil-
ity of the type of gas concerned. A too
low methane number will result in
knocking combustion and thus damage
the engine. We would like to point out
that the methane number will consider-
ably drop, especially if a liquid gas mix-
ture (propane/air and butane/air) is
added. We therefore recommend verifi-
cation with the local gas supplier that
this is not done so.
INSTRUCTION
As for the rest, please observe the
instructions in the chapter „Gas
connection“ of the assembly
instructions as well as the directives
contained in worksheet G 260 or G 261,
respectively, issued by the Deutsche
Vereinigung des Gas- und
Wasserfaches e.V. (DVGW).
Fuel values to be observed
parameter
value
calorific value Hi,N
> 5 kWh/Nm3
methane number 1) MZ
> 80
minimum flow pressure in the
controlled system for the gas
20 mbar 2)
maximum flow pressure in the
controlled system for the gas
50 mbar
maximum gas pressure varia-
tions (short variations due to
control activities)
± 3 mbar
maximum changing speed of
the gas pressure 3)
3 mbar/min
relative humidity 
< 60 %
Temperature of gas mixture
downstream of gas/air mixer TG
10 °C < TG< 30 °C
chlorine content Cl
< 80 mg / Nm3CH4
fluorine content F
< 40 mg / Nm3CH4
total chlorine/fluorine Σ(CI,F)
< 100 mg / Nm3CH4
dust content < 5 m
< 10 mg / Nm3CH4
oil vapour
< 400 mg / Nm3CH4
silicon content Si
< 2 mg / Nm3CH4
sulphur content S
< 200 mg / Nm3
hydrogen sulfide H2S
< 150 ppm
< 228 mg / Nm³
ammonia content NH3
< 40 ppm
< 30 mg / Nm³
Table 3 Fuel values during the operation of a CHP module
1)
Operations with a lower methane number might be possible
after the CHP module manufacturer has examined the
circumstances.
2)
For the Vitobloc 200 EM-401/549 and EM-530/660
modules, the minimum flow pressure is 30 mbar.
3)
Flow pressure in the module’s control system for the gas.

Preparations
12 Operating instructions for the natural gas-fuelled CHP module VITOBLOC 200
6130329 GB
2.1.2 Engine lubrication oil
Principles
The use of lubrication oil that the CHP module manu-
facturer specifies for the relevant type of gas is a
prerequisite for the safe and wear-resistant operation
of the engine. Especially in view of possible warranty
claims in a case of damage, we like to emphasize the
operator’s duty of care.
The service life of the lubrication oil depends on the
operating conditions, especially
-the gas quality,
-the ambient conditions,
-the operating mode of the CHP module and
-the quality of the lubrication oil.
The contaminants contained in special types of gas,
such as dumpsite gas and biogas, can considerably
reduce the service life of the lubrication oil.
It is necessary to establish the relevant changing
interval by analyzing the old oil, with the first of these
analyses being carried out during the first mainte-
nance, or in the case of special types of gas, after
approx. 400, 1,000 and 2,000 operating hours.
Please note that also the trends of several analyses
must be taken into consideration when assessing the
wear and tear, apart from complying with the limits as
such. The following characteristic values need to be
analyzed and recorded:
designation
unit
measuring method
viscosity
mm²/sec (cSt)
DIN 51 366, ASTM D 445.
DIN EN ISO 3104, (DIN 51 562-1*)
water content
%
DIN 51 366, ASTM D 1744.
(EN ISO 12937*)
glycol content
ppm
DIN 51 375, ASTM D 4291
TBN (total base number)
% or mgKOH**/g
ISO 3771
TAN (total acid number)
acc. to TBN
ASTM 664
SAN (strong acid number)
mgKOH**/g
ASTM 664
i ph (Initial ph value)
on request
oxidation 5.8 µm
A/cm
DIN 51 451
nitration 6.1 µm
A/cm
DIN 51 451
wearing metals
aluminium
mg/kg
DIN 51 396-2
chromium
mg/kg
DIN 51 396-2
copper
mg/kg
DIN 51 396-2
iron
mg/kg
DIN 51 396-2
lead
mg/kg
DIN 51 396-2
tin
mg/kg
DIN 51 396-2
silicon
mg/kg
DIN 51 391, ASTM D 5185
sodium
mg/kg
DIN 51 396-2
* CHP module with MAN engine
** potassium hydroxide
Table 4 Characteristic values of a lubrication oil analysis

Preparations
VITOBLOC 200 Operating instructions for the natural gas-fuelled CHP module 13
6130329 GB
The lubrication oil must be sampled directly from the
lubrication oil circuit, while the engine is running, or
from the lubrication oil pan immediately after the en-
gine has stopped. The first cubic centimetres of the
sample must be returned into the engine. Then fill the
clean sampling bottle and send it to the laboratory
without any delay.
Change the lubrication oil filter cartridges
•in accordance with the operating instructions or
the maintenance schedule, or
•at least once a year.
•Make the old oil available for recycling.
•Prevent the oil from seeping into the sewer system
or into the ground. Attention: Risk of drinking
water contamination.
•Treat disused filter inserts and cartridges as spe-
cial refuse.
In order to ensure that your plant is looked after and
taken care of in the most optimal way and that the oil
analyses can be safely assessed, we recommend the
conclusion of a maintenances contract with
Viessmann Kraft-Wärme-Kopplung GmbH.
Brands of engine oil approved for natural gas operations
Table 5 Approved gas engine oils
This engine oil must be used for all MAN engines
(Lambda = 1 and Turbo). Here, the extended oil
change intervals of the BHKW manufacturer
Viessmann Kraft-Wärme-Kopplung GmbH are
applicable. For any warranty claims, the specific
maintenance intervals must be followed and if
required, demonstrated by means of oil analyses at
own responsibility.
Other engine lubricants
All other engine lubricants can be used at own re-
sponsibility according to the approved list of MAN
Truck & Bus AG (Document: MAN-Werksnorm
M3271-2 for natural gas). The oil change is subject to
the shortened maintenance intervals stated there and
must be carried out at own responsibility as per the
specifications / conditions.
approval granted to
product designation
viscosity class
synthetic oil gas-fuelled engines
Petro-Canada
Sentron LD 8000
SAE-40

Preparations
14 Operating instructions for the natural gas-fuelled CHP module VITOBLOC 200
6130329 GB
2.1.3 Coolants
Mandatory components
The cooling system must be filled with a mixture of
drinkable tap water and an anti-freeze agent contain-
ing a corrosion-preventive additive for engine cooling
systems.
-62 vol.-% water
Suitable for this purpose is potable tap water with the
analysis values that are restricted as follows:
appearance: colourless, clear, and free from mechan-
ical contaminants
hardness: maximum 20° dGH
chloride: maximum 100 ppm
sulphate: maximum 150 ppm
pH-value at 20 °C: 6.5 - 8.5
PLEASE NOTE
Enquiries about existing analyses of the
drinking water can be made at the mu-
nicipal authorities. If the quality of the
drinking water is insufficient, mix the lo-
cally available drinking water with fully
dematerialized water or distillate or
condensate until the analysis values as
stipulated above have been achieved.
-38 vol.-% anti-freeze agent
WARNING
Use only anti-freeze agents with corro-
sion-preventive additives for engine
cooling systems that have been ap-
proved in the CHP module manufactur-
er’s instructions for the operating re-
sources (see Table 6 “Approved anti-
freeze agents“).
A minimum concentration of 38 vol.-%
of anti-freeze agent must always be ob-
served, since the corrosion protection
will not be ensured with less than the
38 vol.-% as required.
How to handle anti-freeze concentrate
WARNING
When handling anti-freeze concentrate
wear protective gloves and goggles.
Please observe the safety data sheet
(can be obtained from glycol suppliers).
If having been in contact with the
concentrate:
⚫ Objects
Wipe off any spillage with an absorbent material and
dispose it as special refuse.
⚫ Skin
Wash the relevant parts of the body with water and
soap.
⚫ Eyes
Rinse they eyes thoroughly for 15 min under running
water with the lids spread apart and seek medical
advice thereafter.
Control of the coolant and its renewal
●Check the concentration every quarter year with a
density spindle or a refractometer.
●Never allow the anti-freeze concentration to drop
below 38 vol.-%.
●Always compensate losses of coolant with a mix-
ture of water and 38 vol.-% anti-freeze.
•
CAUTION
Do not use containers designated for
drinking water or foodstuffs
●The entire coolant must be exchanged after 2
years at the latest.
●Treat coolant as well as corrosion and/or anti-
freeze agents as special refuse when disposing
them.
●When disposing disused coolant observe the regu-
lations of the local authorities.

Preparations
VITOBLOC 200 Operating instructions for the natural gas-fuelled CHP module 15
6130329 GB
Approved anti-freeze agents
approval granted to
product designation
Agip Deutschland AG
Agip Antifreeze Plus
Agip Schmiertechnik
Agip/Autol Langzeitfrostschutz
Aral AG
Aral Kühlerfrostschutz A
Aral Kühlerschutz Extra Aral
Kühlerschutz D
Avia-Mineralöl AG
Avia Frostschutz
Avia Frostschutz APN
BASF AG
Glysantin G 03
Glysantin G 48
Glysantin mit Protect Plus
BASF/USA
BASF/USA BC Antifreeze G 9313
Bucher & Cie. AG/Switzerland
Frostschutz Motorex
Caltex Services Ltd.
Caltex CX Engine Coolant
DEA Mineral oil AG
DEA Kühlerschutz
Deutsche Shell Chemie GmbH
GlycoShell
DOW Chemical Europe S.A.
DOW Gefrierschutzmittel D 824-13F
W Kühlmittel D 542/1993
Elf Lub/France
Elf Antifreeze Special
Glacelf SX
EUROL Mineralölhandels GmbH
Eurol Afrostin
EVVA/Austria
EVVA Antifreeze
Fina Europe S.A.
Fina Termidor P 100
Fuchs Mineralölwerke GmbH
Fricofin Kühlerfrostschutz
Genol
Genol Antifreeze
Ginuoves Georges S.A.
York LT 716
Henkel Härtol GmbH
Frostox MB 02
Hoechst
Genantin Extra B
INA Industrija Zagreb/Croatia
INA Antifriz AI Super
Mobil Oil AG
Frostschutz 500
Frostschutz 500 Plus
ÖMV AG
ÖMV Frostschutzmittel
Ravensberger
Ravenol Alu-Kühlerfrostschutz
Shell Aseol AG/Switzerland
Aseol Antifreeze 26-30
Aseol FN 26-33
Shell Austria AG
Glycoshell AF 511
Texaco Technology Europe/Ghent
Texaco Frostschutz NF (EXT 6024)
Total Deutschland GmbH
Total Multiprotect OZO Frostschutz S
Total OZO Frostschutz S
YACCO/France
Antigel Yacco
Table 6 Anti-freeze agents containing corrosion-preventive additives for the engine cooling system of a CHP module

Preparations
16 Operating instructions for the natural gas-fuelled CHP module VITOBLOC 200
6130329 GB
2.1.4 Heating water
Quality regulations for hot water in conformity
with VDI Guideline 2035
The current edition of the manufacturer’s data and
VDI Guideline 2035 (Guidelines for Preventing Dam-
age from Corrosion and Stone Formation in Warm
Water Heating Plants) are definitive for the quality of the
hot water.
The chloride content should not be in excess of 30 mg/l
and the quality of the heating water should satisfy the
requirements of VDI 2035.
VDI 2035 makes requirements of the quality of the hot
water depending upon the overall heating output and
specific plant content.
CAUTION
You can calculate the specific plant vol-
ume in several heat generators with the
smallest single heat performance (see
VDI 2035 for greater detail).
total heating perfor-
mance
total hardness
total hardness
total hardness
in KW
in °dH
at <20 l/kW
minimum boiler heating
surface
in °dH
at >20 l/kW <50 l/kW mini-
mum boiler heating surface
in °dH
at >50 l/kW
minimum boiler heating
surface
<50 kW
no requirements or
<16.8°dH
11.2°dH
0.11°dH
>50 kW <200 kW
11.2°dH
8.4°dH
0.11°dH
>200 kw <600 kW
8.4°dH
0.11°dH
0.11°dH
>600 kW
0.11°dH
0.11°dH
0.11°dH
Table 7 Quality characteristic values for the filling and supplemental water for heating plants with Vitobloc 200 CHP modules
CAUTION
The mud separator provided by the cus-
tomer should be cleaned every half year.
Preventing corrosion
Corrosion in heating plants can essentially be attributed
to the presence of oxygen in the hot water. Therefore,
the probability of damage from corrosion in metallic
materials is low in hot water which is low in oxygen.
Possible sources of oxygen input are:
●low-pressure formation in the heating system
●air inclusion with filling and supplemental water
●oxygen input through the heating water coming
directly into contact with air (an open system)
●oxygen diffusion via permeable components such
as seals, plastic pipes, membranes and hoses
●the oxygen content of the filling and supplemental
water
●expansion tank for boilers that are too small
Chemical additives to the heating water
There is normally not any corrosion in warm water
heaters that are correctly designed, installed and oper-
ated. This is why additives can generally be dispensed
with.
CAUTION
Do not use any chemical additives in the
heating water without obtaining a clear-
ance certificate from the manufacturer of
the chemicals with reference to the de-
sign of the heating plant and materials
used.

Preparations
VITOBLOC 200 Operating instructions for the natural gas-fuelled CHP module 17
6130329 GB
2.2 Filling Fuels
2.2.1 Disassembling/Assembling the
Sound Hood
CAUTION
Only ever use the supplied original cab-
inet spanner to avoid damage to the
locks.
Always remember the following when opening and
closing the locks:
Closing:
Raise the sound hood plate and press against the
corresponding frame.
Caution: There is the danger of breakage if the sound
hood plate drops. This is why it is necessary to wear
protective clothing/shoes.
The lock is open in the initial position
(the dot marks on the lock are 180° to
one another)
Lock the sound-absorbing hood and
turn the spanner 90°
(the dot marks on the lock are now 90°
to one another)
Press on the sound-absorbing hood
while turning the spanner another 90°
(the dot marks on the lock are now op-
posite one another)
Opening:
Raise the sound hood plate and press against the
corresponding frame.
Caution: There is the danger of breakage if the sound
hood plate drops. This is why it is necessary to wear
protective clothing/shoes.
The lock is closed in the initial position
(the dot marks on the lock are opposite
one another)
Press on the sound-absorbing hood
while turning the spanner 90°
(the dot marks on the lock are now 90°
to one another)
Turn the spanner another 90°
(the dot marks on the lock are now 180°
to one another)

Preparations
18 Operating instructions for the natural gas-fuelled CHP module VITOBLOC 200
6130329 GB
2.2.2 Filling and venting the engine cooling system
Coolant with anti-freeze
Fill the cooling system with a mixture of potable tap
water and anti-freeze containing a corrosion-
preventive additive for engine cooling systems.
WARNING
Use only anti-freeze agents with corro-
sion-preventive additives for engine
cooling systems that have been ap-
proved in the CHP module manufactur-
er’s instructions for operating re-
sources. Please refer to section 2.3
“Coolants“ for a list of anti-freeze
agents with corrosion-preventive addi-
tives for engine cooling systems and
further information about the water
quality required.
Handling anti-freeze concentrate
WARNING
When handling anti-freeze concentrate
wear protective gloves and goggles
Please observe the safety data sheet
(which can be obtained from glycol
suppliers).
If having been in contact with the concentrate:
●Objects
Wipe off any spillage with an absorbent material
and dispose it as special refuse.
●Skin
Wash the relevant parts of the body with water and
soap.
●Eyes
Rinse they eyes thoroughly for 15 min under run-
ning water with the lids spread apart and seek
medical advice thereafter.
Mixing coolant
CAUTION
Do not use containers designated for
drinking water or foodstuffs.
●Mix the coolant in the required quantity and con-
centration.
WARNING
A minimum concentration of 30 vol.-%
of anti-freeze agent must always be ob-
served, since the corrosion protection
will not be ensured with less than the 30
vol.-% as required.
NOTE
Since the CHP module will be put up in
frost-free rooms (minimum temperature:
+10 °C), a higher anti-freeze concentra-
tion is not required. The cooling system
has been designed in such a way that a
coolant with a maximum of 30 vol.-% of
anti-freeze can remain in the system in
Central Europe also in summer, as long
as the cooling system as such functions
reliably.
Fill in quantities pursuant to the technical description
for the CHP module.

Preparations
VITOBLOC 200 Operating instructions for the natural gas-fuelled CHP module 19
6130329 GB
Filling the cooling system
•Connect the pressure hose of an electric pump
or of a hand pump with the intake (Fig. 1, item 1).
•Open the stop cock (Fig. 1, item 2) and fill in the
coolant slowly up to approx. 1 bar.
•Check the filling pressure at the manometer (Fig.
1, item 3). The pressure in the cold state has to
be in the range of 1.1-1.3 bar.
Venting the cooling system
•Remove the top sound-insulation cover at rear
(Fig. 2, item 1).
•Vent the cooling system at the gas separator
bypass (Fig. 2, item 2).
•Vent the cooling system at the cooling water
distributor (Fig. 2, item 3).
•Close the stop cock at the cooling water distribu-
tor (Fig. 2, item 3) and remove the pressure
hose.
•Close the stop cock at the exhaust gas heat
exchanger (Fig. 2, item 4) and remove the pres-
sure hose.
WARNING
When venting the cooling system
please make absolutely sure that no
flammable coolant is spilled on hot sur-
faces –danger of ignition.
Fig. 1 Intake for the engine coolant with stop cock and
manometer
Fig. 2 Vent connection for the engine cooling system at
the gas separator bypass

Preparations
20 Operating instructions for the natural gas-fuelled CHP module VITOBLOC 200
6130329 GB
2.2.3 Filling in engine lubrication oil
Fill in fresh engine lubrication oil
●into the engine and
●into the additional tank for fresh oil (reserve for
operating the automatic lubrication oil system).
WARNING
Use only engine oil for gas-fuelled en-
gines that has been approved in the
CHP module manufacturer’s operating
instructions (see sub-section 2.1.2
Fehler! Verweisquelle konnte nicht
gefunden werden. ”Brands of oil ap-
proved for gas-fuelled engines“).
How to handle engine lubrication oil
WARNING
When handling engine lubrication oil
wear protective gloves and goggles.
Please observe the safety data sheet
(can be obtained from suppliers of lu-
brication oil).
If having been in contact with engine oil:
●Objects
Wipe off any spillage with an absorbent material
and dispose it as special refuse. Change oil-
soaked clothing and shoes. Do not put oil-soaked
cloths into your pockets.
●Skin
Wash with water and soap or with special hand
cleaning paste and brush the relevant parts of the
body, if necessary.
●Eyes
Cover the eyes and seek medical advice immedi-
ately.