Yanmar neoTower User manual

OPERATION MANUAL
Combined heat and power unit neoTower®
CHP 5.0 - 30.0
Status 01.2020

2 | RMB/ENERGIE GmbH Operation manual CHP 5.0 - 30.0 | Status 01.2020
Contents
1. Document information .................. 4
1.1 Validity . . . . . . . . . . . . . . . . . . . . . .4
1.2 Supporting documents . . . . . . . . . . . . . 4
1.3 Safety instructions. . . . . . . . . . . . . . . .5
1.4 Explanation of symbols . . . . . . . . . . . . . 5
2. Safety information...................... 6
2.1 Intended use . . . . . . . . . . . . . . . . . . 6
2.2 Authorised target groups . . . . . . . . . . . . 6
2.2.1 Manufacturer.................... 6
2.2.2 Operator ....................... 6
2.2.3 Trained personnel ................ 6
2.2.4 User .......................... 6
2.3 General safety instructions . . . . . . . . . . . 7
3. Product information .................... 8
3.1 Functional principle . . . . . . . . . . . . . . . 8
3.2 Registering with the energy provider . . . . . . 8
3.3 Modes of operation . . . . . . . . . . . . . . . 8
3.3.1 Ready for e-car charging button ..... 8
3.3.2 Summer operation ............... 8
3.3.3 Heat-optimised .................. 8
3.3.4 Electricity-optimised .............. 8
3.3.5 Shutdown ...................... 8
3.4 Safety devices. . . . . . . . . . . . . . . . . .9
3.5 Product variants . . . . . . . . . . . . . . . . .9
3.6 Product overview . . . . . . . . . . . . . . . 10
3.6.1 Generation unit CHP 5.0 - 7.2 ..... 10
3.6.2 Generation unit CHP 11.0 - 20.0 ... 10
3.6.3 Generation unit CHP 25.0 - 30.0 ....11
3.6.4 Control cabinet ..................11
3.6.5 Modem ........................11
3.6.6 Expansion tank connection block ... 12
3.6.7 MSM adapter magnetic filter
(“MSM filter”)................... 12
3.7 Scope of supply . . . . . . . . . . . . . . . . 12
4. Storage.............................. 13
5. Assembly ............................ 14
5.1 Safety instructions for assembly . . . . . . . 14
5.2 Installation location requirements . . . . . . . 14
5.2.1 Overview of the installation location . 14
5.2.2 Installation room ................ 15
5.2.3 Heating system ................. 16
5.2.4 Flue gas routing ................ 16
5.2.5 Exhaust air duct ................ 16
5.2.6 Supply air supply ............... 16
5.2.7 Gas supply .................... 17
5.2.8 Water supply ................... 17
5.2.9 Condensate drain ............... 17
5.2.10 Power supply .................. 17
5.2.11 Reactive current compensation .... 17
5.2.12 Mobile communications network.... 17
5.3 Assembly steps . . . . . . . . . . . . . . . . 18
5.3.1 Preparing for assembly........... 18
5.3.2 Unpacking the system ........... 18
5.3.3 Positioning the generation unit ..... 19
5.3.4 Screwing the control cabinet in
position ....................... 20
5.3.5 Screwing the expansion tank
connection block in position ....... 20
5.3.6 Connecting the generation unit..... 20
5.3.7 Connecting the temperature sensors 24
5.3.8 Connecting the modem........... 24
5.3.9 Connecting the control cabinet ..... 25
5.3.10 Checking the connections......... 25
5.4 Test run . . . . . . . . . . . . . . . . . . . . 26
5.4.1 Opening the generation unit ....... 26
5.4.2 Preparing the expansion tank
connection block ................ 26
5.4.3 Replenishing the cooling water..... 26
5.4.4 Starting the test run ............. 27
5.4.5 Checking the system ............ 27
5.4.6 Stopping the test run. . . . . . . . . . . . . 28
5.4.7 Closing the generation unit........ 28
6. Commissioning ....................... 29
Contents

RMB/ENERGIE GmbH | 3 Operation manual CHP 5.0 - 30.0 | Status 01.2020
7. Operating ............................ 30
8. Cleaning ............................. 31
9. Service repairs ....................... 32
9.1 Maintenance. . . . . . . . . . . . . . . . . . 32
9.2 Fault resolution . . . . . . . . . . . . . . . . 32
9.3 Repair . . . . . . . . . . . . . . . . . . . . . 32
10. Disassembly ......................... 33
11. Disposal ............................. 34
11.1 Disposing of packaging . . . . . . . . . . . . 34
11.2 Disposing of the system. . . . . . . . . . . . 34
12. Appendix ............................ 35
12.1 Technical data . . . . . . . . . . . . . . . . . 35
12.2 Hydraulic diagrams . . . . . . . . . . . . . . 35
12.2.1 Heating system variant 1 –
1 CHP, 1 buffer tank, peak load
boiler connected directly to buffer
tank .......................... 36
12.2.2 Heating system variant 2 –
1 CHP, 2 buffer tanks, peak load
boiler connected directly to buffer
tank .......................... 37
12.2.3 Heating system variant 3 –
1 CHP, 1 buffer tank, peak load
boiler connected to buffer tank via
hydraulic separator .............. 38
12.2.4 Heating system variant 4 –
1 CHP, 2 buffer tanks, peak load
boiler connected to buffer tank via
hydraulic separator .............. 39
12.2.5 Heating system variant 5 –
2 CHP, 2 buffer tanks, peak load
boiler connected to buffer tank via
hydraulic separator .............. 40
12.3 EC declaration of conformity . . . . . . . . . 41
12.4 Proof of conformity - Generation unit . . . . . 42
Contents

4 | RMB/ENERGIE GmbH
Document information
Operation manual CHP 5.0 - 30.0 | Status 01.2020
1. Document information
i
1.1 Validity
Original operation manual. In this manual, the word
“system” or “CHP” is used to denote the product.
This manual is valid for the following products:
BCHP 5.0
BCHP 7.2
BCHP 11.0
BCHP 16.0
BCHP 20.0
BCHP 25.0
BCHP 30.0
The descriptions are identical for all products;
any differences are specifically highlighted.
All illustrations show the product “CHP 5.0”.
This manual is protected by copyright law. Duplication,
reproduction and transmission is only permitted with
the permission of the manufacturer.
Subject to change without notice.
1.2 Supporting documents
Additional documents belong to this operation manual
and must be observed.
System documentation
The documentation valid for the delivered system
(e.g. technical data, maintenance plan) is included in
the scope of delivery.
“RMB/Control” operating manual
The “RMB/Control” operating manual describes how
to control the system via the operational display and is
included in the scope of delivery.
Wiring diagrams
The wiring diagrams are located on the inside of the
control cabinet door.
Manuals for system components
The manuals for the supplied system components
(e.g. modem) are included in the scope of delivery.
Manuals for accessories
The manuals for optional accessories (e.g. flue gas
silencer, exhaust air kit) are provided with each
product.
Maintenance manual
The maintenance manual describes specific tasks for
maintaining the system that must only be performed
by the manufacturer. The maintenance manual is not
included in the scope of delivery.
Further documents and information (e.g. forms,
planning notes, technical drawings) are available on
the manufacturer's website.
Јwww.rmbenergie.com

RMB/ENERGIE GmbH | 5
Document information
Operation manual CHP 5.0 - 30.0 | Status 01.2020
1.3 Safety instructions
DDANGER!
Information highlighted with the word HAZARD warns
against a hazardous situation that will lead to death or
severe injury.
DWARNING!
Information highlighted with the word WARNING warns
against a hazardous situation that can lead to death or
severe injury.
DCAUTION!
Information highlighted with the word CAUTION warns
against a situation that can lead to minor or moderate
injuries.
DATTENTION!
Information highlighted with the word ATTENTION
warns against a situation that can lead to material or
environmental damage.
1.4 Explanation of symbols
Text
ARequired action
BList
DCross reference to another point in this document
Cross reference to other documents that must be
observed
ЈInternet link
Illustrations
A
2.
B
1.
x
1. Numbered action sequence
APart designations with upper case letters
xDimensions with lower case letters or units in mm
Arrows indicating movement and direction

6 | RMB/ENERGIE GmbH
Safety information
Operation manual CHP 5.0 - 30.0 | Status 01.2020
2. Safety information
2.1 Intended use
The system is a combined heat and power unit for
generating electricity and heat. The system is intended
exclusively for incorporation in heating circuits in
buildings.
The system is designed for bivalent operation, i.e.
it must be combined with an additional heat source
(“peak load boiler”) in order to operate.
The system is designed for the following energy
demand.
System Annual energy requirement
Electricity kWh Heat kWh
CHP
5.0 - 7.2
20,000 - 50,000 60,000 - 100,000
CHP
11.0 - 20.0
80,000 - 130,000 180,000 - 300,000
CHP
25.0 - 30.0
100,000 - 250,000 200,000 - 400,000
The system is only permitted for use in a technically
sound condition once it has been commissioned by the
manufacturer or a specialist partner authorised by the
manufacturer.
Intended use also includes reading and following this
manual.
Any other use is considered contrary to intended use.
2.2 Authorised target groups
This manual is intended for various target groups that
are authorised for specific duties.
2.2.1 Manufacturer
The manufacturer supplies the product and has the
following duties:
BTraining experts on assembly, maintenance,
disassembly and disposal.
BCommissioning the system.
Only the manufacturer has access to the “Experts”
area of the “RMB/Control” control mechanism.
2.2.2 Operator
The operator is responsible for the building in which
the product is installed. The operator has the following
duties:
BFulfilling the requirements specified by the energy
provider (e.g. registration, approval, compensation).
BMeeting the installation location requirements.
BTraining the user.
BComplying with statutory occupational health and
safety obligations.
BComplying with the valid safety, accident prevention
and environmental protection regulations.
BProviding and complying with the documentation.
BEnsuring that the product is always kept in a
technically sound condition.
BStoring the system when necessary.
2.2.3 Trained personnel
Trained personnel are responsible for the assembly,
maintenance, disassembly and disposal of the product.
The following points must be observed:
BAll tasks must only be performed by qualified
personnel who have been trained by the
manufacturer and who are familiar with assembly
technology, gas and water installations, and current
safety regulations.
BSpecial installation tasks (e.g. tasks involving
the building structure or the ventilation system)
must only be performed by the suitably qualified
personnel of specialist companies.
BElectrical installations must only be performed by
qualified, skilled electricians.
Only qualified personnel trained by the manufacturer
have access to the “Specialist” area of the
“RMB/Control” control mechanism.
2.2.4 User
Users may perform operational and cleaning tasks on
this product. Obligations of the user:
BTo be trained on the product by the operator.
BTo be familiar with this manual.
Trained users have access to the non-protected areas
of the “RMB/Control” control mechanism, but not to the
“Experts” and “Specialist” areas.

RMB/ENERGIE GmbH | 7
Safety information
Operation manual CHP 5.0 - 30.0 | Status 01.2020
2.3 General safety instructions
DWARNING!
Hazard caused by failing to observe the manual!
This manual contains important information for handling
the system safely. Potential hazards are specifically
highlighted. Failing to observe such information can
lead to death or severe injuries.
ARead the manual carefully.
AFollow the safety instructions contained in this
manual.
AFollow the safety instructions on the system
AStore the manual in an accessible place.
If you can smell gas, immediately proceed as follows:
BClose the gas valve.
BDo not generate any naked flames.
BDo not operate any electrical switches
(e.g. light switches, all-pole separating points).
BDo not use any electrical appliances in the
hazardous area (e.g. telephone).
BVentilate the rooms.
BInform the manufacturer, gas utility company or
qualified service company.
Use of the system is prohibited in the following cases:
BIf the system or individual components are
damaged.
BIf the system has been altered or modified without
authorisation.
BIf the supply and return lines (e.g. gas, flue gas,
water, electricity, condensate drain) are altered or
modified without authorisation.
BIf any safety devices are missing or inoperable.
D“3.4 Safety devices” (page 9).
BDuring the construction phase of the building.
BIf the system has been in storage for more than
5 months after delivery.
D“4. Storage” (page 13).
BIf the system has been decommissioned for more
than 5 months.
BFor children or individuals who are incapable of
assessing the hazards associated with operating
the system.
The manufacturer does not accept any liability or
guarantee for damage or loss in the following cases:
BFailing to observe this manual.
BContrary-to-intended use.
BImproper handling.
BUse by unauthorised target groups.
BFailing to meet the installation location
requirements.
BUsing replacement parts that have not been
authorised by the manufacturer.
BBypassing the system’s safety devices.
BRemoving the system’s seals and sealants.
BFailing to comply with the maintenance intervals.
Additional safety instructions are provided in the
respective chapters of this manual.
D“4. Storage” (page 13).
D“5. Assembly” (page 14).
D“6. Commissioning” (page 29).
D“7. Operating” (page 30).
D“8. Cleaning” (page 31).
D“9. Service repairs” (page 32).
D“10. Disassembly” (page 33).
D“11. Disposal” (page 34).

8 | RMB/ENERGIE GmbH
Product information
Operation manual CHP 5.0 - 30.0 | Status 01.2020
3. Product information
3.1 Functional principle
The combustion of gas in an industrial gas engine
powers a high-performance alternator that produces
electricity. The heat that is generated by this process is
used for hot water provision and heating.
This principle is referred to as combined-heat-and-
power.
The control mechanism manages and monitors the
combustion process in the generation unit. The system
is operated via the operational display on the control
cabinet.
3.2 Registering with the energy provider
The energy provider must be informed about the
installation of the system. Obligations of the operator:
AInform the energy provider about the system before
it is assembled.
AFulfil the requirements specified by the energy
provider (e.g. registration, approval, compensation).
AProvide the energy provider with all the relevant
system data.
Technical data.
The electricity produced over and above the operator’s
own requirement can be fed into the energy provider’s
local electricity network in return for compensation. A
suitable application must be submitted to the energy
provider for this purpose.
3.3 Modes of operation
The system can be operated in five modes of operation
(including shutdown). The modes of operation are set
via the operational display.
“RMB/Control” operating manual.
3.3.1 Ready for e-car charging button
Special mode for charging electric vehicles. It is still
possible to produce electricity in this mode when the
storage battery has reached the maximum value.
3.3.2 Summer operation
In summer operation mode, the system only operates
at minimum capacity. The system only starts if the
storage battery has insufficient charge.
3.3.3 Heat-optimised
The system starts if a temperature requirement has
been set. If the storage battery has reached a specific
percentage charge, the system begins to power down
steplessly.
3.3.4 Electricity-optimised
The system starts to operate according to a
temperature requirement. Once a specific storage
battery charge has been reached, the system aligns
itself to the electricity consumption of the building.
3.3.5 Shutdown
The system is in hibernation mode. The system does
not start according to temperature requirements.

RMB/ENERGIE GmbH | 9
Product information
Operation manual CHP 5.0 - 30.0 | Status 01.2020
3.4 Safety devices
DWARNING!
Risk of burns, pinching or electric shock!
The safety devices are intended to ensure the system
is handled safely. Missing or faulty safety devices can
lead to hazardous situations.
AEnsure that the protection devices are not removed.
AFollow the safety instructions on the system.
AOnly remove the covers if you are required and
authorised to do so.
The system is equipped with the following safety
devices:
BEmergency stop switch
BPressure-relief valve
BProtective covers
BSafety stickers
3.5 Product variants
BCHP 5.0
BCHP 7.2
BCHP 11.0
BCHP 16.0
BCHP 20.0
BCHP 25.0
BCHP 30.0

10 | RMB/ENERGIE GmbH
Product information
Operation manual CHP 5.0 - 30.0 | Status 01.2020
3.6 Product overview
3.6.1 Generation unit CHP 5.0 - 7.2
The generation unit contains the actual combined
heat and power unit with the combustion engine, the
alternator unit and the heat exchangers.
The generation unit is the core piece of equipment for
producing the electricity and heat.
I
A
H
B
C
E
F
G
D
K
J
L
A “Buffer water supply line” connection
B “Flue gas” connection
C “Gas” connection
D “Condensate” connection
E “Buffer water return line” connection
F Control cabinet wiring harness
G Supply air intake grille
H Housing cover
I Expansion tank connection
J Type plate
K “Exhaust air” connection (room-air dependent)
L Hoop guard
3.6.2 Generation unit CHP 11.0 - 20.0
The generation unit contains the actual combined
heat and power unit with the combustion engine, the
alternator unit and the heat exchangers.
The generation unit is the core piece of equipment for
producing the electricity and heat.
A
J
I
B
C
K
L
F
G
H
D
E
A “Buffer water supply line” connection
B “Buffer water return line” connection
C “Flue gas” connection
D “Gas” connection
E “Condensate” connection
F “Exhaust air” connection (room-air dependent)
G Supply air intake grille
H Control cabinet wiring harness
I Housing cover
J Expansion tank connection
K Type plate
L Hoop guard

RMB/ENERGIE GmbH | 11
Product information
Operation manual CHP 5.0 - 30.0 | Status 01.2020
3.6.3 Generation unit CHP 25.0 - 30.0
The generation unit contains the actual combined
heat and power unit with the combustion engine, the
alternator unit and the heat exchangers.
The generation unit is the core piece of equipment for
producing the electricity and heat.
A
L
I
B
C
J
K
F
G
H
D
E
A “Exhaust air” connection (room-air dependent)
B “Buffer water supply line” connection
C Expansion tank connection
D “Flue gas” connection
E “Condensate” connection
F “Gas” connection
G “Buffer water return line” connection
H Control cabinet wiring harness
I Housing cover
J Type plate
K Supply air intake grille
L Hoop guard
3.6.4 Control cabinet
The control cabinet contains all the components
required to control the system.
A
F
E
G
B
C
D
B
A Housing
B Aeration and ventilation
C Control cabinet door
D Emergency stop switch
E Operational display
F Master switch
G Cable bushings
3.6.5 Modem
The modem makes it possible to monitor the system
remotely and read data via the mobile communications
network.
E
C
A
D
B
A Antenna (slot “mobile”)
B Antenna (slot “mobile”)
C Power supply
D LTE modem
E Connection cable (slot “LAN 1”)

12 | RMB/ENERGIE GmbH
Product information
Operation manual CHP 5.0 - 30.0 | Status 01.2020
3.6.6 Expansion tank connection block
The expansion tank offsets temperature-related
fluctuations in volume within the motor circuit (primary
circuit).
C
B
A
F
G
H
E
D
A Manometer
B Cap valve
C Expansion tank
D Self-bleeding device
E Pressure-relief valve
F Fill-and-drain valve (connection for replenishing
water-glycol mixture 60:40)
G Connection to generation unit
H Drain valve
3.6.7 MSM adapter magnetic filter (“MSM filter”)
The combination filter filters magnetite and suspended
solids out of the water in the heating system.
A
A
B
C
D
E
A Valve
B Filter head (with indication of the direction of flow)
C Lock nut
D Brass cup
E Filter cartridge
3.7 Scope of supply
A
B
N
D
C
E
F
G
H
I
J
K
L
M
A Generation unit
B Control cabinet
C Expansion tank connection block
D MSM filter
E Valve
F Temperature sensor
G Modem1
H Balance strips
I Rear cover
J Front cover
K Supply air intake grille
L Cooling medium (water-glycol mixture 60:40)
M Square spanner
N Documentation (e.g. operation manual)
1Includes 24 months of remote monitoring (effective
from commissioning; extension available subject to
charge)

RMB/ENERGIE GmbH | 13
Storage
Operation manual CHP 5.0 - 30.0 | Status 01.2020
4. Storage
The system is prepared by the manufacturer for
operation on delivery. The system must be put into
operation within 5 months following delivery. If that is
not possible, the system must be preserved.
Storage of the system by the operator.
D“2.2.2 Operator” (page 6).
DATTENTION!
Risk of damage caused by improper storage!
During long periods of downtime, lubricants and liquids
settle within the system. Frost and damp conditions
can damage parts of the system.
AStore the system in a frost-free, dry place.
AArrange for the manufacturer to rust-proof the
system if it is to be kept out of operation for more
than 5 months. The shelf life of the preservative is
12 months.
When taking the system out of storage, the next steps
must be discussed with the manufacturer.
AContact the manufacturer.

14 | RMB/ENERGIE GmbH
Assembly
Operation manual CHP 5.0 - 30.0 | Status 01.2020
5. Assembly
5.1 Safety instructions for assembly
DWARNING!
Hazard caused by failing to observe the assembly
instructions!
Errors made when installing the system can cause
serious injuries or material damage to the system or
the building.
This chapter contains important information regarding
the safe assembly of the system.
ARead this chapter carefully before assembling the
system.
AFollow the safety instructions.
ACarry out the assembly as described.
The assembly must only be performed by trained
personnel.
Electrical work must only be performed by qualified,
skilled electricians.
D“2.2.3 Trained personnel” (page 6).
BThe system must be undamaged and in a faultless
condition before assembly.
BOnly use suitable fittings.
BCables and lines must not be damaged, kinked or
crimped.
BBefore assembling, ensure that the supply voltage
has been and remains disconnected.
The supply voltage is only reconnected when
instructed in the respective assembly step.
BThe generation unit must be transported to
the installation location by means of a suitable
transportation device (e.g. lift truck).
If it is not possible to transport it to the installation
location (e.g. lack of space):
AContact the manufacturer.
5.2 Installation location requirements
DWARNING!
Risk of suffocation, gas explosions or material
damage caused by incorrectly installing the
system!
Failing to observe these requirements can lead to
hazardous situations when handling electricity, gas or
hot water. This chapter contains important information
for preventing hazardous situations.
AEnsure that all of the installation location
requirements are complied with.
5.2.1 Overview of the installation location
To operate the system, some equipment must be
provided on site. The following illustration shows
examples of the required components.
A
B
I
G
J
K
L
M
N
E
H
C
D
F
A Buffer tank
B Temperature sensor holding fixture
C Buffer water supply line
D Buffer water return line
E Reactive current compensation
F Modem
G Supply air opening
H Supply voltage
I Flue gas routing
J Flue gas silencer
K Condensate drain
L Gas supply
M Gas meter
N Gas flow monitor
The heating system also includes the peak load boiler
and pipework system that connects the system via the
buffer tank.

RMB/ENERGIE GmbH | 15
Assembly
Operation manual CHP 5.0 - 30.0 | Status 01.2020
5.2.2 Installation room
The installation room must meet the following
requirements:
BThe installation room must comply with the effective
applicable laws and regulations for boiler rooms
(e.g. in Germany, the ordinance for heat-producing
appliances (Feuerstättenverordnung)).
BThe substrate on which the generation unit is to
be installed must be flat, even, solid, dry and load-
bearing.
BThe ambient air temperature must be between
+5 °C and +30 °C.
BThe room height must be at least 2,400 mm from
the installation surface.
BThe system must be protected against frost and the
elements.
The following are not permitted:
BInstallation on floating screed.
BOperation of tumble dryers in the same room.
BStorage of explosive or highly flammable materials
(e.g. paper, paints, petrol) within the installation
location.
BUse of aggressive substances (e.g. sprays,
solvents, chlorinated cleaning agents, paints,
adhesives) in the vicinity of the system.
If the system is installed in vaulted cellars or bare
smooth-walled rooms (hard-walled), there is a risk of
noise and sound resonance.
The system must be positioned so that the following
requirements are fulfilled:
BNone of the system’s ventilation or extraction
devices may be blocked or closed.
BThe emergency stop switch must always be
accessible.
Space requirement CHP 5.0 - 7.2
> 1000 > 1000
> 1000
> 1000
1226
1097
635
Space requirement CHP 11.0 - 20.0
1480
> 1000 > 1000
> 1000
> 1000
1097
643
1233
708
Space requirement 25.0 - 30.0
> 1000 > 1000
> 1000
> 1000
1659
1400
781
The minimum clearance to the generation unit
(> 1,000 mm on all sides) must be maintained.
Minimum distance for maintenance work:
B700 mm free space above the system.
B300 mm free space next to the control cabinet.
If the minimum distances are not maintained:
AContact the manufacturer.

16 | RMB/ENERGIE GmbH
Assembly
Operation manual CHP 5.0 - 30.0 | Status 01.2020
5.2.3 Heating system
The structural elements of the building’s heating
system primarily comprise the peak load boiler, the
buffer tank, and the pipework system and radiators.
The peak load boiler supplies the required residual
heat if the heating energy requirement exceeds the
capacity of the system (e.g. in extremely cold weather).
For the system to operate, a buffer tank is required,
which must comply with the following requirements:
BThe buffer tank must have holding fixtures for the
temperature sensors.
BThe buffer tank must have shut-off devices fitted on
the connections to the system.
BThe buffer tank must be designed to meet the
system specifications.
BMinimum 100 litres per kW thermal
for installations < 10 kWth
BMinimum 50 litres per kW thermal
for installations > 10 kWth
These specifications are technical minimum conditions.
Regional or national funding guidelines (e.g. in
accordance with BAFA in Germany) may differ and
must be checked.
The dimensioning of the pipework system must be
designed to meet the following requirements:
BMaximum heat requirement of the building.
BMaximum thermal capacity of the system.
5.2.4 Flue gas routing
For the system to operate, the building must
have a flue, which must comply with the following
requirements:
BThe local laws and regulations must be complied
with (e.g. in Germany, the building regulations).
BThe flue gas routing must comply with the local
regulations (e.g. in Germany, DIN 18160).
BThe flue gases must be removed via a flue.
BAs a fundamental rule, the flue must extract the flue
gases via the roof.
BThe dimensions for the exhaust gas ducting and
flue must be calculated on an individual basis.
BThe gradient of the horizontal section must be min.
5 cm per metre.
BThe flue must be inspected and approved for
operation (e.g. by a master chimney sweep).
BA flue gas silencer must be fitted in the flue gas
routing. The flue gas silencer (optionally available)
must be installed near the generation unit.
BThe flue gas routing must have a water-filled siphon
at its lowest point.
5.2.5 Exhaust air duct
DWARNING!
Risk of suffocation due to improper use of exhaust
air!
The exhaust air must not be used for heating purposes.
Poisonous gases may be produced inside the
generation unit that can lead to death by suffocation.
AEnsure that the exhaust air from the generation unit
is guided outside.
AEnsure that the supply air is not contaminated by
the exhaust air.
An accessory is required (optionally available) if
exhaust air and flue gas are extracted together:
BExhaust air kit if extracting from one system.
BBackflow preventer if extracting in combination with
another heat source (peak load boiler or another
system).
Additional devices with exhaust air (e.g. washer-dryers)
may only be installed subject to consultation with a
suitable specialist or chimney sweep.
5.2.6 Supply air supply
Sufficient supply air must be supplied for the
combustion process and the ambient temperature:
BThe total requirement of the heating system (e.g. for
the peak load boiler) must be born in mind.
BThe supply air supply must meet the system
specification.
Technical data.
BThe supply air must not be supplied via a concentric
pipe if the inner pipe is used for flue gas routing.
BIf the ambient temperature in the installation room is
permanently above 30 °C, additional air exchange is
required.

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5.2.7 Gas supply
For the system to operate, a gas supply is required that
must comply with the following requirements:
BThe gas supply must comply with the established
regulations (e.g. in Germany, TRGI).
BThe system specifications (e.g. type and
composition of the gas) must be complied with.
Technical data.
BThe building’s system must be fitted with a gas flow
monitor, gas meter and a gas filter.
BThe gas flow monitor must meet the system
specifications.
Technical data.
BConnection via a gas appliance outlet is never
permitted.
An accessory is required (optionally available) if
exhaust air and flue gas are extracted together:
BExhaust air kit if extracting from one system.
BBackflow preventer if extracting in combination with
another heat source (peak load boiler or another
system).
5.2.8 Water supply
DATTENTION!
Risk of damage caused by poor water quality!
Too high a proportion of suspended solids and
magnetite along with the incorrect water hardness can
damage the generation unit or shorten its service life.
ACheck the water quality regularly.
AUse the MSM filter.
BThe water quality must comply with the
specifications of the applicable standards and
Directives (e.g. in Germany, VDI Regulation 2035).
BThe heating system water must be free from
mechanical impurities.
BThe hardness of the water must be < 0.11 °dH.
BConductivity < 100 µS/cm.
BPH value > 8.2 and < 9.0.
5.2.9 Condensate drain
For the system to operate, the building must have a
condensate drain, which must comply with the following
requirements:
BThe condensate drain must be depressurised.
BThe inner diameter of the condensate drain must
not be reduced.
BA neutralization device is recommended for each
system to collect condensate containing oil.
BThe siphon must be constructed from a corrosion-
and acid-resistant material (e.g. plastic or stainless
steel).
BThe siphon must be regularly filled with water to
prevent it from drying out.
BThe siphon must also be filled with water during an
interruption of operation.
BThe local water disposal regulations must be
considered.
5.2.10 Power supply
For the system to operate, the building requires a
connection to the electricity supply that must comply
with the following requirements:
BThe specifications and technical connection
conditions of the energy provider must be taken into
consideration (e.g. electricity meter).
BThe start-up power and cable lengths must be taken
into account when calculating the cable cross-
sections.
BThe supply voltage must meet the system
specifications.
Technical data.
5.2.11 Reactive current compensation
For the system to operate, the energy provider
stipulates the need for reactive current compensation.
The reactive current compensation reduces the
reactive current generated by the system and thus
relieves the supply network. The reactive current
compensation must meet the system specifications.
Technical data.
5.2.12 Mobile communications network
Remote monitoring via the modem requires access
to the mobile communications network. The modem
must be accessible. The position of the modem has an
influence on the reception quality.
The reception quality may be improved as required by
means of the following accessory (optionally available):
BExternal antenna (distance max. 15 m)
BPatch cable (max. 100 m long)

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5.3 Assembly steps
Brief overview:
5.3.1 Preparing for assembly
5.3.2 Unpacking the system
5.3.3 Positioning the generation unit
5.3.4 Screwing the control cabinet in position
5.3.5 Screwing the expansion tank connection block in
position
5.3.6 Connecting the generation unit
5.3.7 Connecting the temperature sensors
5.3.8 Connecting the modem
5.3.9 Connecting the control cabinet
5.3.10 Checking the connections
5.3.1 Preparing for assembly
AFamiliarise yourself with the assembly situation and
the documentation.
BSystem
BSystem components
BSafety devices
BAccessories
BInstallation location
BOperation manual and supporting documents
AGather together the required tools and materials.
AKeep the assembly area clear of objects than may
get in the way or be damaged.
ACheck that all of the installation location
requirements have been fulfilled.
D“5.2 Installation location requirements”
(page 14).
AEnsure that the supply voltage has been and
remains disconnected. Only connect the supply
voltage when instructed in the respective assembly
step.
If accessories (e.g. flue gas silencer, exhaust air kit)
are required for the assembly process:
AEnsure that the accessory is correctly assembled
and ready for connection.
AEnsure that the lines from the accessories have
been laid correctly and are accessible.
Manuals for accessories.
5.3.2 Unpacking the system
DATTENTION!
Risk of damage caused by improper handling!
The system may be damaged during unpacking or
transportation.
ADo not cut through the protective packaging.
AKeep objects that might damage the system away
from it (e.g. tools).
ARemove the packaging material from the system.
ARemove the parts included in the scope of delivery
from on top of the generation unit.
ACheck the system and all the parts it contains for
damage.
ACheck the scope of delivery according to the
delivery note for completeness.
If parts are missing or damaged:
AContact the manufacturer.
ARemove the packaging material from the installation
location.
D“11.1 Disposing of packaging” (page 34).

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5.3.3 Positioning the generation unit
DATTENTION!
Risk of damage to the generation unit caused by
improper transportation!
In narrow transportation routes, it may be necessary
to disassemble parts of the generation unit in order to
move the device into the installation location.
Disassembly for transport may only be carried out by
the manufacturer.
AContact the manufacturer.
ASelect a suitable installation location.
D“5.2.2 Installation room” (page 15).
APosition the balance strips.
APlace the generation unit on the balance strips.
AEnsure that the generation unit stands level.
AScrew on the front cover.
AScrew on the rear cover.
AScrew on the Supply air intake grille.

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5.3.4 Screwing the control cabinet in position
AOpen the control cabinet.
AMark the drill hole positions on the wall.
ADrill the holes for the screws.
AScrew the control cabinet onto the wall.
AObserve the minimum distances.
D“5.2.2 Installation room” (page 15).
5.3.5 Screwing the expansion tank connection
block in position
AMark the drill hole positions on the wall.
ADrill the holes for the screws.
AScrew the expansion tank connection block onto the
wall.
5.3.6 Connecting the generation unit
When connecting the system to the heating system it is
necessary to follow the appropriate hydraulic diagram.
D“12.2 Hydraulic diagrams” (page 35).
Always match the connections to the identifiers on the
generation unit.
Pay attention the to connection sizes and type when
connecting the lines.
Generation unit connection sizes
Connection Connection size and type
CHP
5.0 - 7.2
CHP
11.0 - 20.0
CHP
25.0 - 30.0
Buffer water
return line
1” male
thread
1” male
thread
1” male
thread
Buffer water
supply line
1” male
thread
1” male
thread
1” male
thread
Expansion
tank
3/4” male
thread
3/4” male
thread
3/4” male
thread
Condensate 3/4” male
thread
3/4” male
thread
3/4” male
thread
Flue gas DN 80 DN 80 DN 80
Exhaust air DN 100 DN 100 DN 160
Gas 1/2” female
thread
1/2” female
thread
1” male
thread
ARemove the cover.
If necessary, the entire rear cover can be released and
removed.