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