Viessmann VITOBLOC 200 Bedienungsanleitung

5841436 GB 09/2019 Please retain for future use

Installation instructions

for contractors

VITOBLOC 200

Type EM-530/660 version SCR Part no. 7727282

Type EM-530/660 version SCR-ready Part no. 7727283

CHP unit for operation with natural gas

Company details

2 Installation instructions VITOBLOC 200 EM-530/660 version SCR

5841436 GB

This appliance meets all basic

requirements of the applicable standards

and guidelines. Conformity has been

verified. All associated documents and the

original Declaration of Conformity are

available from the manufacturer.

NOTE!

The Vitobloc 200 CHP unit is not suitable

for 60 Hz operation. It is therefore not

available for the American and Canadian

markets in particular.

Service partner

Viessmann Kraft-Wärme-Kopplung GmbH

D-86899 Landsberg am Lech

Tel.: +49 (0)8191 9279-0

Fax: +49 (0)8191 9279-23

Email: [email protected]

www.viessmann.de

These instructions are protected by copyright. All rights

derived from this copyright are reserved (even when only

excerpts are used), unless a contractual agreement is

reached in this regard.

Viessmann Werke GmbH & Co. KG reserves the right to

change the product described herein at any time and

without notice, in line with technological advances, unless

contractually specified otherwise

Original document

 Table of contents 
VITOBLOC 200 EM-530/660 version SCR Installation instructions 3 
5841436 GB 
 
1Introduction......................................................................................4
1 Structure of the safety instructions..............................................................................4 
2 Depiction of safety instructions ...................................................................................4 
3 Safety symbols..............................................................................................................5 
4 Trademarks....................................................................................................................5 
2Intended use.....................................................................................6
3Safety................................................................................................7
1 Legal disclaimer ............................................................................................................7 
2 Safety equipment...........................................................................................................7 
3 Personnel.......................................................................................................................8 
4 General safety regulations............................................................................................9 
5 Special safety regulations...........................................................................................10 
6 Information regarding particular types of hazard......................................................11 
4Product description.......................................................................14
1 Overview ......................................................................................................................14 
2 Materials provided as standard..................................................................................15 
5Transport, storage and siting .......................................................16
1 Transport......................................................................................................................16 
2 Storage.........................................................................................................................17 
3 Siting ............................................................................................................................17 
6Installation at the installation site.................................................21
1 Ventilation provided by operator................................................................................21 
2 Heating connection .....................................................................................................22 
3 Gas connection............................................................................................................23 
4 Exhaust gas connection..............................................................................................25 
5 Condensate drain ........................................................................................................26 
6 Connection of AdBlue™ and compressed air ...........................................................27 
7 Fitting/removing noise attenuating elements............................................................28 
8 Electrical connection...................................................................................................29 
7Commissioning..............................................................................31
8Control and operation ...................................................................31
9Information regarding service and maintenance.........................31
Appendix ........................................................................................32
1 Engine lubricating oil ..................................................................................................32 
2 Coolant.........................................................................................................................32 
3 Permissible types of antifreeze ..................................................................................32 
4 Heating water...............................................................................................................33 
5 Gas quality...................................................................................................................34 
6 AdBlueTM.......................................................................................................................34 
7 Compressed air ...........................................................................................................34 
8 Type testing in accordance with EU Gas Appliances Regulation............................35 

Introduction

4 Installation instructions VITOBLOC 200 EM-530/660 version SCR

5841436 GB

1 Introduction

This document applies to the combined heat and

power (CHP) unit Vitobloc 200 EM-530/660 (versions

SCR and SCR-ready) –also referred to below as the

"machine". This document must always be kept within

easy reach of the system.

Constant development may result in minor changes to

the illustrations, functional steps and specifications.

Viessmann Werke GmbH & Co. KG expressly

disassociates itself from all content of all linked

websites and does not consider such content its own.

This declaration applies to all external links and

references to the internet specified within this

document.

1.1 Structure of the safety instructions

Safety instructions each consist of 5 elements.

Fig. 1 Safety instructions structure

1 Keyword

2 Type and source of hazard

3 Potential consequences of the hazard

4 Avoidance of the hazard

5 Hazard symbol

1.2 Depiction of safety instructions

The safety instructions in this documentation are

important for safety and must be observed.

DANGER

Meaning

Designates an imminent danger

If the situation is not avoided, it will

result in death or serious, irreversible

injury.

WARNING

Meaning

Designates a potentially dangerous

situation

If the situation is not avoided, it will

result in death or serious, irreversible

injury.

CAUTION

Meaning

Designates a potentially dangerous

situation

If the situation is not avoided, it may

result in slight or minor, reversible

injury.

PLEASE NOTE

Meaning

Designates a potentially harmful

situation

If the situation is not avoided, the

machine or an object in its vicinity may

be damaged.

Introduction

VITOBLOC 200 EM-530/660 version SCR Installation instructions 5

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1.3 Safety symbols

The following signs (safety symbols) are attached to

the machine or must be affixed on/in the plant room

by the operator:

1.3.1 Prohibition signs

Access for unauthorised persons

forbidden!

Areas identified in this way may only

be accessed by people who have

been expressly authorised to do so,

e.g. in connection with work to be

performed there. Access is prohibited

for all other people.

Fire, naked flames and smoking

forbidden!

Identifies danger zones in which fire,

naked flames and smoking are

prohibited.

Access prohibited for persons with

active implants!

(e.g. cardiac pacemakers)

Identifies danger zones that must not

be accessed by persons with active

implants.

Access prohibited for persons with

passive implants!

(e.g. artificial joints)

Identifies danger zones that must not

be accessed by persons with metal

implants.

1.3.2 Warning signs

Warning of dangerous electrical

voltage!

Means "stop" before entering danger

zones containing live parts.

Warning of hot surfaces!

Means "stop" before entering danger

zones that may contain hot surfaces.

1.3.3 Command signs

Wear safety shoes!

Prescribes that protective footwear

must be worn during transportation

and installation.

Use ear defenders!

Requires ear defenders to be worn

during work in the installation room

while the CHP unit is in operation

1.4 Trademarks

Reference is made in this document to various

registered trademarks that are not specifically

identified as such within the text. The absence of any

identification does not necessarily mean that the

corresponding product name is free of third party

rights.

Intended use

6 Installation instructions VITOBLOC 200 EM-530/660 version SCR

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2 Intended use

The operator of the Vitobloc 200 EM-530/660 CHP

unit (versions SCR and SCR-ready) must observe the

relevant country-specific laws and regulations.

Target group

This document is intended solely for use by

contractors; see chapter 3.3 Personnel.

Application

The Vitobloc 200 EM-530/660 CHP unit (versions

SCR and SCR-ready) is intended exclusively for the

generation of three-phase current 400 V, 50 Hz and

DHW in natural gas mode.

It is only intended for industrial and commercial

applications.

Any use that differs from or goes beyond this is

considered inappropriate. The manufacturer rejects all

liability for any losses arising from such inappropriate

use. The operator alone bears the associated risks.

Intended use also includes observance of these

instructions and compliance with the inspection and

servicing conditions.

Incorrect use

All applications deviating from the intended use are

deemed to be impermissible incorrect use. This

includes:

●Application areas not listed under "Application".

●Use of operating fluids that do not correspond to

the manufacturer's specifications.

●Use outside the permissible technical operating

limits.

●Use in areas at risk of explosion.

●Use outdoors.

●Bypassing of safety equipment.

●Operation as an emergency generator.

●Operation in permanent island mode.

●Use only for heat generation if power is not drawn

off simultaneously.

●Siting in the same room as a boiler system with

atmospheric burner or an NH3refrigeration unit

with an interconnected air supply.

EC Declaration of Conformity and Declaration of

Incorporation

This CHP unit is considered a complete machine as

referred to in the EC Machinery Directive.

The machine complies with the EC Machinery

Directive. This has been established by means of a

conformity assessment process.

Declaration of Conformity

The Declaration of Conformity is the basis for the

system's CE designation. The CHP unit may only be

operated in accordance with country-specific

legislation, regulations and standards.

The controller has a CE designation in accordance

with the EMC Directive and the Low Voltage Directive.

Safety

VITOBLOC 200 EM-530/660 version SCR Installation instructions 7

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3 Safety

3.1 Legal disclaimer

The CHP unit is built in accordance with the latest

engineering standards and recognised safety

regulations. Nevertheless, impermissible use can still

result in risk to life and limb or to machine impairment

and other material losses.

Only use the CHP unit if it is in perfect technical

condition, in accordance with its intended use, and if

you are aware of all safety and risk-relevant factors.

Only use it with due regard to the operating

instructions. Faults that may have a detrimental

impact on safety must be corrected without delay.

Use of prescribed and/or approved operating fluids in

line with the specification is a prerequisite for the

recognition of warranty claims.

Operation of the CHP unit at levels exceeding the

limits invalidates the warranty. The manufacturer

accepts no liability for faults and/or damage

(corrosion, contamination, wear) caused by gases or

materials that were not known and agreed to at the

time the contract was concluded.

Safety information

Information concerning safety cannot be interpreted

against Viessmann Werke GmbH & Co. KG. Even if

all safety instructions are followed, there is no

guarantee that the CHP unit will not cause any injuries

or damage.

No modifications may be made to the CHP unit

without the approval of Viessmann Werke GmbH &

Co. KG. Additional components not included in the

standard delivery may be integrated into the system.

The operator is responsible for any damage to the

CHP unit or other material assets caused by such

components.

DANGER

Impermissible modifications to the

machine!

Risk to life, serious personal injury

resulting in irreversible damage

Never perform any modifications or

alterations to the machine without

permission.

3.2 Safety equipment

The installer protects the CHP unit from unauthorised

access by installing it in a locked plant room. The

installer is also responsible for ensuring that all safety

equipment is fully installed and fully functional.

Furthermore, the installer is responsible for attaching

the safety symbols.

DANGER

Missing or non-functional safety

equipment!

Risk to life, serious personal injury

resulting in irreversible damage

NEVER remove or disable safety

equipment.

Safety

8 Installation instructions VITOBLOC 200 EM-530/660 version SCR

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3.3 Personnel

All personnel working on the CHP unit must be

trained in its use. They must also have read and

understood the documentation, including the chapter

concerning safety. We recommend that this is

confirmed with their signature.

The term "personnel" includes the installer, the

operator and the user of the machine.

PLEASE NOTE

Failure to observe the installation

instructions!

Serious material damage to the

machine and its surroundings

The specifications in the installation

instructions must be observed.

Siting, replacement, adjustment,

servicing and maintenance may only be

carried out by personnel with specific

training on the relevant component of

the machine.

Installer (e.g. specialist company)

The installer must integrate the CHP unit safely into a

system.

DANGER

Missing or non-functional safety

equipment!

Risk to life, serious personal injury

resulting in irreversible damage

NEVER remove or disable safety

equipment.

PLEASE NOTE

Installation, control and operation by

unauthorised or unqualified persons!

Serious material damage to the

machine and its surroundings

No unauthorised persons are permitted

within the working area.

Only employ qualified, trained

personnel.

The installer is responsible for the following tasks:

●Installing the CHP unit.

●Connecting the CHP unit.

●Installing the prescribed safety and protective

equipment.

●Attaching the necessary safety symbols.

●Displaying the Declaration of Conformity for the

system.

●Preparing the operating instructions for the

system.

●Training the operator/user. The operator/user

must sign to confirm they have participated in this

training.

Installation personnel

The responsibilities of the installation and

commissioning personnel must be defined.

The personnel must meet the following requirements:

●They must have read and understood all the

documentation, including the chapter concerning

safety.

●They must be trained and instructed in the work to

be performed.

●They must use the personal protective equipment.

●Only qualified personnel may carry out work on

the machine. Qualified personnel are people who

can assess the work to be performed and identify

potential risks based on their technical training

and experience as well as their knowledge of

applicable standards.

●Depending on country-specific legislation,

regulations and standards, the installer may need

to adapt these conditions.

Operator

The operator of the CHP unit is responsible for it

being used as intended. The operator must ensure

safe, technically flawless operation of the machine as

well as define and comply with all safety regulations

for the personnel.

The operator is responsible for compliance with

country-specific legislation, regulations and

standards.

Safety

VITOBLOC 200 EM-530/660 version SCR Installation instructions 9

5841436 GB

3.4 General safety regulations

Only use the CHP unit if it is in perfect technical

condition in accordance with its intended use, and if

you are aware of all safety-relevant factors. Incorrect

handling may result in personal injury and material

damage.

In the event of any defects or faults being identified

with regard to operational safety or operational

reliability, the CHP unit must be shut down

immediately or not started up in the first place.

DANGER

Incorrect handling of the machine with

regard to operational reliability!

Risk to life, serious personal injury

resulting in irreversible damage

Refrain from all unsafe working methods.

Do not carry out any modifications,

additions or alterations to the machine

which may adversely affect safety.

Take measures to ensure safe, fully

functional operation.

Only operate the machine if all protective

and safety equipment is fully functional.

Comply with the safety regulations.

PLEASE NOTE

Unauthorised modification to

programmable control systems!

Serious material damage to the

machine and its surroundings

No unauthorised persons are permitted

within the machine's working area.

Only qualified, trained personnel may

operate the machine.

●In the event of malfunctions, shut down and

secure the machine immediately! Correct all faults

immediately.

●Spare parts must meet the technical requirements

stipulated by the manufacturer. This is always

guaranteed in the case of original spare parts.

●Appropriate workshop equipment is essential for

carrying out the installation work.

●The location of fire extinguishers and how they are

used must be made known!

●Observe the fire alarm and firefighting procedures.

Safety

10 Installation instructions VITOBLOC 200 EM-530/660 version SCR

5841436 GB

3.5 Special safety regulations

3.5.1 Siting and storage

PLEASE NOTE

Incorrect siting or storage!

Material damage due to corrosion

Protect the machine and its parts from

rust.

Prevent the formation of condensation.

3.5.2 Assembly work and installation

●Adhere to the settings prescribed in the installation

instructions! Only qualified personnel may perform

such work.

●For all work involved in operating or setting up the

machine and its safety equipment, observe the

start-up and shutdown procedures described in

the operating instructions!

●When replacing larger assemblies, attach them

carefully to lifting gear and secure them in such a

way that no risk can arise from this. Only use

appropriate, technically flawless lifting gear and

lifting accessories with sufficient load bearing

capacity! Do not stand or work under suspended

loads!

●Only entrust experienced personnel with the

fastening of loads and instruction of crane drivers!

The person providing guidance must remain within

sight of or in voice contact with the operator.

●When performing overhead installation work,

always use the intended or other safe climbing

aids and working platforms. Do not use machine

parts as climbing aids! Wear safety harnesses

when carrying out servicing work at a height!

●Always retighten any threaded connections that

have been loosened during installation work.

●If any safety equipment needs to be removed

during installation, it must be inspected

immediately after completing the installation work.

●Ensure the safe and environmentally responsible

disposal of operating fluids and fuels!

●Installation of the machine and its peripheral

connection systems may only be carried out by

authorised personnel from a specialist company,

who have been instructed in these tasks by the

manufacturer.

●Work on parts carrying gas must be carried out by

a licensed specialist.

●The applicable engineering standards as well as

all building and statutory regulations apply to the

practical execution of this work.

●Design the safety equipment in accordance with

all locally applicable regulations.

●Observe the accident prevention regulations.

3.5.3 Commissioning

●Observe start-up and shutdown procedures,

machine ramp-up and control displays!

●Before switching on/commissioning the machine,

ensure that no-one can be put at risk by the

machine starting up.

●Before commissioning the machine, check all

safety equipment and other protective devices for

completeness and correct function. Check all

machine parts for the presence of any foreign

bodies.

●Before commissioning, it is essential to check that

the operating fluids comply with the

manufacturer's specifications.

●No unauthorised people or objects are permitted

within the danger zone during commissioning.

PLEASE NOTE

Unsuitable operating fluids!

Serious material damage to the

machine

Gases and combustion air must meet

the manufacturer's specifications in

accordance with chapter 10.5.

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