Hoval PowerBloc EG Scheda tecnica

Subject to modification

Operating and installation manual

Hoval PowerBloc EG (12,15,20)

Hoval PowerBloc FG (12,15,20)

4 218 891 / 00 –09/20

Subject to modifications

2 of 131

Table of contents

1. General information.........................................................................................................5

1.1. The principle of cogeneration .................................................................................5

2. Basic information ............................................................................................................6

2.1. Copyright and reservation of rights.........................................................................6

2.2. Warranty.................................................................................................................6

2.3. Liability...................................................................................................................7

2.4. Responsibilities of the owner..................................................................................7

2.5. Standards and directives........................................................................................8

2.6. Notes on the representation of symbols and signal words....................................10

2.7. Service addresses................................................................................................11

3. Safety..............................................................................................................................12

3.1. Basic safety instructions.......................................................................................12

3.1.1. Observance of the operating instructions................................................12

3.1.2. Qualification of the personnel, duty of care of the owner.........................12

3.2. Safety markings on the product............................................................................12

3.3. Safety markings in this manual.............................................................................13

3.3.1. DANGER marking...................................................................................13

3.3.2. WARNING marking.................................................................................13

3.3.3. CAUTION marking..................................................................................15

3.3.4. IMPORTANT marking.............................................................................15

3.4. Waste disposal.....................................................................................................16

3.5. Intended use of the plant......................................................................................16

3.5.1. General...................................................................................................16

3.5.2. Possible misuse......................................................................................17

3.5.3. Fire hazard / fire fighting.........................................................................17

3.5.4. Mechanical hazards................................................................................17

3.5.5. Electrical hazards ...................................................................................18

3.6. General safety instructions...................................................................................18

3.7. Special safety instructions....................................................................................21

3.7.1. Fuel variants...........................................................................................21

3.7.2. Generator protection...............................................................................21

3.7.3. Coolant tank with safety closure .............................................................21

3.7.4. Temperature monitoring..........................................................................21

3.7.5. Integrated network and plant protection..................................................22

3.7.6. CO sensor (optional)...............................................................................22

3.7.7. Base group with frame............................................................................22

3.7.8. Driveline..................................................................................................22

3.7.9. Gas engine.............................................................................................22

3.7.10. Generator ............................................................................................23

3.7.11. Lubricating oil supply ..............................................................................23

3.7.12. Gas line ..................................................................................................23

3.7.13. Heat exchanger system..........................................................................24

3.7.14. Power factor correction...........................................................................25

4. Technical documentation..............................................................................................26

Subject to modifications

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4.1. Technical documentation..........................................................................................26

4.2. Transport and installation..........................................................................................28

4.2.1. Safety.....................................................................................................28

4.2.2. Transport................................................................................................29

4.2.3. Storage conditions..................................................................................29

4.2.4. Installation ..............................................................................................30

4.3. Assembly and installation.....................................................................................31

4.4. Installation and connection conditions..................................................................37

4.4.1. Installation conditions of the cogeneration plant......................................40

4.4.2. Combustion air .......................................................................................40

4.4.3. Extract air ...............................................................................................40

4.4.4. Condensate............................................................................................41

4.4.5. Gas connection.......................................................................................42

4.4.6. Electrical integration ...............................................................................42

4.4.8. Hydraulic integration into the heating system..........................................42

4.4.9. Dimensions and weight...........................................................................46

4.4.10. Floor and base........................................................................................46

4.4.11. Water quality……………………………………………………………………46

4.4.12. Installation diagram.................................................................................47

4.4.13. Connection conditions ............................................................................48

4.4.14. Connection diagram................................................................................49

4.4.15. Power supply..........................................................................................51

5. Commissioning and decommissioning........................................................................52

5.1. Commissioning.....................................................................................................53

5.1.1. Safety.....................................................................................................53

5.1.2. Assembly and installation .......................................................................54

5.1.3. Preparatory work for installation of the CHP plant...................................54

5.1.4. Installing the CHP plant ..........................................................................54

5.1.5. Connecting the CHP plant ......................................................................54

5.1.6. Connection work.....................................................................................54

5.1.7. Start-up...................................................................................................55

5.1.8. Preparing for initial commissioning .........................................................55

5.1.9. Carrying out initial commissioning...........................................................55

5.2. Decommissioning, corrosion protection and disposal ...........................................56

5.2.1. Special notes for decommissioning.........................................................56

5.2.2. Final decommissioning and disposal.......................................................56

5.2.3. Corrosion protection ...............................................................................57

5.2.4. Waste disposal.......................................................................................57

6. ATROMATIC operating instructions.............................................................................58

6.1. Introduction ..........................................................................................................58

6.2. Menu structure.....................................................................................................58

6.3. Main screen..........................................................................................................60

6.3.1. Chimney sweep function.........................................................................62

6.4. Details –Menu structure 1....................................................................................63

6.4.1. History –Menu structure 1.1...................................................................63

6.4.2. Power, Output, network, motor (menu structure 1.2.)..............................71

Subject to modifications

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6.4.3. Temperatures (menu structure 1.3.)........................................................72

6.4.4. Oil change / service interval (menu structure 1.4.)..................................73

6.4.5. System information / language (menu structure 1.5.)..............................74

6.5. Code / setup (menu structure 2.)..........................................................................75

6.6. User level 1..........................................................................................................75

6.6.1. Power curve (menu structure 2.1.)..........................................................76

6.6.2. Schedule (menu structure 2.2.)...............................................................77

6.6.3. Time / date (menu structure 2.3.)............................................................79

6.6.4. LAN (menu structure 2.4)........................................................................80

6.6.5. E-mail (menu structure 2.5).....................................................................82

6.6.6. Additional functions (menu structure 2.6.)...............................................83

6.7. User level 2..........................................................................................................98

6.7.1. Oil change (menu structure 2.6.9)...........................................................99

6.7.2. Service interval (menu structure 2.6.10)................................................100

6.7.3. Allowed power (menu structure 2.6.11).................................................101

6.7.4. Fresh oil pump (menu structure 2.6.12)................................................102

6.7.5. System operator (menu structure 2.6.13)..............................................103

6.7.6. Serial number (menu structure 2.6.14)..................................................104

6.7.7. Temperature configuration (menu structure 2.6.15) ..............................105

6.7.8. Manual control (menu structure 2.6.16) ................................................106

6.7.9. Other parameters (menu structure 2.6.17)............................................107

6.8. Stop mode / error (menu structure 2.6.19)..........................................................112

6.8.1. Error window.........................................................................................112

6.8.2. Error list (menu structure 2.6.20) ..........................................................115

6.9. Warning (menu structure 2.6.21)........................................................................118

6.10. Standards...........................................................................................................120

7. Service and maintenance............................................................................................121

7.1. Safety.................................................................................................................121

7.2. Cleaning and lubrication.....................................................................................122

7.2.1. Cleaning ...............................................................................................122

7.2.2. Lubrication............................................................................................122

7.3. Maintenance intervals and servicing work ..........................................................122

7.3.1. Maintenance intervals...........................................................................122

7.3.2. Repair work ..........................................................................................123

7.4. Connection work.................................................................................................124

7.5. Electrical installation...........................................................................................124

7.6. Connecting to the electrical grid .........................................................................124

8. Remote maintenance and installation........................................................................125

8.1. Installing the remote maintenance module: ........................................................125

8.2. CHP plant software configuration .......................................................................127

8.3. Cascade connection:..........................................................................................128

8.4. Changing the Micro SD card...............................................................................129

8.5. Connection diagram for the remote maintenance module:..................................130

131

Basic information

Subject to modifications

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1. General information

1.1. The principle of cogeneration

Cogeneration plants use an internal combustion engine to drive a generator that

generates electrical power. The resulting waste heat is used as heating energy (as shown

in Figure 1: Principle of cogeneration). Such cogeneration plants are also referred to as

combined heat and power (CHP) plants.

Figure 1: Principle of cogeneration

Cogeneration enables decentralised generation of heat and electricity. Although it has

been in use for decades, the technology based on it has only been used to a limited

extent.

The decisive step forward is the innovative control system. CHP plants with static control

only adapt moderately to the change in demand parameters. Thanks to dynamic control

modules, the CHP plant adapts to different load specifications. The CHP plant converts

the energy contained in the gas fuel with an efficiency of almost 100 %. This enormously

increases energy efficiency in the combined heat and power supply of medium-sized

properties.

It can be used in buildings with an annual electricity consumption of approx. 60,000 kWh

or more and an annual fuel consumption of approx. 150,000 kWh or more. These include,

for example, residential complexes from approx. 18 residential units, accommodation

facilities, nursing homes and senior citizens' homes, commercial properties with heating

and cooling requirements, communal facilities, churches, etc.

Basic information

Subject to modifications

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2. Basic information

2.1. Copyright and reservation of rights

These operating instructions are protected by copyright. The passing on and

reproduction of this document, exploitation and communication of its contents

are FORBIDDEN, unless expressly permitted in writing by Hoval. Violations will

result in damages. All rights in the event of patent, utility model or design

registration are reserved.

Hoval reserves all rights to this document and to the object depicted therein. Without the

prior written consent of Hoval, this document may not be reproduced in whole or in part,

copied or in any form made accessible to third parties in whole or in part and used outside

the purpose for which it was handed over to the recipient.

These operating instructions essentially contain information on the structure, function,

assembly, commissioning, operation and maintenance of your cogeneration plant.

All appendices are integral parts of the operating instructions.

Your cogeneration plant has been built in accordance with recognised safety regulations.

However, improper use may endanger persons or cause damage to property.

2.2. Warranty

Non-compliance with the operating instructions shall invalidate the warranty, as shall any

modification or repair to the plant without the prior written consent of Hoval. Furthermore,

Hoval shall not be liable for damage or accidents caused by improper handling, excessive

strain or force majeure.

In principle, the "Standard terms and conditions of delivery" of Hoval apply. Hoval grants a

warranty / guarantee of 12 months on its combined heat and power plants starting from

the respective commissioning date or at the latest 3 months after the delivery date.

The following conditions must be met in order for the warranty to be approved:

All major customer services during the warranty period are carried out exclusively

by Hoval or a specialist company approved or authorised by Hoval.

If the plant is not put into operation within 3 months of delivery and/or notification

of readiness for dispatch, a subsequent application of corrosion protection shall be

necessary and must be paid for.

The plant is not allowed to be operated beyond the maximum rated power, which

is indicated for the respective type on the technical data sheet.

The plant must not be operated with defective or improperly installed safety and

monitoring devices.

A gas engine oil approved by Hoval must be used as engine oil. For further

information, see the "Operating materials" chapter.

The owner is not allowed to make any technical changes to the plant.

Only genuine spare and wear parts are allowed to be used for repairs.

Basic information

Subject to modifications

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2.3. Liability

Hoval is only liable for direct personal injury and damage to property on the basis of the

applicable product liability law if the plant is used for the purpose prescribed in the

operating instructions or for the contractually agreed use.

Hoval shall not be liable for compensation for damage that has not occurred to the plant

itself (loss of use, loss of production and profit as well as other direct or indirect losses).

2.4. Responsibilities of the owner

The CHP plant was designed and built taking into account a risk assessment and after

careful selection of the harmonised standards to be complied with and other technical

specifications. It thus corresponds to the state of the art and guarantees a maximum

of safety.

However, this safety can only be achieved in operational practice if all necessary

measures are taken. It is the duty of care of the owner of the plant to plan these measures

and to check they are carried out.

In particular, the owner must ensure that

the plant is only used for its intended purpose

the plant is only operated in perfect, functional condition and the safety devices in

particular are regularly checked for their functionality

the necessary personal protective equipment is available to the operating,

maintenance and repair personnel, and is used

the operating instructions are always available in a legible condition and complete

at the place of use of the plant

only sufficiently qualified and authorised personnel operate, maintain and repair

the plant

this personnel is regularly instructed in all applicable questions of occupational

safety and environmental protection and is familiar with the operating instructions

and in particular with the safety instructions contained therein

no safety and warning notices attached to the plant are removed and all of them

remain in a legible condition

a risk assessment (within the meaning of Article 5 of the Occupational Health and

Safety Act) is carried out to determine the other hazards arising from the special

working conditions at the location where the plant is to be used

all further instructions and safety instructions resulting from the risk assessment of

the workplaces at the plant are summarised in one operational instruction (in the

sense of Article 6 of the Work Equipment Usage Ordinance).

Basic information

Subject to modifications

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2.5. Standards and directives

The plant has been designed and built in accordance with the currently valid technical

rules and recognised safety regulations. The basic safety requirements, standards and

guidelines were applied in the design of the plant.

The safety of the plant is documented by the declaration of conformity.

All safety data refers to the currently valid regulations of the European Union. In other

countries, the applicable laws and regulations must be observed. In addition to the safety

instructions in these operating instructions, the accident prevention regulations for power-

operated working machines as well as the generally applicable regulations for

environmental protection must be observed and adhered to.

Instructions, ordinances and laws

2006/42/EC

EC Machinery Directive

2006/95/EC

Low-Voltage Directive

2004/108/EC

Directive on Electromagnetic Compatibility

BImSchv

German Federal Immission Control Ordinance

MFeuVo

Model firing ordinance of the federal states FeuVo

Fundamental standards

DIN EN ISO 60204-1

Safety of machinery; Electrical equipment of machines

DIN EN ISO 12100

Safety of machinery; Basic concepts, general principles

for design

DIN EN ISO 13857

Safety of machinery; Safety distances to prevent hazard

zones being reached by upper and lower limbs

DIN EN ISO 13850

Safety of machinery; Emergency stop function - Principles

for design

DIN EN ISO 13732

Ergonomics of the thermal environment; Methods for the

assessment of human responses to contact with surfaces

DIN EN 547

Safety of machinery; Human body measurements

DIN EN 574

Safety of machinery; Two-hand control devices

DIN EN 614

Safety of machinery; Ergonomic design principles

DIN EN 626

Safety of machinery; Reduction of risk to health from

hazardous substances emitted by machinery

DIN EN 894

Safety of machinery; Ergonomics requirements for the

design of displays and control actuators

DIN EN 953

Safety of machinery; Guards - General requirements for

the design and construction of fixed and movable guards

DIN EN 981

Safety of machinery; System of auditory and visual danger

and information signals

Basic information

Subject to modifications

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DIN EN 1037

Safety of machinery; Prevention of unexpected start-up

DIN EN 1127-1

Explosive atmospheres; Explosion prevention and

protection, Part 1: Basic concepts and methodology

DIN EN 12828

Heating systems in buildings - Design of hot water systems

(replacement for DIN 4751)

DIN EN 12831

Heating systems in buildings

DIN EN 13849

Safety of machinery; Safety-related parts of control systems

DIN EN 14336/2005

Heating systems in buildings

DIN EN 14868/2003

Protection of metallic materials against corrosion

DIN EN 60529

Degrees of protection provided by enclosures (IP Code)

DIN EN 61310-2

Safety of machinery; Indication, marking and actuation,

Part 2: Requirements for marking

Product-dependent standards

ISO 8999

Reciprocating internal combustion engines, graphical

symbols

DIN EN ISO 13407

Human-centred design processes for interactive systems

DIN EN ISO 6826

Reciprocating internal combustion engines, fire protection

DIN ISO 8528 ff.

Reciprocating internal combustion engine driven alternating

current generating sets

DIN EN 1679-1

Reciprocating internal combustion engines; safety,

Part 1: Diesel engines

DIN EN 12601

Reciprocating internal combustion engine driven alternating

current generating sets; safety

DIN 1988

Codes of practice for drinking water installations (TRWI)

DIN 3380

Gas pressure regulators for supply pressures up to 100 bar

DIN 3386

Gasfilters having a maximum working pressure of less or

equal to 5 bar - Requirements and testing

DIN 3398-3

Pressure cut-off switches for gaseous substances;

requirements and testing

DIN 4751

Safety requirements for heating installations with flow

temperatures up to 110 °C replaced by DIN EN 12828

DIN 6280-14

Generating sets; Reciprocating internal combustion

engines driven generating sets, Part 14: Combined heat

and power system (CHPS) with reciprocating internal

combustion engines; basics, requirements, components,

application and maintenance

Basic information

Subject to modifications

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Other basic regulations

BGV A8

Safety and health marking at the workplace

TRF 1996

Technical rules for liquid gas

ATV –Worksheet A251

Introduction of condensation water from gas and oil-

operated firing plants in public sewage and small-scale

water treatment plants, edition Nov. 1998, GFA Verlag für

Abwasser, Abfall und Gewässerschutz

VDI 2035

Water treatment for heating systems

2.6. Notes on the representation of symbols and signal words

DANGER

Warning of personal injuries that are already acute at the moment of the warning.

Warning of dangerous situations which, if not avoided, will result in serious injury or death.

WARNING

Warning of personal injuries that depend on behaviour.

Warning of dangerous situations which, if not avoided, can result in serious injury or

death.

CAUTION

Warning of damage to property which cannot result in personal injury.

Warning of dangerous situations which, if not avoided, could result in minor to

moderate injury.

IMPORTANT

Provides information on how to avoid damage to property or misuse.

Draws attention to possible damage to property and other important information.

NOTICE

Information about the handling of the machine and activities to be carried out on or with it.

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