chp ce - london borough of havering · 4 | explanation of symbols and safety instructions 6 720 805...

Operating instructions for users

Combined heat and power unit

CHP CE
240 NA
6 72

0 80

4 10

3-00

.2T

6 72

0 80

5 12

6 (2

013/

08) G

B

2 | Table of contents

Table of contents

1 Explanation of symbols and safety instructions . . . . . . . . . . . . 31.1 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 Product information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.1 Scope of Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.2 Correct use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.3 EC Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . 52.4 Standards, regulations and directives . . . . . . . . . . . . . . . 52.5 Data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.6 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.7 Layout and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.7.1 Sound insulation enclosure . . . . . . . . . . . . . . . . . . . . . . . 62.7.2 Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.7.3 Side views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.8 Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.9 Dangerous areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102.10 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102.11 Reduction in output subject to ventilation

air temperature and installed height . . . . . . . . . . . . . . . 11

3 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123.1 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123.2 Starting the CHP module . . . . . . . . . . . . . . . . . . . . . . . 123.2.1 Starting the gas engine in manual mode . . . . . . . . . . . 123.2.2 Connecting the generator circuit breaker . . . . . . . . . . 133.2.3 Switching to automatic mode . . . . . . . . . . . . . . . . . . . . 13

4 Control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144.1 Control system main menu . . . . . . . . . . . . . . . . . . . . . . 144.1.1 Touch screen explanation . . . . . . . . . . . . . . . . . . . . . . . 144.1.2 Cleaning the touch screen . . . . . . . . . . . . . . . . . . . . . . 144.1.3 Automatic output reduction display . . . . . . . . . . . . . . . 154.1.4 Status display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154.1.5 Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164.1.6 User interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5 Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175.1 Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . 175.2 Function diagrams submenu . . . . . . . . . . . . . . . . . . . . 175.2.1 CHP overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175.2.2 CHP trend function diagram . . . . . . . . . . . . . . . . . . . . . 175.2.3 Buffer tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175.2.4 CHP mains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185.2.5 GCB synchronisation . . . . . . . . . . . . . . . . . . . . . . . . . . 185.2.6 MCCB synchronisation . . . . . . . . . . . . . . . . . . . . . . . . . 185.3 Statistics submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195.3.1 CHP statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195.3.2 Current faults/warnings . . . . . . . . . . . . . . . . . . . . . . . . 195.3.3 Fault and warning history . . . . . . . . . . . . . . . . . . . . . . . 195.3.4 Operator's log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195.3.5 CHP temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205.4 Settings submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205.4.1 Calling up setting screens and entering values . . . . . . 205.4.2 Output control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5.4.3 Engine coolant control . . . . . . . . . . . . . . . . . . . . . . . . . . 215.4.4 Extract air ctrl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225.4.5 Controller setting extract fan . . . . . . . . . . . . . . . . . . . . . 225.4.6 Flow temperature control . . . . . . . . . . . . . . . . . . . . . . . . 225.4.7 Flow temperature controller setting . . . . . . . . . . . . . . . 235.4.8 Lambda servovalve start position . . . . . . . . . . . . . . . . . 235.4.9 Return temperature start point . . . . . . . . . . . . . . . . . . . 245.4.10 Cylinder management . . . . . . . . . . . . . . . . . . . . . . . . . . . 245.4.11 Emergency cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245.4.12 Oil top-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255.4.13 Configuration reduction by mains frequency . . . . . . . . 255.4.14 Cos ϕ curve entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265.4.15 Date/Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265.5 Manual level submenu . . . . . . . . . . . . . . . . . . . . . . . . . . 275.5.1 Calling up the manual level . . . . . . . . . . . . . . . . . . . . . . . 275.5.2 Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275.5.3 Lambda servovalve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275.5.4 Flow temp. servovalve . . . . . . . . . . . . . . . . . . . . . . . . . . 275.6 Language submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285.7 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285.7.1 Service Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

6 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296.1 Stopping the CHP module . . . . . . . . . . . . . . . . . . . . . . . 296.1.1 Switching to manual mode . . . . . . . . . . . . . . . . . . . . . . . 296.1.2 Disconnecting the generator circuit breaker . . . . . . . . . 296.1.3 Stopping the gas engine in manual mode . . . . . . . . . . . 296.2 Temporarily taking the system out of use . . . . . . . . . . . 296.3 Shutting down the CHP system in an emergency . . . . . 30

7 Environmental protection and disposal . . . . . . . . . . . . . . . . . 31

8 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328.1 Setting values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338.2 Operating values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

CHP CE 240 NA6 720 805 126 (2013/08)

Preliminary remarks | 3

Preliminary remarksThe enclosed instructions are intended for trained personnel (users) and contractors (e.g. competent personnel of an authorised contractor). Text is written to be understood by the target group in question.

Definitions of personnelApart from the differentiation between trained personnel and contractors, these operating instructions also differentiate between licensed and authorised contractors.Trained personnelPersonnel who have received training from a contractor in the following areas:• Operation and operating modes of the CHP system• Potential dangers if incorrect action is taken • Safety measures and essential protection devices▶ Training records, proving competency, are to be maintained.ContractorsPeople who possess the following skills and knowledge as a result of their vocational training and experience:• Knowledge of the relevant standards• Ability to expertly assess the work assigned to them• Ability to recognise dangersLicensed contractorA contractor licensed by the gas supplier to connect the system to the gas supply (Gas Safe Registered UK).Authorised contractorA contractor authorised by the manufacturer to carry out commissioning, service and maintenance work.

1 Explanation of symbols and safety instructions

1.1 Explanation of symbols

Warnings

The following signal words are defined and can be used in this document:• NOTE indicates that material losses may occur.• CAUTION indicates that minor to medium personal injury may occur.• WARNING indicates that serious or life-threatening personal injury

may occur.• DANGER indicates that severe personal injury or death may occur.

Important information

Additional symbols

The combined heat and power module is abbreviated to CHP module in these instructions. Warnings in the text are indicated by a warning triangle.

In addition, signal words are used to indicate the type and seriousness of the ensuing risk if measures for minimising danger are not taken.

This symbol indicates important information where there is no risk to people or property.

Symbol Explanation▶ Step in an action sequence Cross-reference to another part of the document• List entry– List entry (second level)

Table 1

6 720 805 126 (2013/08)CHP CE 240 NA

4 | Explanation of symbols and safety instructions

1.2 Safety instructions

Product safetyThe CHP module has been designed and built in accordance with currently recognised standards and safety requirements. However, personal injury or material damage may arise if it is used incorrectly.Use the product as follows:• Only for its intended purpose• Only in perfect technical condition• With awareness of safety concerns and dangers.

General codes of conduct in case of emergency▶ Never put your life at risk.▶ If possible without endangering yourself: bring other people to

safety.▶ If possible without endangering yourself or others: shut down the

CHP module.

Risk of explosion; if you smell gas action:▶ Close the gas isolation valve ( Fig. 51, page 29).▶ Press the emergency stop switch ( Fig. 52, page 30).▶ Open windows and doors.▶ Do not smoke! Never use lighters or any other source of naked flame!▶ Never operate electrical switches, including telephones, plugs or

doorbells.▶ From outside, warn all occupants of the building, but do not ring

doorbells. Call your gas supplier and licensed contractor.▶ If you can actually hear gas escaping, leave the building immediately.

Prevent third parties from entering and notify the police and fire brigade from outside the building.

Danger of poisoning. Insufficient ventilation can lead to dangerous flue gas leaks.▶ Never block ventilation and extract air apertures or reduce their size.▶ Provide vents in accordance with the requirements of the CHP

module.▶ Never operate the CHP module if the fault cannot be rectified

immediately.▶ Inform the system user in writing of the problem and associated

danger.

Danger of escaping flue gases▶ Ensure that the exhaust pipes and seals are not damaged.▶ Have a contractor confirm the integrity of the flue system.▶ Record and archive every pressure test using a pressure test report.

Risk of hot surfacesWithin the sound insulation enclosure, surface temperatures can occur that would result in burns.▶ Only authorised contractors are permitted to carry out service and

maintenance work inside the sound insulation enclosure.▶ You must allow the sound insulation enclosure to cool down for at

least 1 hour after shutdown before starting any work.

Danger posed by explosive gases and easily flammable materials▶ Work on components that carry gas must only be carried out by a

licensed contractor and must be recorded.▶ Never use or store easily flammable materials (paper, curtains,

clothing, thinners, paints, etc.) near the CHP module.

Danger from electric shock when the control panel is open▶ Any work on electrical or electronic components may only be carried

out by a licensed contractor.▶ Safeguard the CHP module against unintentional reconnection. Set

the service switch to 0 (maintenance) and remove the key ( Fig. 50, page 29).

▶ Press the emergency stop switch and disconnect the CHP module from the mains supply by extracting the mains fuse.

▶ Check that the power supply has been disconnected.▶ Only switch the voltage back on once the work has been completed

and the situation has been inspected (e.g. no one should be put in danger).

▶ Do not use mobile phones or other wireless devices.Danger of destruction, automatic starting and unintended functions.

Danger due to automatic start-up of the CHP moduleThe CHP module starts automatically following an external start demand. If the CHP module has been shut down, safeguard it against unintentional restarting.▶ Set the service switch on the control panel to 0 (maintenance)

( Fig. 50, page 29).▶ Remove the key from the service switch.

Operating the CHP module▶ To ensure safety, the operator must be clear of their responsibilities

in regards to operating the CHP module at commissioning.▶ No operating mode that jeopardises the safety of the CHP module is

permissible.▶ Any modification of the CHP module that jeopardises its safety must

be notified to the operator immediately.▶ Only operate the CHP module in perfect technical condition.▶ Only operate the CHP module with functioning safety equipment.▶ Never disable safety equipment.▶ Check the entire system every day for leaks and unusual noises.▶ When working on the CHP module, always use the personal

protective equipment specified in the accident prevention guidelines.

▶ Only authorised contractors are allowed to open the sound insulation enclosure and control panel.

CHP CE 240 NA6 720 805 126 (2013/08)

Product information | 5

2 Product information

2.1 Scope of Delivery• CHP module (completely assembled with sound insulation enclosure

and control panel)• System documentation, operating instructions and installation and

maintenance instructions• Accessories according to delivery note▶ Check that the delivery is complete and undamaged.

2.2 Correct useThe CHP module is used to generate electrical energy and heat based on the principle of combined heat and power.

FuelThe permitted fuel is 100 % natural gas (methane count > 80). Technically, the natural gas must be free from mist, dust and liquids and must not contain significant levels of corrosive substances. Natural gas must not contain phosphorus, arsenic or heavy metals.LPG mixtures are not permitted.The use of other types of gas (e.g. LPG, biogas) is not permitted.

Cooling and combustion airCooling and combustion air is drawn from the installation room. Keep the supply of cooling air and combustion air free of corrosive substances (e.g. halogenated hydrocarbons that contain chlorine or fluorine compounds). This will help to prevent corrosion.

Operation and maintenanceCorrect use includes the observation of the operating, service and repair conditions.Only use genuine spare parts.

2.3 EC Declaration of ConformityThe design and operation of this product conform to European Directives and the supplementary national requirements. Its conformity is confirmed by the CE marking. A printed version of the Declaration of Conformity can be found in the documentation folder. You can also ask the manufacturer for a copy of the Declaration of Conformity for this product. See the contact address on the back cover of these instructions.

2.4 Standards, regulations and directives

Observe all technical guidelines, country-specific regulations and standards applicable to installation and operation. These include the following:• Local Building Regulations concerning boiler room installations• Local building regulations concerning the ventilation facilities and

chimney connection• Requirements for the electrical connection to the power supply• The technical rules of the gas supplier concerning the connection of

the CHP module to the gas mains

2.5 Data plateThe data plate is attached to the side of the control panel. The data plate contains the following information:

2.6 InputsThe following materials are used:• Natural gas• Engine oil• Coolant• Heating water• Combustion and intake airFor more detailed information regarding approved operating materials, including their quality and composition, refer to the installation and maintenance instructions.

Technical modifications and differences in models may result in illustrations and descriptions in these instructions deviating from the delivered CHP module.

You can find the precise fuel specification in the installation and maintenance instructions.

For the installation and operation of the CHP module:▶ Observe all country-specific standards and

guidelines.

• Type of module • Suction temperature• Serial number • Max flow temperature• Electrical rated output • Permitted operating pressure• Thermal rated output • Gas inlet pressure• Fuel consumption • Gas category• Gas type • Year of construction• Methane count • Address of manufacturer• Installation height

6 720 805 126 (2013/08)CHP CE 240 NA

6 | Product information

2.7 Layout and functionThe CHP module is supplied with a fully factory fitted and wired control panel.The CHP module comprises a gas engine, generator and heat exchangers. The gas engine provides direct drive for the generator. The generator generates electrical power that is fed into the main Low Voltage distribution system on site. Excess power can be fed into the grid of the local Distribution Network. The engine gives off heat, which is transferred to what is known as the internal cooling circuit from the engine coolant and subsequently the flue gas. The heat exchangers are used to transfer the heat from the internal cooling circuit to the heating system. This system for converting and using energy is called combined heat and power (CHP).

2.7.1 Sound insulation enclosureThe sound insulation enclosure is designed to reduce the sound pressure level and to act as protection against accidental contact. It surrounds the entire CHP module with the exception of the control panel.

2.7.2 Control panelThe control panel contains all the control elements for the user.The control panel contains the CHP control system and the power electronics with fuses, circuit breaker and isolator.

Fig. 1 Detail of control panel with control elements

[1] Control panel[2] Touch screen[3] Key switch for enabling emergency power (option)[4] Enclosure lighting[5] Service Switch[6] Acknowledgement button for emergency stop and smoke alarm[7] Emergency stop switch

6 720 619 105-06.2T

Kabinenbeleuchtung

CHP CE 240 NA6 720 805 126 (2013/08)


2.7.3 Side views

Fig. 2 CE 240 NA – System components, front view

[1] Control panel [2] Automatic filing of engine oil sump with oil solenoid valve

(ball valve inside) [3] Data plate [4] Oil tank [5] Thermal safety valve with shut-off valve[6] Safety gas train for natural gas with gas filter, gas solenoid valves,

pressure switch and gas pressure governor[7] Lambda control for natural gas [8] High limit safety cut-out, engine coolant, bank A[9] Speed/output regulator [10] Water-cooled exhaust gas collector, bank A [11] Cylinder 1, bank A [12] Smoke measuring head [13] Enclosure temperature sensor (external) [14] Pressure switch, heating water (maximum pressure monitoring) [15] Heating water expansion vessel (red)[16] Pressure switch, heating water (minimum pressure monitoring)[17] Engine coolant pump (black, concealed)[18] Pressure switch, engine coolant[19] Engine coolant expansion vessel (blue)[20] Lambda probe (installed in the catalyst enclosure)[21] High limit safety cut-out, heating water[22] Oil pressure switch with pressure gauge[23] Level switch for automatic oil top-up facility[24] Engine oil filter (two pieces)[25] Exhaust gas heat exchanger[26] Drain for engine oil sump (bottom ball valve on inside)

6 720 643 002-01.2T

2

1

3

5 6 7 10 11 12 1394

202126 25

14

15

16

17

18

19

2223

8

24

6 720 805 126 (2013/08)CHP CE 240 NA


Fig. 3 CE 240 NA – System components, rear view

[1] Engine coolant heat exchanger[2] Heating pump (option)[3] 3-way valve for flow temperature control[4] Ventilation of engine coolant circuit[5] Cylinder 7, bank B[6] Water-cooled flue gas collector, bank B[7] Gas-air mixer[8] High limit safety cut-out for gas-air mixture[9] High limit safety cut-out, engine coolant, bank B[10] Air filter[11] Drain for oil reservoir (ball valve outside)[12] Battery system[13] Ignition unit[14] Flue gas silencer[15] Starter[16] Drain & fill valve for engine coolant [17] Drain & fill valve for heating water

2.8 Safety equipment

6 720 643 002-02.2T

3

1

6 1054 87 9

17

2

14 1315 12 1116

DANGER: Risk to life due to faulty or absent safety equipment▶ Carry out a visual inspection of all safety equipment

every day.▶ Following each service, carry out a function check of

all safety equipment.▶ Record the checks.▶ Never disable safety equipment.

CHP CE 240 NA6 720 805 126 (2013/08)


Component Safety function LocationEmergency stop switch • Isolates the power supply

• Isolates the gas supply by closing the double solenoid valve

• Control panel ( Fig. 2 [1], page 7)• On the doors and escape routes

(to be attached externally by the operator)Equipotential bonding • All conducting parts are linked to the equipotential

bondingSound insulation enclosure • Designed to provide sound insulation and to act as

protection against accidental contactAround the CHP module

Temperature monitor • The following temperatures are monitored in the CHP module:– Flow temperature– Return temperature– Coolant temperature (gas engine)– Temperature inside the enclosure– Exhaust gas temperature downstream of catalyst– Exhaust gas temperature behind flue gas heat

exchanger– Mixture temperature (CHP module with

turbocharging)

The temperature sensors are installed inside the sound insulation enclosure.

Safety gas train • Safety gas train with double solenoid valve and thermally activated shut-off device (TAE) with ball valve to shut off the gas supply

• Ball valve and TAE on the top of the CHP module. • Solenoid valve inside the sound insulation

enclosure.Level switch for oil filling • Prevents the oil level from becoming too high or too low Inside sound insulation enclosure.Double-bit key for the control panel and sound insulation enclosure

• Access for authorised personnel only.

Operating instructions • The operating instructions with the safety instructions contained therein are part of the safety concept and must be available at all times.

• Available at the CHP module(to be ensured by the operator)

Table 2 Safety equipment

6 720 805 126 (2013/08)CHP CE 240 NA


2.9 Dangerous areasThe dangerous area is defined as 900 mm around the CHP module. Operators must keep the dangerous area free from objects so that unrestricted access is possible at all times.When the sound insulation enclosure is open, only authorised contractors may enter the dangerous area.

Fig. 4 Dangerous area

[1] Dangerous area during service, repair and cleaning work [2] Work area of the trained personnel

2.10 Technical data

Unit CE 240 NAThree-phase power generation V/Hz 400/50Electrical output (without excess cos ϕ =1)

kWel 240

Thermal output (tolerance ± 5 %)

kWth 374

Fuel Input ISO 3046-1 (tolerance ± 5 %)±

kW 669

Modulation range kWel 120-240Overall efficiency % 91.8Power to heat ratio to AGFW FW308 kWel/kWth 0.64Length mm 4380Width mm 1510Height mm 1980Total weight in operation kg Approx.

5200Weight (empty) kg Approx.

4400Table 3 Technical data

6 720 804 104-01.1T

CHP CE 240 NA6 720 805 126 (2013/08)


2.11 Reduction in output subject to ventilation air temperature and installed heightThe engine output of the CHP module depends on the ventilation air temperature and the installation height above sea level. During commissioning, the maximum CHP output must be adjusted to suit the height of the installation location and the ventilation air temperature.Reduction in output and minimum yield from approx. 300 m above sea level ( Fig. 5).

Fig. 5 Reduction in output subject to ventilation air temperature and installation height

x Installed heighty CHP output

If you do not adjust the maximum CHP output to suit the installation height and the ventilation air temperature, the sound pressure level may increase, and the performance and service life may be reduced.

6 720 805 126 (2013/08)CHP CE 240 NA

12 | Commissioning

3 Commissioning

3.1 Commissioning

3.2 Starting the CHP module

The sequence describes how to recommission the CHP module following a temporary shutdown. This involves starting the gas engine in manual mode, connecting the generator circuit breaker and then switching to automatic mode.

3.2.1 Starting the gas engine in manual mode▶ Open the gas isolation valve on the CHP module.

Fig. 6 Gas isolation valve open

▶ Check the gas supply pressure on the pressure gauge.

▶ Set the service switch on the control panel to 1 (operation).The touch screen displays the main menu. Ready is shown on the status display.

Fig. 7 Service switch in position 1

▶ Press Manual on the user interface.▶ Press Start on the user interface.

– The gas engine starts in manual mode. – Open the solenoid valves of the safety gas train. – Idle is shown on the status display.

Fig. 8 Starting up the CHP system

[1] Manual field[2] Start field

DANGER: Risk to life due to incorrect commissioning!▶ The CHP module must only be commissioned by the

manufacturer or an authorised contractor.▶ Only allow the CHP module to be commissioned by

the manufacturer's service personnel.

Detailed information on commissioning is provided in the installation instructions.

The requirements are summarised in the "Preparations for commissioning checklist", which is enclosed with the documents.▶ Complete, record and return the checklist.

WARNING: Personal injury due to incorrect commissioning!▶ The CHP module must be commissioned by trained

personnel and authorised contractors only.▶ Make sure that no one is present in the dangerous

area of the CHP module.

Service switch0 = Maintenance1 = Operation

AcknowledgementEmergency stop + smoke alarm

6 720 647 284-35.1TL

6 720 805 120-03.1TL

Idle

CHP CE 240 NA6 720 805 126 (2013/08)

Commissioning | 13

3.2.2 Connecting the generator circuit breakerPrerequisite: The CHP module is in manual mode. Idle is shown on the status display.▶ Press Mains on on the user interface.

The control synchronises the frequency, phase and voltage between mains power supply and generator. The status display shows Mains synchronisation.

Fig. 9 Connecting the generator circuit breaker

[1] Mains on fieldAfter successful synchronisation, the generator breaker switch is switched on (ca. 1 min). Mains operation is shown on the status display.

3.2.3 Switching to automatic modeThe CHP system's default mode is automatic mode. All external requirements and output defaults are suppressed in manual mode.▶ Check whether a start demand from the higher-level control system

is present.▶ Press Auto on the user interface. The operating mode switches to

automatic mode without any interruption.

Fig. 10 Setting up automatic mode

[1] Auto field

If there is no external start demand, the CHP module shuts down once Auto has been pressed on the user interface.

6 720 805 120-02.1TL

6 720 805 120-64.1TL

6 720 805 126 (2013/08)CHP CE 240 NA

14 | Control system

4 Control system

4.1 Control system main menu

Fig. 11 Touch screen - main menu

[1] "Automatic output reduction" message[2] Operating status display[3] Submenu[4] Key lock for cleaning the touch screen[5] User interface[6] Power LED

4.1.1 Touch screen explanationThe touch screen has a 5.7" TFT colour monitor. The screen is compliant with IP 65 rating.

The Overview main menu is displayed on the touch screen after the CHP system has been switched on.

4.1.2 Cleaning the touch screen▶ Press Clean screen on the user interface.

All user interfaces are locked for 60 seconds. The touch screen can be cleaned without running the risk of a user interface accidentally being activated whilst cleaning the screen.

After 60 seconds have passed, the touch screen automatically displays the main menu.

3

6 4

1 2

5

6 720 805 120-09.1TL

Mainsoperation

Information on handling the touch screen.▶ Never touch or clean the touch screen with pointed,

hard or sharp-edged objects.▶ Never use corrosive liquids containing solvents,

thinners or scouring agents to clean the touch screen.

▶ Never subject the touch screen to excessive pressure during operation and cleaning.

CHP CE 240 NA6 720 805 126 (2013/08)

Control system | 15

4.1.3 Automatic output reduction displayAutomatic output reduction is displayed on the left next to the status display in a light-blue field.

4.1.4 Status displayThe status display shows the current operating condition of the CHP module.Pending faults and warnings are acknowledged here.

Display MessageOutput red. input

Output red. inputThe set value input is lower than the maximum CHP output. Output is ramped down to the input value.

Output red.engine temp.

Output red. engine temp.The CHP module reduces its output in automatic mode, as the engine temperature is too high.

Output red.temp. Mixture

Output red. mixture temp.The CHP module reduces its output in automatic mode, as the mixture temperature is too high.

Output red. Turbo temp.

Output red. turbo temp.The CHP module reduces its output in automatic mode, as the flue gas temperature upstream of the turbocharger is too high.

Output red.knock ctrl

Output red. knock ctrlThe CHP module reduces its output due to severely fluctuating gas quality (methane count).

Output red.ext. Signal!

Output red. external signalA lower set value is specified externally.

Output red.BUS default

Output red. BUS defaultA BUS system specifies a lower set value.

Output red.mains draw

Output red mains draw The output of the CHP module is reduced via mains drawing control.

Output red. P(f) Output red. curve P(f)If the mains frequency is too high, the CHP module reduces its output in automatic mode.

50% Ripple ctrl rec. 50 % ripple ctrl rec.Output reduction is triggered by means of the input of a ripple control receiver. Output is ramped down to 50 % Pmax.

Table 4 Output reduction

Display System status NoteReady The CHP module is ready to be activated.Preparing to start A start demand has been issued to the CHP module. The gas tightness check is carried out before the gas engine

is started. If the check is successful, the starting procedure for the gas engine is initiated.

Starting procedure The starter starts the gas engine.Idle The gas engine is running. The generator circuit breaker is

open (Mains on user interface inactive).Displayed in manual mode only

Mains synchronisation The control system synchronises the CHP module with the connected mains.

Following this, the generator circuit breaker is connected.

Mains operation The gas engine is running. The generator circuit breaker is closed (“Mains on” user interface active).

Ctrl shutdown The controlled shutdown has stopped the CHP module. The engine coolant temperature was too high.

Displayed in automatic mode only

Mains failure There is a mains failure. The generator circuit breaker was opened and the CHP module stopped.

Lock service switch The CHP module is locked by the service switch.Ackn. fault There is a fault. Acknowledge the fault after removing its cause. Only then is

the CHP module ready to start again.Acknow. warning There is a warning. Acknowledge the warning after removing its cause.Reset delay after mains off The CHP module was switched off following a mains failure

or because a threshold value was exceeded. The delay until restart is running.

The CHP module starts after a delay of 1-10 minutes. A random generator specifies the length of the delay. The remaining delay is displayed ( Fig. 48, page 28).

Block P(f) mains frequency The CHP module is switched off because a set mains frequency was exceeded.

The CHP module starts after a delay of 1-10 minutes. A random generator specifies the length of the delay. The remaining delay is displayed ( Fig. 48, page 28).

Ext. Block The CHP module is switched off because there is a block at a digital input.

The CHP module restarts when there is no longer an external block.

Waiting for start-up position

The CHP module moves to the start-up position. When the CHP external control has finished, the control valve of the CHP module moves to the start-up position.

Table 5 Overview of the status displays

6 720 805 126 (2013/08)CHP CE 240 NA

16 | Control system

4.1.5 SubmenusThe submenus allow system data to be requested and adjusted.

4.1.6 User interfacesThe user interfaces allow commands to be entered. The background of the user interface is displayed in green when it is active.

Block MRD operation The CHP module is switched off because no mains is available, for example.

The CHP module does not start if another mains replacement device (MRD) is in operation.

Block ripple ctrl rec. The CHP module is switched off. The output is set via a ripple control receiver.

A ripple control receiver specifies an output of 0%.

Emergency power operation

The CHP module is in emergency power operation. The CHP system is not connected to the public grid (isolated operation) and feeds in power on a rail.

Display System status Note

Table 5 Overview of the status displays

Submenu Function DescriptionFunction diagrams Presentation of function diagrams, setting values and

actual values Chapter 5.2 from page 17

Statistic Presentation of the current operating values, the operator's log and records of the fault/warning history and temperature trends

Chapter 5.3 from page 19

Settings Entering and changing setting valuesBy trained personnel and authorised contractors only


Manual level Manual control of the installed componentsSettings made by trained and authorised contractors only


SERVICE Installation instructions This area is protected by a code.Language Changing the language Chapter 5.6 from page 28

Table 6 Function of the submenus

User interface Function DescriptionAuto Switching from manual mode to automatic mode If a start demand from a higher-level control system is

present, the system switches to automatic mode without any interruption ( Chapter 3.2.3, page 13).

Manual Switching from automatic mode to manual mode Prerequisite: Manual and Mains on fields are active. The system can then be switched to manual mode without any interruption ( Chapter 6.1.1, page 29).

Start Starts the gas engine in manual mode Chapter 3.2.1 from page 12.Stop Stops the gas engine in manual mode Chapter 6.1.3 from page 29.Mains on Connects the generator circuit breaker in manual mode The generator circuit breaker is only switched after the

frequency, phase angle and voltage have been successfully synchronised between the mains and the generator. Synchronisation can take up to 1 minute ( Chapter 3.2.2, from page 13).

Mains off Disconnects the generator circuit breaker in manual mode After pressing the user interface, the generator output is first ramped down to 0 kW. Only then will the generator circuit breaker disconnect the CHP module from the mains.

Table 7 Function of the user interfaces

CHP CE 240 NA6 720 805 126 (2013/08)

Menu | 17

5 Menu

5.1 Operating instructions▶ Call up and navigate a submenu.Selecting a submenu changes the command line at the bottom edge of the screen. The arrow keys at the bottom right allow you to navigate the further function diagrams.• Up arrow: switches to the main menu• Left arrow: switches to the previous submenu screen• Right arrow: switches to the next submenu screen.The colours of the values and symbols have the following meanings:• Value with pink background: set value• Value with blue background: actual value• Green symbol: device in operation• Red symbol: fault• Grey symbol: device shut down.

5.2 Function diagrams submenuThe Function diagrams submenu displays the current operating condition of the CHP module.

5.2.1 CHP overviewAn overview of the installed CHP module is shown in the first function diagram.

Fig. 12 "CHP overview with flow control" function diagram

5.2.2 CHP trend function diagramPressing the r.h. cursor key calls up the CHP trend function diagram.In this function diagram, the engine coolant temperature and the heating water flow and return temperatures for the last minutes are shown in colour in diagrammatic form.

Fig. 13 "CHP trend" function diagram

5.2.3 Buffer tank

Cylinder management function:If the current top buffer temperature [6] drops below the set Start point cylinder (flow) value, the CHP module receives a start demand and begins to fill the buffer cylinder. If the bottom buffer temperature [5] rises above the set Stop point cylinder (return) value, the cylinder is full and the CHP module receives a stop demand ( Fig. 14).

Fig. 14 "Buffer" with 3-way valve function diagram

[1] Set and actual CHP module flow temperature[2] Set and actual CHP module power[3] Return temperature actual value[4] Setting the 3-way valve for flow temperature control[5] Set and actual “Stop point cylinder (return/off)”[6] Set and actual “Start point cylinder (flow/on)”

NOTICE: Material damage due to incorrect settings!▶ The CHP module must be operated by trained

personnel and authorised contractors only.

Subject to the CHP version, not all of the options described below are available.

The values in the displays shown below represent typical examples. These values may vary from the values that are actually displayed.

6720805126-04.1TL

Enclosure temp.

Output red. zero drawn

Return

FlowExtract fan

Nat gas

Exhaust gas HE

Output:

Lambda:

CAT

Air

StartManual Mains onMains offStopAuto

Speed:

Mainsoperation

Only for CHP modules with the buffer cylinder control option activated.

6720805126-06.2TL

FlowEngineReturn

Manual Mains onMains offStopAuto

Start

Mainsoperation

6

5

23

1

4

Mainsoperation

6 720 811 062-08.1TL

Manual Mains on

Mains off

Cylinder

Return

Output

Cylinder:

FlowON:

OFF:

6 720 805 126 (2013/08)CHP CE 240 NA

18 | Menu

5.2.4 CHP mainsPressing the r.h. cursor key calls up the CHP mains function diagram. This function diagram displays information on the power supply and generator as well as the status of the generator circuit breaker (GCB). For CHP modules with the option "emergency power operation", the moulded case circuit breaker ("MCCB") is also shown, together with the voltage and frequency of the emergency power busbar.

Fig. 15 Function diagram for “CHP mains” including all options

G GeneratorGLS Generator circuit breakerNLS Moulded case circuit breaker

(for CHP module with the option "emergency power operation")[1] Generator voltages and frequency. Actual and set cos ϕ (set value

optional)[2] Emergency power busbar voltage and frequency

(for CHP modules with the option "emergency power operation")[3] Mains power supply voltages and frequency.[4] Actual and set mains supply

(only in modules with mains drawing control)[5] Actual and set values for generator output and generator current

5.2.5 GCB synchronisationPressing the right arrow cursor key calls up the GCB synchronisation function diagram.This function diagram shows the differential voltage between the mains and generator, the differential frequency between the mains and generator, and the phase angle between the mains and generator.The display shows the values in digital form on the left and as synchroscopes on the right.

Fig. 16 "GCB synchronisation" function diagram

5.2.6 MCCB synchronisationPressing the right arrow cursor key calls up the MCCB synchronisation function diagram.

In the event of mains failure, the second moulded case circuit breaker isolates the CHP module from the mains. Only then can the generator circuit breaker be switched on and power the CHP module emergency power busbar.Once the mains power supply has been reinstated, the moulded case circuit breaker is switched on without interruption following synchronisation of the mains and generator frequency, voltage and phase angle.

Fig. 17 "MCCB synchronisation" function diagram

As soon as the generator circuit breaker receives a command to switch on, synchronisation between the mains and generator frequency, phase angle and voltage begins. Once all the variables have been synchronised, the generator circuit breaker switches the generator to the mains power supply. The output of the CHP module is then slowly increased to the set value.

70 kW

26.4 V

0 kW1 kW

49.98 Hz

G- 1.00

1.00

393 V392 V393 V

393 V 49.98 Hz

49.98 Hz393 V392 V392 V

69 kW102 A106 A

98 A

Spare busbarBus bar:

Mains:

Grid draw:

Control voltage:

6 720 805 126-12.2TL

3

2

1

45

GLS

GLS

NLS


Start

Mainsoperation

This function diagram is only shown for CHP modules that are designed for "emergency power operation" (isolated operation) and have a second moulded case circuit breaker.

6720805126-09.1TL

Phase angle:

Differential voltage:

Differential frequency:

ReadyGCB synchronisation:

Manual Mains on

Mains offStopAutoStart

6720805126-10.1TL

MCCB synchronisation:

Phase angle:

Diff. volt: Diff. frequency:


Start

Ready

CHP CE 240 NA6 720 805 126 (2013/08)

Menu | 19

5.3 Statistics submenuThe Statistics submenu displays the current operating values, warning and fault histories, the operator's log and the operating temperatures of the latest few hours.

5.3.1 CHP statisticsThis screen collates and displays all the operational data for the CHP module that has been gathered since commissioning.

Fig. 18 "CHP statistics"

Switching cycles GCB refers to the generator circuit breaker (GCB) of the CHP module.A switching cycle includes one start and one stop action of the circuit breaker.The Mains failure count counts every power failure, including those caused by pressing the emergency stop switch or other power failures induced manually at the CHP module.

5.3.2 Current faults/warningsThis submenu displays currently active faults and warnings together with the time and date of their occurrence.

Fig. 19 "Current faults/warnings" statistics

5.3.3 Fault and warning historyThis submenu displays all the faults and warnings that have occurred together with the time and date of their occurrence.

Fig. 20 "History" statistics screen

Displays:• Red font on white background: active fault• Red font on light-blue background: rectified and acknowledged fault• Dark-blue font on white background: active warning• Dark-blue font on light-blue background: acknowledged warning

5.3.4 Operator's logAll commands and messages that have been generated automatically or entered into the control system manually via switches or the touch screen, are archived in the operator's log and indicate the date and time.

Fig. 21 "Operator's log" statistics

Displays:• Black font: INTO messages• Blue font: OUTOF messagesExample from Fig. 21:• The CHP module stopped on 12.08.2009 at 15:23.• Service switch - state = INTO: the service switch was switched off

(set to 0).• Service switch - state = OUTOF: the service switch was switched on

(set to 1).• Manual start - state = INTO: start command entered with the Manual

start user interface.

6720805126-13.1TL

Mains operation

Active energy count:

Switching cycle MCCB1/MCCB2:

Ackn. fault

6 720 805 120-28.1TL

6 720 805 120-29.1TL

Ackn. fault

6 720 805 120-30.1TL

6 720 805 126 (2013/08)CHP CE 240 NA

20 | Menu

5.3.5 CHP temperaturesThis diagram displays the temperatures, the valve position and the CHP output in percent.These values are recorded from the time the CHP control system is commissioned.This archive is not buffered. The values are lost when the control voltage is cut off (emergency stop switch or MCB/fuse).

Fig. 22 "CHP temperatures" diagram

[1] Current operating values[2] Temperature trends for engine temperature, flow temperature,

return temperature, enclosure temperature[3] Scrolling forwards and backwards through the diagram display[4] Jumps to current status[5] Zoom function for changing the scalingThe data is saved once a minute onto an SD card. The diagram is only shown temporarily.

5.4 Settings submenuThe Settings submenu allows you to set the CHP set values.

5.4.1 Calling up setting screens and entering values▶ Press Settings on the user interface.

The first setting screen is displayed (e,g. Output control).

Entering set values▶ Press the field with a pink background to change the set value.

The input mask appears.▶ Enter the set value. The set value must be within the displayed set

value limits.▶ Press the OK key.

The set value is transferred to the control system. The input mask closes.

If you do not change the set value, you can exit the input mask by pressing ESC on the user interface.

Fig. 23 “Output” input mask

Flow Enclosure: 32 °C

Output: 100 %

6 720 805 120-31.1TL

1 2

3 4 5

NOTICE: Material damage due to incorrect settings!Incorrect setting values can result in damage to the CHP module.▶ Only trained personnel and authorised contractors

may change setting values in the CHP control system.

If the set value is outside the permissible limits, it cannot be saved. A fault display is not shown.

6 720 642 999-11.2T

CHP CE 240 NA6 720 805 126 (2013/08)

Menu | 21

5.4.2 Output controlThis setting screen allows the maximum electrical output of the CHP module to be entered.

Fig. 24 "Output control" setting screen (e.g. with mains drawing control)

Mains drawing control

Mains drawing control ensures that only a defined output is drawn from the mains (set mains drawing). The CHP output is varied so that the current mains output always matches the set value. A demand is issued to the CHP module if the power drawn from the mains exceeds the value set as the start point. A stop demand is sent to the CHP module if the power drawn from the mains falls below the value set as the stop point.In this context, positive values indicate power drawn from the mains – negative values indicate power exported to the grid.

5.4.3 Engine coolant control

Engine coolant control regulates the transfer of heat to the external heating system subject to the engine coolant temperature.If the return temperature from the external heating system rises briefly, then the CHP module uses engine coolant control in place to reduce the output to be transferred. This process reduces the shutdown frequency due to the maximum engine temperature being reached.

Fig. 25 "Engine coolant control" setting screen

Input of the start of output reductionIf the engine coolant temperature set here is exceeded, the CHP control system starts to reduce the electrical output until the minimum output at a temperature of 92 °C is reached. If the engine coolant temperature rises to 94 °C, the CHP module shuts down (controlled shutdown). The output reduction is linear.

Entering the minimum output

The minimum output of the CHP module can be changed to any value between 50 % and 100 % of the rated output.

Only for CHP modules with mains drawing control.

Changing the values for power drawn from the mains control can cause cycling of the CHP module. The settings may only be changed by contractors or trained personnel with exact knowledge of the system requirements.

The minimum CHP output value corresponds to 50 % of the CHP module's electrical rated output.

Setting value Setting limitsSet mains drawing Min.: stop point + 10 kW

Max.: start point - 10 kWMinimum difference between start and stop point

Minimum CHP output + 10 kW

Table 8 Setting value limits for mains drawing control

If the difference between the start point and set mains drawing is smaller than the minimum CHP output, mains drawing control cannot achieve the set value for power drawn from the mains. For a CHP module with an output of 50 kW, the differential is 25 kW.

6 720 805 120-8.1TL

Power from mains ctrl (+ : drawn / - : feed-in)

Draw f mains CHP start point

Draw f mains CHP stop point

Set mains drawing

Current mains output

Engine coolant control is only active in automatic mode.

NOTICE: Material damage due to entering incorrect values!Changing a value here can result in the ramping up of the control circuits.▶ Settings must be changed by contractors or trained

personnel only.

6720805126-07.1TL

92

6 720 805 126 (2013/08)CHP CE 240 NA

22 | Menu

HelpThe Help field displays the output reduction in a graph.

Fig. 26 Example "Engine coolant control function"

[1] Maximum output[2] Start of output reduction[3] Minimum output[4] Ctrl shutdown

5.4.4 Extract air ctrlThe start and stop points of the extract air fan are entered in this setting screen. The temperature inside the CHP sound insulation enclosure is captured by a temperature sensor and displayed together with the speed of the extract air fan.

Fig. 27 "Extract air ctrl" setting screen

5.4.5 Controller setting extract fanThe controller for the extract air fan can be set in this setting screen.

Fig. 28 "Controller setting extract fan" setting screen

5.4.6 Flow temperature control

The flow temperature is controlled to the set value via the 3-way control valve in the return.• If the flow temperature falls below the set value, heating water from

the flow is mixed with the return. The flow temperature rises, the gas engine is cooled less and the heating water temperature in the flow increases. If the flow temperature exceeds the set value, heating water from the flow is not mixed with the return.

Fig. 29 "Flow temperature control" setting screen

The temperature differential can be matched to the respective system conditions during commissioning (default value = 3 °C).

In order to ensure good control behaviour, the standard values can be set in Std. controller setting on the user interface. The standard values may differ from the values set during commissioning. ▶ Note down the set values before pressing the user

interface.

Engine coolant temp.

6 720 805 120-14.1TL

6720805126-14.1TL

Extract air ctrl:

Setting of start/stop points of extract air fan

Switching point extract fan ON

Switching point extract fan OFF

Current enclosure temperature

Current speed extract fan


Start

Mains operation

When it is set correctly, a PID-controlled circuit is highly accurate and quick. During commissioning, the controller parameters are matched to the respective local system properties. These settings may only be changed by authorised contractors or trained personnel. Changing parameters can result in the ramping up of control circuits in the control system.

Only for CHP module with the option Flow temperature control".

Config reductionby frequency:

power reduction by frequency mode

Disable VDE 4105

power reduction settings (DIN 4105)

start power reduction frequencypower reduction gradient

Help

50,2 Hz

40,0 %/Hz

50,05 Hz

10 %/min

start frequencyMax. ramp for power increase

6720805126-15.1TL

BDEW

6720805126-16.1TL

Flow temperature control:

The control valve in the return regulates theflow temperature to its set value

Set flow temp.

Current flow temp.

Current return temp.

Current valve position

Current el. output


Start

Mains operation

CHP CE 240 NA6 720 805 126 (2013/08)

Menu | 23

Notice regarding the 3-way valveThe position of the 3-way valve corresponds to the path A-AB and is indicated in percent ( Fig. 30).• Valve position = 20 %:

Minimum allowed valve position for recirculation of hot heating water from the flow into the return.

• Valve position 100 %: The path B-AB is fully closed. No heating water is fed from the flow into the return.

Fig. 30 Flow paths of 3-way valve

[1] 3-way valve

5.4.7 Flow temperature controller settingThe controller for the 3-way valve between flow and return can be set in this setting screen.

Fig. 31 "Controller setting flow temp." setting screen

5.4.8 Lambda servovalve start position

The gas/air ratio in the combustion air mixture is determined by means of the Lambda servovalve. The mixture becomes leaner or richer depending on the position of the valve. The startup behaviour of the engine is influenced by the valve position.

Fig. 32 "Start pos. Lambda servovalve" setting screen

Input Lambda servovalve start positionAfter startup and each time the CHP module is stopped, the stepper motor moves the Lambda servovalve to the start position.New start position run of Lambda servovalveA new start position run is required for the function check of the Lambda servovalve and can be set when the engine is not running.▶ Press New start position run of Lambda servovalve.

The motor of the Lambda servovalve moves to the set start position.

In order to ensure good control behaviour, the standard values can be set in Std. controller setting on the user interface. The standard values may differ from the values set during commissioning. ▶ Note down the set values before pressing the user

interface.

6720805126-17.1TL

Output red. zero drawn

Exhaust HE

Flow

Return

ure temp.tract fan

Mains onMains off

Mains operation

6 720 805 120-39.1TL

When it is set correctly, a PID-controlled circuit is highly accurate and quick. During commissioning, the controller parameters are matched to the respective local system properties. These settings may only be changed by authorised contractors or trained personnel. Changing parameters can result in the ramping up of control circuits in the control system.

NOTICE: Material damage from incorrect settings.Incorrect setting values can result in damage to the CHP module.▶ Only trained personnel and authorised contractors

may change setting values in the CHP control system.

6720805126-19.1TL

Start pos. Lambda servovalve

Adjust position of Lambda servovalveduring engine start

Input start pos. Lambda servovalve (steps)

Current valve position (steps)

Start pos. run only if machine is idle:

New start position runof Lambda servovalve

Mains operation


Start

6 720 805 126 (2013/08)CHP CE 240 NA

24 | Menu

5.4.9 Return temperature start point

The start demand can be generated from the external system return temperature. This requires an additional temperature sensor to be installed immediately upstream of the CHP connection point, in the system return.

Fig. 33 "Start point return temp." setting screen

In automatic mode, a start demand is issued to the CHP module when the temperature falls below the set point. The CHP module runs until controlled shutdown takes place (engine coolant temperature = 94 °C).

5.4.10 Cylinder management

The start and stop demands can be generated from the cylinder temperatures.

Fig. 34 "Cylinder management" setting screen

In automatic mode, a start demand is issued to the CHP module when the temperature falls below the set start point and a stop demand is issued when the set stop point is reached.

5.4.11 Emergency cooler

If the CHP module has to supply power despite the lack of heat transfer (mains draw, emergency power), the heating return is cooled in the case of excessive temperatures.

For CHP modules without a higher-level control system.

NOTICE: Material damage due to frequent starting of the CHP module.The fault 5 x ctrl. shutdown can be triggered if the CHP module is operated too frequently by automatic start and stop demands.▶ Do not set the Start point return temp. too high.

The boiler temperature of any auxiliary peak load boiler must be matched to the set value.

6 720 805 120-43.1TL

Only for CHP modules with buffer cylinders.

For CHP modules with the “Flow temperature control” option, set the Stop point cylinder (return) value lower than the selected Set flow temp. value, otherwise the CHP module cannot fully heat up the cylinder. We recommend using the Set flow temp. as the stop point, minus 15 degrees.

Only for CHP modules which are equipped with an emergency cooling system.

NOTICE: Material damage due to incorrect settings!Changing a value here can result in the ramping up of the control circuits.▶ Settings must be changed by contractors or trained

personnel only.

6 720 805 120-23.1TL

CHP CE 240 NA6 720 805 126 (2013/08)

Menu | 25

Fig. 35 "Emergency cooler" setting screen

To prevent the CHP module from overheating, the set value for the return temperature must be selected in such a way that an adequate supply of cooling heating water is ensured from the return to CHP module.

5.4.12 Oil top-upThe fresh oil solenoid valve can be opened for a maximum of 20 minutes in this setting screen.This function is necessary when changing the oil (installation and maintenance instructions).

Fig. 36 "Oil top-up" setting screen

5.4.13 Configuration reduction by mains frequencyThe output reduction is enabled based on the overfrequencies from a specified mains frequency in this setting screen. Three settings are available:• Disable• To VDE 4105• To BDEW

DisableOutput reduction by mains frequency is disabled. Frequency control and shutdown does not take place. No other settings are required.

Fig. 37 "Config reduction by mains frequency" – Disable

VDE 4105 (low voltage)Output reduction by mains frequency is enabled in accordance with VDE 4105. Output is regulated based on the P(f) curve (following the curve). The following settings are possible:• Start frequency: frequency from which the output is ramped down.• Gradient: value by which the output is ramped down per Hz.• Start frequency: frequency from which the CHP module restarts

following a frequency shutdown.• Maximum ramp: value by which the output is continuously ramped

up.

Fig. 38 "Config reduction by mains frequency" – VDE 4105

These values are preset during commissioning.

Oil changes may only be carried out by the manufacturer or authorised contractors.▶ Only top up the oil when the engine is at a standstill.

6720805126-22.1TL

Emergency cooler:

Htg. return is cooled in emergency mode byemergency cooler when temperatures are excessive.

Set return temp


Current el. output

Mains operation


Start

6 720 805 120-24.1TL

Mainsoperation

The output reduction default is set at the factory. It is not possible for the user to change it.



Disable VDE 4105 BDEW

6720805126-11.1TL

Mainsoperation



Disable VDE 4105

power reduction settings (DIN 4105)

start power reduction frequencypower reduction gradient

Help

50,2 Hz

40,0 %/Hz

50,05 Hz

10 %/min

start frequencyMax. ramp for power increase

6720805126-15.1TL

BDEW

6 720 805 126 (2013/08)CHP CE 240 NA

26 | Menu

To BDEW (medium voltage)Output reduction by mains frequency is enabled in accordance with BDEW. The following settings are possible:• Start frequency: frequency from which the output is ramped down.• Gradient: value by which the output is ramped down per Hz.• Enabling frequency: frequency from which the frequency is ramped

up.

Fig. 39 "Config reduction by mains frequency" – BDEW

Help▶ Press Help on the user interface.The output reduction by mains frequency with the previously set values is displayed in a graph.

Fig. 40 Example "Output reduction based on the P(f) curve"

[1] Frozen output from which output reduction starts[2] Frequency from which the output is ramped down[3] Current CHP output[4] Current frequency[5] Frequency from which the output can be ramped up again

(BDEW only)[6] Countdown delay after mains off: once the time until enable has

passed, the CHP module can be put back into mains parallel operation

5.4.14 Cos ϕ curve entryThe network operator can give a cos j curve with max. 5 grid points. The given values are set in the following setting screen:

Fig. 41 "Cos j curve" setting screen (in the example according to VDE 4105)

5.4.15 Date/TimeThis setting screen allows the current date and time to be entered.The correct date and time are important as all status and fault displays are filed with the date and time in the Statistics menu.

Fig. 42 "Date and time" setting screen

50,20 HZ

40,0 %/HZ

50,05 Hz

6 720 805 126-05.1TL



Disable VDE 4105

power reduction settings (BDEW)

start power reduction frequency

Help

power reduction gradient

power increase frequency

BDEW

Curve P(f):

BACK

Delta P = 40% Pm pro Hz(VDE 4105: curve

BDEW: incr.power if f < 50,05 Hz)Frequency limit

50,20 Hz0,0 %

100,0 % 0,00 Hz

0 Sek.

Initial value forreduction P(f)

current load from curve P(f)delta P

f Mains

countdown delay after mains off

5

6

1

432

6 720 805 120-16.1TL

Type of output reduction Setting range cos jTo VDE 4105 –0.9...1.0...+0.9To BDEW –0.95...1.0...+0.95

Table 9

6720805126-08.2T

Edit curve cos Phi (P):Set point value range for cos Phi

range: - 0,9 ... 1.0 ... + 0,9neg. cos Phi = under-excited

cos Phi at min. 50% (25 kW) power 1.001.001.001.001.001.00

cos Phi at 60% (30 kW) powercos Phi at 70% (35 kW) powercos Phi at 80% (40 kW) powercos Phi at 90% (45 kW) power

cos Phi at 100% (50 kW) power

Actual set point: 1.00Current output: 0 %

Actual value: 1.00

Mainsoperation

6 720 805 120-25.1TL

CHP CE 240 NA6 720 805 126 (2013/08)

Menu | 27

▶ Press Time setting on the user interface.The setting screen for entering the date and time is displayed.

Fig. 43 "Date and time" setting screen

▶ Change the values.▶ Press Adopt date and time on the user interface.

The selected values are saved.

5.5 Manual level submenu

5.5.1 Calling up the manual level▶ Press Manual level on the user interface.

The first Manual level screen is displayed.

5.5.2 ExhaustIn this screen you can manually adjust the speed of the extract air fan.

Fig. 44 "Manual extract air"

▶ To adjust the speed manually, press the Extract fan set to manual user field. The background colour of the user field changes from grey to green.Then the speed set in the Set extract fan to manual input field is regulated to the set value.

5.5.3 Lambda servovalveTo change the ratio of the gas-air mixture, move the Lambda servovalve manually to OPEN or CLOSE. If the Lambda servovalve moves towards OPEN, the proportion of the gas is increased, making the mixture richer.If the Lambda servovalve moves towards CLOSE, the proportion of the air rises, making the mixture leaner.

Fig. 45 "Manual Lambda servovalve"

5.5.4 Flow temp. servovalveThe servovalve for flow temperature control can be manually adjusted for test purposes on this screen.For a detailed description of flow temperature control, see Chapter 5.4.6, from page 22.

Fig. 46 "Manual flow temp. servovalve"

▶ Press user field Valve set to manual.The background colour of the user field changes from grey to green.

▶ Change valve position in the Set valve to manual input field. Value range: 20...100 %.

You must switch between summertime and wintertime manually.

Exiting the Manual level screens automatically stops manual mode.

Adopt date and time

6 720 805 120-26.1TL

6720805126-23.1TL

Manual extract air:

Manual mode active as long as this window is shown!

Extract fan set to manual:

Extract fan control ON

Set extract fan to manual

Current enclosure temperature

Mainsoperation

NOTICE: Material damage due to incorrect settings!The catalyst can become damaged by excessive temperature.▶ When you adjust the Lambda servovalve, observe

the temperature downstream of the catalyst.

6720805126-24.1TL

Manual Lambda servovalve:


Current valve position (steps)

Current Lambda signal

Temp downstr of catalyst

Stop Stop

Servovalve OPEN Servovalve CLOSE

Mainsoperation

6720805126-25.1TL

Manual flow temp. control:


Input manual valve position

Current flow temp.


Valve set to manual:

Valve ctrl. ON

Mainsoperation

6 720 805 126 (2013/08)CHP CE 240 NA

28 | Menu

5.6 Language submenuThe menu language can be selected in the Language submenu.

Fig. 47 Language submenu

▶ Select the Language submenu.The setting screen is displayed.

▶ Press the required country key.The language you have selected is saved. The display switches to the main menu automatically.

5.7 Service

▶ Press Service on the user interface.The Code setting screen is displayed.

5.7.1 Service Code

Fig. 48 Service “Code”

Entering the codeEntering the code unlocks a protected service area. Extensive changes to the control system can be made in the service area.

Reset delay after mains offThis function is only available for CHP modules with the“ VDE 4105 low voltage” option.The CHP module was switched off following a mains failure or stopped via mains monitoring. The CHP module is ready to start after a delay of 1...10 minutes. In accordance with German Low Voltage Directive VDE 4105, the delay can be acknowledged during commissioning or servicing.▶ Press Reset delay after mains off on the user interface.

The delay is set to 0. The CHP module is ready to again.

Scout battery voltageThe storage battery voltage in the control system is displayed.If the storage battery voltage < 2500 mV:▶ Replace the battery during the next maintenance work.

6 720 805 120-10.1TL

Language selection

NOTICE: System damage due to incorrect operation!▶ Changes must only be made in the service menu by

the manufacturer or authorised contractors.

The Service submenu is protected by a code.

Code:

Code input:

Batt. Scout:

0

180 Sek

3112 mV

Reset delay after mains off

6 720 805 120-17.1TL

CHP CE 240 NA6 720 805 126 (2013/08)

Decommissioning | 29

6 Decommissioning

6.1 Stopping the CHP moduleThe CHP module must be switched to manual mode before it can be shut down. This is the only way that the CHP module can be disconnected from the mains supply and the gas engine stopped.

6.1.1 Switching to manual modeWhen the CHP module is in automatic mode and Start and Mains on are active on the user interface, the CHP module can be switched to manual mode without any interruption.

▶ Press Mains on on the user interface.▶ Press Start on the user interface.▶ Press Manual on the user interface.

The operating mode switches to manual mode without any interruption.

Fig. 49 Shutting the CHP module down

[1] Mains on field[2] Start field

6.1.2 Disconnecting the generator circuit breakerPrerequisite: The CHP module is in manual mode.▶ Press Mains off on the user interface.

The generator output is ramped down to 0 kW. The generator breaker switch disconnects the CHP module from the mains power supply. Idle is shown on the status display.

6.1.3 Stopping the gas engine in manual modePrerequisite: The CHP module is in manual mode.▶ Press Stop on the user interface.

The gas engine stops. Ready is shown on the status display.▶ Set the service switch on the control panel to 0 (maintenance).

Fig. 50 Service switch in position 0

▶ Remove the key.The CHP module is prevented from being reconnected unintentionally.

▶ Close the gas isolation valve on the CHP module.

Fig. 51 Gas isolation valve closed

6.2 Temporarily taking the system out of useIf the system is to be taken out of use for more than 12 weeks, protect the CHP module against environmental influences.▶ Close vents.▶ Seal off the exhaust pipe (plug-in disc).▶ Separate the condensate hose at the hose connection.▶ Have the licensed contractor protect the CHP module.▶ Open the electrical connection at the on-site circuit breaker.▶ Attach an information sign to the CHP module.▶ Ensure that the surroundings are clean and dry.

NOTICE: Frost damage!The CHP module can freeze up in cold weather if it is switched off. To protect the CHP module from freezing:▶ Open the air vent at the highest point in the CHP

module.▶ Drain the heating water from the lowest point in the

CHP module.▶ Check that the engine coolant contains enough

antifreeze.

If the CHP module is switched to manual mode when Mains on is active on the user interface but without a prior start demand, the CHP module stops immediately.

26 720 805 120-66.1TL

Mainsoperation



6 720 647 284-07.1TL

6 720 805 126 (2013/08)CHP CE 240 NA

30 | Decommissioning

Treatment of batteriesIf the CHP module is to be shut down for a longer period of time, batteries can severely discharge.

There are 2 options to prevent deep discharge:• Keeping the CHP module connected to the mains ensures that the

battery charger continues to be supplied with power. • Disconnecting the battery.

6.3 Shutting down the CHP system in an emergency

Pressing the emergency stop switch interrupts the power supply to the CHP module immediately. Interrupting the power supply has the following effects:• The solenoid valve immediately interrupts the gas supply.• The generator circuit breaker opens and disconnects the CHP

module from the mains.• The gas engine stops.

Fig. 52 Emergency stop switch

[1] Emergency stop switch

Batteries will be irreversibly destroyed by long periods of inactivity.

NOTICE: In an emergency:Life-threatening situations can arise in emergencies (e.g. in the event of a fire). The following applies irrespective of the shutdown procedure described:▶ Never put your life at risk.▶ Press the emergency stop switch



6 720 647 284-06.1TL

CHP CE 240 NA6 720 805 126 (2013/08)

Environmental protection and disposal | 31

7 Environmental protection and disposalEnvironmental protection is a key commitment of the Bosch Group. Quality of products, efficiency and environmental protection are equally important objectives for us. All legislation pertaining to the environment is strictly observed. To protect the environment we use the best possible technology and materials, subject to economic considerations.

PackagingWhere packaging is concerned, we participate in country-specific recycling systems that ensure optimal recycling. All of our packaging materials are environmentally compatible and can be recycled.

Old appliances and components that have been replacedOld appliances and replaced components contain materials that should be recycled. The assemblies are easily separated and the types of plastic are clearly marked. Individual assemblies can easily be sorted and put into recycling and disposal systems.

Disposal of engine oilUsed engine oil, filters or other parts covered in oil must be stored by the operator or service contractor at designated oil collection sites and regularly disposed of in an environmentally responsible manner.

The operator is responsible for ensuring that the CHP system is operated in a safe and environmentally friendly manner.

Record and archive your disposal confirmations issued by the disposal firm.

6 720 805 126 (2013/08)CHP CE 240 NA

32 | Service

8 ServiceCorrectly operating a CHP module requires the performance of regular service and maintenance work in accordance with the manufacturer's instructions ( installation and maintenance instructions).

We recommend that you enter into a service or maintenance contract with the manufacturer or a contractor authorised by the manufacturer.

Only the manufacturer or contractors who have been trained and authorised by the manufacturer may carry out service and cleaning work inside the sound insulation enclosure!Cleaning work outside the sound insulation enclosure can be carried out following simple instructions.

Failure to observe the maintenance intervals will result in a loss of warranty protection.

To prevent system damage:▶ Rectify the causes of faults immediately.

On account of its automatic operation (automatic start) processes, all service and repair work on CHP modules requires advanced technical and subject-specific know-how. Consequently, all service or repair work must only be carried out after full training has been received.

DANGER: Risk to life due to automatic CHP module start-up (e.g. following an external start demand).In order to shut down the CHP module, e.g. for service work, and to prevent it from restarting intentionally ( Chapter 6, page 29):▶ Set the service switch on the control panel to 0

(maintenance).▶ Remove the key from the service switch.

The installation instructions contain information regarding possible faults and warnings. Faults and warnings must be rectified by an authorised contractor only.You can find the installation instructions in the system documentation.

CHP CE 240 NA6 720 805 126 (2013/08)

Service | 33

8.1 Setting values

Unit Date: Date: Date: Date: Date: Date: Date:

Output control

Maximum output kW

Power from mains ctrl (optional)

CHP start point kW

CHP stop point kW

Set mains drawing kW

Engine coolant control

Start at °C

Minimum output kW

Extract air ctrl

Extract fan ON °C

Extract fan OFF °C

Extract fan controller

KP

TN

TVs

Flow temperature control

Flow temperature °C

Flow temperature controller

KP

TN

TVs

Table 10 Setting values

6 720 805 126 (2013/08)CHP CE 240 NA

34 | Service

Lambda servovalve

Lambda servovalve start position

Steps

Start point return temp (optional)

Start point return temperature °C

Cylinder management (optional)

Start point cylinder (flow) °C

Stop point cylinder (return) °C

Emergency cooler (optional)

Set return temp °C

Mixture cooling (only 400 NA)

Mixture temperature set value °C

Reduction by mains frequency (option)

Select:

o VDE 4105 o BDEW

Cos j curve entry

Cos j up to min. output 50%

Cos j at 60%

Cos j at 70%

Cos j at 80%

Cos j at 90%

Cos j at 100%


Table 10 Setting values

CHP CE 240 NA6 720 805 126 (2013/08)

Service | 35

8.2 Operating values


Engine temperature °C

Flow temperature °C

External return temperature °C

Return temperature °C

Valve %

Output kW

Exhaust downstr. KAT °C

Exhaust downstr. HE °C

Mixture temperature °C

Coolant pressure bar

Hours run

Start pulse

Switching cycles GCB

Average runtime

Maintenance

Mains failure

Ctrl shutdown

Active energy count MW

Gas meter m3

Heat count MW

Butterfly valve %

Oil level cm

Table 11 Operating values

6 720 805 126 (2013/08)CHP CE 240 NA

Bosch TermotechnologyCotswold Way, Warndon, Worcester WR4 9SW

All Enquiries: 0330 123 3004www.bosch-industrial.co.uk

chp ce - london borough of havering · 4 | explanation of symbols and safety instructions 6 720 805...

Documents