Vitobloc BACnet/IP Gateway - Viessmann · Installation and operating instructions for contractors Vitobloc BACnet/IP Gateway CHP unit accessory for VITOBLOC 200 50 to 530 kW el 5671

Installation and operating instructions for contractors

Vitobloc BACnet/IP Gateway

CHP unit accessory for VITOBLOC 200

50 to 530 kWel

5671 514-1 01/2015

Imprint

2 CHP unit accessory • Installation and operating instructions • BACnet/IP Gateway • VITOBLOC 200

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NOTE

The Vitobloc 200 CHP unit is not suitable for 60 Hz operation. It is therefore not available for the American and Canadian markets in particular.

Note:

This technical guide contains instructions for design engineers regarding the design, use and operating conditions of a CHP unit.

For technical details please refer to the individual product catalogue, or for implementation planning, refer to the relevant technical unit description.

For assistance with preliminary work during the project planning phase please contact our advisers.

Subject to technical modifications.

Continuing development may result in minor differences in the illustrations, operating steps and specifications.

Updating the documentation

Please let us know if you have any suggestions for improving our documentation, or if you have noticed any errors.

Manufacturer’s address

Viessmann Werke GmbH & Co.KG D-35107 Allendorf Telephone +49 (0)6452 70-0 Fax: +49 (0)6452 70-2780 www.viessmann.de

Publication date: 01/2015

http://www.viessmann.de/


Table of contents

VITOBLOC 200 CHP unit accessory • Installation and operating instructions • BACnet/IP Gateway 3

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Table of contents

1. Safety instructions ................................................................................................................ 4

2. Function ................................................................................................................ 5

3. Type ................................................................................................................ 5

4. Installation 4.1 Mounting rail installation .................................................................. 6 4.2 Power supply ................................................................................... 8 4.3 Connecting the floating digital outputs ............................................. 9 4.4 Connecting the interfaces................................................................10

5. BACnet / IP 5.1 Data points.......................................................................................11 5.2 Sensor assignment by type of CHP unit .........................................16

6. Commissioning ...............................................................................................................18

7. Maintenance ...............................................................................................................18

8. Disposal ...............................................................................................................18


Safety instructions

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1 Safety instructions

General These operating instructions contain general information that must be observed

during installation, operation and maintenance. They must therefore be read by the installer and relevant qualified technician(s) prior to installation and commissioning. They must always be available at the system.

Identification of safety instructions

Caution Note

Failure to observe the safety instructions identified with this hazard symbol in these installation and operating instructions may result in risks to personnel.

Failure to observe the safety instructions identified with this symbol may result in risks for the device or the system and its functions.

This symbol indicates information that will simplify work and ensure safe operation.

Personnel qualifications

The personnel designated to operate, maintain, inspect and install this equipment must have the appropriate qualifications for such work. The system operator is responsible for ensuring that this is the case.

The safety instructions listed in these operating instructions must be observed, as must all applicable national regulations for accident prevention and any in-house working, operating or safety instructions issued by the operator.

Risks from failure to observe the safety instructions

Safety instructions for the operator (risk analysis according to EN 12100)

Safety instructions for maintenance, inspection and installation work

Failure to observe the safety instructions may result in risks to personnel as well as to the environment and the system.

LIABILITY

The manufacturer will not accept any liability if these safety instructions are not observed.

In particular, failure to observe these instructions may pose the following risks:

Failure of important system functions

Failure of prescribed methods of service and maintenance

Risks to personnel due to electrical and mechanical effects

Electrical hazards

Hazards arising from electrical current, e.g. as a result of removing safety covers, must be prevented.

The operator must ensure that all maintenance, inspection and installation work is carried out by authorised, qualified personnel who have used the operating instructions to acquaint themselves with the device.

In principle, work may only be carried out on the device when the CHP unit is in an idle state and isolated from the power supply.

Directly after work has been completed, all safety and protective equipment must be replaced and returned to full function.


Function

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Unauthorised modifications and production of spare parts

Alterations or modifications to the device are only permissible following consultation with the manufacturer. Original spare parts and accessories authorised by the manufacturer are important to ensure safety. Use of other parts can void the liability for any resulting losses.

Impermissible operation

The device may only be used for the specified purpose. Any installation for an unspecified purpose is strictly prohibited.

2 Function

General The device makes the data from a Vitobloc 200 CHP unit, which is read via the

RS-232, available on the BACnet/IP.

Fig. 1 Schematic diagram of the device

3 Version

Standard delivery The device is a compact unit for installation on a mounting rail.

The mounting rail and fittings are included in the standard delivery of the device.

On-site connection

(building management system)

CHP

unit


Installation

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4 Installation

General operating conditions

The device is always installed in a de-energised state with the wiring disconnected.

In order to ensure fault-free operation of the device, the following conditions must be met and maintained:

Do not use in locations with aggravated operating conditions, such as

corrosive steam or gas, dust formation or high ionising radiation

Permissible ambient temperature during operation 0 °C to +55 °C

Any installation position

Permissible ambient temperature during storage -25 °C to +85 °C

Permissible relative humidity during storage 95 %, without condensation

Caution An earth terminal is required on the profile rail.

4.1 Mounting rail installation

General After removing the packaging, check the device for any transport damage.

Mount the top-hat rail on a clean surface and do not place it under stress.

Caution Drilling swarf, screws and other foreign bodies must be prevented from entering the device.

Install it away from thoroughfares, but ensure there is still easy access.

Protect the device from direct insolation.

Caution Ensure there is adequate heat transfer.

Installing the mounting rail With unit types EM-18/36, EM-20/39, EM-50/81 and EM-70/115, the Vitobloc Gateway must be installed in an external terminal box.

With larger CHP units that have ratings of 140 kWel or more, the mounting rail may be installed in the control panel of the CHP unit.

Fig. 2 Gateway on the side panel of the EM-140/207 CHP unit control panel

Fig. 3 Gateway in the control panel door of the EM-238/363 CHP unit


Installation

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Installing the Gateway Pull the white tabs on the underside of the device downwards until they latch

into place

Push the device onto the top-hat rail

Do not apply pressure to the display as this risks Caution damaging it

Push the white tabs back into their original positions

Once the device has been successfully installed, connect it according to the connection diagram, taking account of the safety instructions

Removing the Gateway The Vitobloc Gateway is always removed in a de-energised state with the wiring disconnected.

Pull the white tabs on the underside of the device downwards until they

unlock

Pull out the orange tabs on the right-hand side of all the terminals in order to release them from the mounting rail

Grip the terminals simultaneously with your thumb and index finger at the top and bottom of the ribbed casing surfaces and pull from the mounting rail


Installation

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4.2 Power supply

Before switching on the power supply, ensure that the components are clean and have been mounted in the correct order on the top-hat rail.

Order from left to right:

CX 9000

KL 2794

KL 9010

Fig. 4 BACnet / IP Gateway

Caution The device requires a voltage of 24 V DC (-15 %/+20 %), connected to an isolated power source protected by a max. 4 A fuse.

Connecting the power supply

Fig. 5 Power supply of the Vitobloc BACnet / IP Gateway

The 24 V DC power supply for the Gateway is connected via the contacts labelled 24 V and 0 V as well as the + and - contacts.

The spring-loaded terminals are designed for wires with a cross-section of between 0.08 and 2.5 mm² (stripped back by 8 to 9 mm).


Installation

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4.3 Connecting the floating digital outputs

KL 2794 The KL 2794 has 4 floating digital outputs. Output 1 switches terminals 1 and 2;

output 2 terminals 5 and 6; output 3 terminals 3 and 4; and output 4 terminals 7 and 8 to continuity. The 4 outputs can be used freely (e.g. for calling the CHP unit)

Fig. 6 KL 2794

Signal-LED1

Contact allocation Plan view

Output 3

Power contact 0 V Output 3

Power contact + 24 V

Output 1

Output 4

Output 4

Output 2

Output 2 Output 1

Signal-LED4

Signal-LED2

Signal-LED3


Installation

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4.4 Connecting the interfaces

RS232 interface The RS232 interface is marked COM1 and is connected with the RS232

interface of the CHP unit via the null modem cable provided.

Connecting cable between CHP unit and Gateway

CHP unit Sub-D 9-pole socket

GATEWAY Sub-D 9-pole socket

2: RxD

3: TxD

3: TxD

2: RxD

5: GND

5: GND

Tab. 1 Connecting cable between CHP unit and Gateway

Note Cable to RS232 standard.

Ethernet interface The CHP unit data is supplied to the BACnet / IP via the Ethernet interface. The device has 2 RJ-45 Ethernet ports, designated X001 and X002. The two ports behave like a switch. Thus the Ethernet cable can be routed further to an additional device. A commercially available Ethernet cable can be used to make the connection (4x2 Category 5 twisted pair copper cable – max. cable length 100 m).

The following IP settings are factory-set:

IP address: 192.168.4.78

Subnet mask: 255.255.255.0

To change the IP settings, the "cerhost" program is required; this can be downloaded from the Beckhoff website.

Link to the latest version: ftp://ftp.beckhoff.com/Software/embPC-Control/CE/Solutions/RemoteDisplay/CeRemDispHost.zip

This is a remote desktop software program which enables the installed Windows Ce user interface to be operated. The network settings in Windows Ce are performed in exactly the same way as in Windows XP.

ftp://ftp.beckhoff.com/Software/embPC-Control/CE/Solutions/RemoteDisplay/CeRemDispHost.zip




BACnet / IP

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5 BACnet / IP

The Gateway makes all data points of the CHP unit's RS232 interface available on the BACnet / IP. Four floating digital outputs for switching purposes (e.g. for calling the CHP unit) are also provided.

5.1 Data points

Designation BACnet type Content / remark

Mode Multistate input 1: OFF 2: manual 3: auto

Status Multistate input 1: OFF 2: ready 3: start 4. operation 5: fault

Operating mode Multistate input 1: OFF 2: manual 3: mains substitute 4: --- 5: selection 100 % 6: set value 0-100 %

Set_value_modulating_operation Analogue input

Fault

Multistate input The first fault reported during a malfunction until all faults have been acknowledged again.

Hours run Analogue input

Minutes run Analogue input

Starts Analogue input

Maintenance interval Analogue input

Unit lockout Analogue input

Advance warning time Analogue input

Next_service

Analogue input Indicates when the next service is due, expressed in hours run. (Next_service - hours run = number of hours run until next service)

NiCrNi_A Analogue input *1

NiCrNi_B Analogue input *1

NiCrNi_C Analogue input *1

NiCrNi_D Analogue input *1


BACnet / IP

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Designation BACnet type Content / remark

PT100_1 Analogue input *1






Battery voltage Analogue input

Oil pressure Analogue input

Lambda probe voltage Analogue input

Speed Analogue input

Temperature_controller Analogue input

Temperature_enabling Analogue input

Mains_voltage_L1 Analogue input



Gen._voltage_L1 Analogue input



Gen._current_L1 Analogue input



Mains_voltage_total Analogue input

Generator_voltage_total Analogue input

Gen._current_total Analogue input

Output Analogue input

Mains frequency Analogue input

Gen._frequency Analogue input

CosPhi Analogue input

Communication fault Binary input

Digital_output1 Binary output Freely usable floating digital output




*1 The temperatures for NiCrNi and PT 100 are assigned differently, depending on the unit type. (See chapter "Sensor assignment by type of CHP unit")

Tab. 2 BACnet data point list


BACnet / IP

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5.1.1 Multistate faults

Value Designation Comments

1 No fault

2 Emergency stop

3 Min. oil level

4 Min. coolant pressure

5 Min. gas pressure

6 Safety temperature

7 Generator temperature

8 Silencer hood temperature

9 Fan fault

10 Coolant pump fault

11 Max. exhaust gas back pressure

12 Feed-in switch

13 External fault

14 Speed too high

15 Coolant temperature

16 Max. exhaust gas temperature

17 Min. exhaust gas temperature

18 Min. oil pressure

19 Max. gas pressure

20 Heating water pump fault

21 Start-up speed <50 rpm

22 Ignition speed

23 Speed window

24 Speed <1200 rpm

25 Start-up fault

26 Synchronisation fault

27 Speed <50 per pickup

28 Max. oil level

29 Max. temperature Pt100_2

30 Max. temperature Pt100_3

31 Max. output

32 Reverse output

33 Output controller fault

34 Lambda controller fault

35 Generator contactor fault

36 Ignition fault

MelanieGermaney

Comment on Text

This was 7 in the file you sent me. We have changed it to keep the chronological order.


BACnet / IP

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Message Designation Comments

37 Oil pressure fault

38 Lambda start position

39 Knocking ON

40 Knocking OFF

41 Time switch deselection Disabled

42 Time switch enabling Disabled

43 Mains fault F < Disabled

44 Mains fault F > Disabled

45 Mains fault U+F <> Disabled

46 Min. knocking output

47 Max. knocking output

48 Mains coupling switch

49 Knocking fault

50 Mains OK Disabled

51 Mains fault Disabled

52 Temperature deselection Disabled

53 Temperature enabling Disabled

54 Service overdue

55 Safety shutdown

56 Engine not idle

57 Battery undervoltage

58 Generator undervoltage

59 Generator overvoltage

60 Generator overcurrent

61 Generator out-of-balance load

62 Tightness test fault

63 Mains circuit breaker fault

64 Sensor fault

65 Max. exhaust gas temperature A

66 Min. exhaust gas temperature A

67 Max. exhaust gas temperature B

68 Min. exhaust gas temperature B

69 Max. exhaust gas temperature C

70 Min. exhaust gas temperature C

71 Max. exhaust gas temperature D

72 Min. exhaust gas temperature D

73 Exhaust gas temp. differential A/B


BACnet / IP

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Message Designation Comments

74 Reserve

75 Max. return temp. PT100/2

76 Max. heating water temp. PT100/3

77 Max. engine oil temp.

78 Max. gas mixture temp.

79 Max. coolant mixture temp.

Tab. 3 Fault messages

5.1.2 EDE files

The EDE files are available on request.

BACnet / IP

16 CHP unit accessory • Vitobloc BACnet/IP Gateway

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5.2 Sensor assignment by type of CHP unit

Sensor

EM-18/36 / EM-20/39

EM-50/81

EM-70/115

EM-140/207

NiCrNi / A

Exhaust gas temperature Exhaust gas temperature

Exhaust gas temperature


NiCrNi / B

- - - - - - - - - - - - - -

- - - - - - - - - - - - - -

- - - - - - - - - - - - - -

- - - - - - - - - - - - - -

NiCrNi / C

- - - - - - - - - - - - - -

- - - - - - - - - - - - - -

- - - - - - - - - - - - - -

- - - - - - - - - - - - - -

NiCrNi / D

- - - - - - - - - - - - - -

- - - - - - - - - - - - - -

- - - - - - - - - - - - - -

- - - - - - - - - - - - - -

PT 100 / 1

Coolant

Coolant

Coolant

Coolant

PT 100 / 2

Heating water return




PT 100 / 3

Heating water

Heating water

Heating water

Heating water

PT 100 / 4

- - - - - - - - - - - - - -

- - - - - - - - - - - - - -

- - - - - - - - - - - - - -

- - - - - - - - - - - - - -

PT 100 / 5

- - - - - - - - - - - - - -

- - - - - - - - - - - - - -

- - - - - - - - - - - - - -

- - - - - - - - - - - - - -

PT 100 / 6

- - - - - - - - - - - - - -

- - - - - - - - - - - - - -

- - - - - - - - - - - - - -

- - - - - - - - - - - - - -

Tab. 4 Sensor assignment overview

Sensor

EM-199/263

EM-199/293

EM-238/363

EM-363/498

NiCrNi / A

Exhaust gas upstream of turbo

Exhaust gas upstream

of turbo

Exhaust gas A


of turbo A

NiCrNi / B

Exhaust gas downstream of turbo

Exhaust gas downstream

of turbo

Exhaust gas B


of turbo B

NiCrNi / C

Exhaust gas downstream of cat.


of cat.


of cat.


of cat.

NiCrNi / D

- - - - - - - - - - - - - -

- - - - - - - - - - - - - -

- - - - - - - - - - - - - -


PT 100 / 1

Coolant

Coolant

Coolant

Coolant

PT 100 / 2





PT 100 / 3

Heating water

Heating water

Heating water

Heating water

PT 100 / 4

Engine oil temperature




PT 100 / 5

Gas mixture temperature


- - - - - - - - - - - - - -


PT 100 / 6

Coolant mixture inlet


- - - - - - - - - - - - - -



ESS Energie Systeme & Service GmbH Amendments a

BACnet / IP


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Sensor

EM-401/549

BM-36/66

BM-55/80

NiCrNi / A

Exhaust gas upstream of turbo A



NiCrNi / B

Exhaust gas upstream of turbo B

- - - - - - - - - - - - - -

- - - - - - - - - - - - - -

NiCrNi / C

Exhaust gas upstream of cat.

- - - - - - - - - - - - - -

- - - - - - - - - - - - - -

NiCrNi / D


- - - - - - - - - - - - - -

- - - - - - - - - - - - - -

PT 100 / 1

Coolant

Coolant

Coolant

PT 100 / 2




PT 100 / 3

Heating water

Heating water

Heating water

PT 100 / 4


- - - - - - - - - - - - - -

- - - - - - - - - - - - - -

PT 100 / 5


- - - - - - - - - - - - - -

- - - - - - - - - - - - - -

PT 100 / 6


- - - - - - - - - - - - - -

- - - - - - - - - - - - - -


Sensor

BM-190/238

BM-366/437

NiCrNi / A

Exhaust gas upstream of turbo

Exhaust gas upstream of turbo A

NiCrNi / B


Exhaust gas upstream of turbo B

NiCrNi / C

- - - - - - - - - - - - - -


NiCrNi / D

- - - - - - - - - - - - - -

- - - - - - - - - - - - - -

PT 100 / 1

Coolant

Coolant

PT 100 / 2



PT 100 / 3

Heating water

Heating water

PT 100 / 4



PT 100 / 5



PT 100 / 6




18 CHP unit accessory • Vitobloc BACnet/IP Gateway

Commissioning

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6 Commissioning

The device is commissioned as part of the general commissioning of the CHP plant or, in the case of retrofitting, by the CHP unit manufacturer's technical service personnel.

7 Maintenance

This accessory is maintenance-free.

8 Disposal

This product and its components must be disposed of in an environmentally responsible manner. Use public or private waste disposal companies.

ESS Energie Systeme & Service GmbH Amendments a


Notes

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Viessmann Werke GmbH & Co KG D-35107 Allendorf Telephone +49 (0)6452 70-0 Fax: +49 (0)6452 70-2780 www.viessmann.de

20

Viessmann Limited Hortonwood 30, Telford Shropshire, TF1 7YP, GB Tel: +44 1952 675000 Fax: +44 1952 675040 E-mail: [email protected]



Documents

Vitobloc BACnet/IP Gateway - Viessmann · Installation and operating instructions for contractors Vitobloc BACnet/IP Gateway CHP unit accessory for VITOBLOC 200 50 to 530 kW el 5671