The technological and engineering solutions we have implemented in our smartblocks, are truly innovative in many respects.
Check out these details that make our smartblocks unique, here.
Gas Stream Combustion
The newly developed GSC (gas stream combustion) technology defines the heartbeat of the smartblock motors. This innovative combustion technology and procedure provides for a complete flaming and combustion of the chamber, which has been reduced to a minimum volume and surface. The uniform combustion and the thermodynamic efficiency will reach maximum peaks.
The result is the smartblockmotor. Stable, robust, resilient, highly efficient and service-friendly.
*The new GSC technology has been registered for patenting and already protected as a trademark.
Depending on the CHP version either synchronous or asynchronous generators are used. For smartblocks used exclusively in grid parallel mode the water-cooled asynchronous generator is the ideal solution.
It features a simple design with very few wear and tear parts. The water-cooling of the redundant heat loss of the generator is used as an additional heat source.
All smartblocks are available either as a grid substitutions or insular system. The special smartblock types designated with a trailing “s” are fitted with air-cooled synchronous generators. Because of their electronic voltage and cosφ regulator they are technically more sophisticated, but they can be used in normal grid parallel mode as well as independently from the public electricity supply grid.
The Central Valve Mixer
The gas mixer has the task of supplying the motor with a gas air mixture as homogenous as possible. The central valve mixer system was especially developed for our smartblocks excels due to its robust construction, ease of adjustment and excellent mixing properties, and guaranteeing a virtually mixture ration over the entire performance range.
In order to maintain the precise lambda value the CHP controller can affect most precise adjustments in the ppm (parts per million) range.
Permanent oil monitor
All smartblocks are fitted with a fully automatic oil circulation system. The core component is a newly developed oil system module into which a multitude of functions have been integrated. This module maintains a constant level of motor oil during the entire running time. It replenishes the motor oil consumed in the engine, controls the oil circulation between the motor and the external oil vessel, and it filters the oil during the circulation by means of an additional auxiliary flow fine filter.
In addition, the module issues timely warnings in case the oil level falls below the correct value. The advantage of the oil circulation system is not only the constant oil level, but especially a substantial increase of the motor oil volume by employing the additional external motor oil tank. The increased oil volume in conjunction with the auxiliary flow fine filter reduces stress on the engine and provides for extended oil change intervals.
The lifetime of the oil is also extended because the main volume of the oil is stored in the external oil tank at relatively low temperatures.
The Exhaust Gas Heat Exchanger
A further milestone in the construction of the smartblock was the patent pending exhaust gas heat exchanger module. A number of conventional assemblies combined and installed in CHPs has been combined in a single, revolutionary and compact module.
The water-cooled exhaust gas manifold, the monitoring of the coolant vessel level, the 3-way catalytic converter, the broadband lambda probe, the exhaust gas temperature transducer as well as calorific condenser exhaust gas heat exchanger have been integrated in a single module.
This integrated solution not only reduces the dimensions of the smartblock, but it also increases serviceability considerably. This way, for example, the catalytic converter can be quickly und easily replaced without disrupting the exhaust line.
The Exhaust Gas Muffler Module
The exhaust gas muffler module is a KW Energie innovation. The exhaust muffler module not only contains the actual exhaust gas noise dampener; it also has a number of other integrated functions.
The form-fitted base with a fastening ring provide for a simple installation without additional supports. If necessary, it can be screwed or bolted to the floor using special boreholes in the base plate and using noise blocking plugs. Inside the base of the exhaust gas muffler module there is a consensate siphon, which will drain the condensate from the CHP, the exhaust muffler module and connected exhust gas line.
By means of the centrally mounted cap nut the condensate drain can be directed in virtually any direction. The safe drain of condensate is of crucial importance to the operational safety of the CHP. To detect possible faults, the exhaust gas muffler module has a float switch to monitor the function of the condensate drain.
In order to be able to easily take the regular exhaust gas easurmenents there is a measurement point fitted to the easily accessible upper end of the exhaust gas muffler module. The exhaust gas exit fitting complies with the Jeremias exhaust gas system EW-KL. A continuation of the exhaust line can be easily connected without any complicated flange connector, saving costs and time.
The Power Control Cabinet
The generator power and performance are controlled, set and monitored in the the power control cabinet integrated in the CHP. It also contains the pre-configured connection cables with plugs for the gas valve, the gas pressure monitor, the condensate switches and the charging pump, as well as further plug and socket inputs for external sensors.
The starter battery and the standard reactive current compensation are placed in separate compartments. The main switch and the emergency stop function are located on the easily accessible cabinet top.
Control Cabinet & BR06
The control cabinet is used to monitor, control and adjust the functions of the smartblock, and it includes the smartblock controller system BR06. Additional functions and controllers such as e.g. heating controller, peak load boiler request etc. can be installed here as well. There are also provisions for inputs and outputs for a number of special functions.
Any economical and environmentally efficient operation of a CHP is only possible with an intelligent control system as well as a continuous monitoring system of the CHP. The powerful CHP controller BR06 is the brain behind all smartblocks and ideally meets the sophisticated requirements. The basis for the controller system is an industrial PLC system with a full graphic display with an ergonomic key pad design. Many years of continuous development resulted in the addition of a great number of protection mechanisms and operating and controlling functions to our software package BR06.