EC POWER XRGI 20G-TO Manual Download Page 1

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SyStem componentS & InStallatIon InStRUctIonS

Summary of Contents for XRGI 20G-TO

Page 1: ...System components Installation INSTRUCTIONS...

Page 2: ...2 Version 1 0 2012 Manual XRGI 20G TO...

Page 3: ...commend you read the manual carefully before using the XRGI This will make you familiar with how exactly the XRGI system works and ensures the manufacturer s warranty is not invalidated Please keep th...

Page 4: ...ing the environment This is why environmentalists welcome it and the Federal Government supports it CHP stands out when it comes to green energy production methods Unlike so lar and wind power CHP doe...

Page 5: ...10 2 Explosive and highly inflammable substances 16 1 2 11 Transportation and accommodation 16 1 2 12 Base 16 1 2 13 Soundproofing 17 2 XRGI 20G TO system components 18 2 1 Main XRGI system component...

Page 6: ...ta transmission 50 3 3 4 Storage tank connections 50 3 3 5 Connecting Q Network Modules and Load Sharer 52 3 3 5 1 Flow Control 52 3 3 5 2 Storage Control 53 3 3 5 3 Boiler Control 54 3 3 5 4 Load Sha...

Page 7: ...1 8 2 HT period 76 4 1 9 Load profiles and heat controlled 76 4 1 9 1 Load profiles 77 4 1 9 2 Heat controlled 78 4 1 10 Power sales 80 4 1 11 Modem calls 81 4 1 12 Technician 82 5 Pre commissioning...

Page 8: ...t accept any liability for any damage that occurs as a result of improper use of the XRGI system The XRGI 20G TO must only be used in combinations ap proved by the manufacturer and with the accessorie...

Page 9: ...arning Potentially hazardous situation for the product and the environment Danger Immediate threat to life and limb For the system operator 1 Manual For the specialised mechanic 1 Assembly instruction...

Page 10: ...RWI DIN 4701 Rules for calculating building heating requirements DIN 4751 Bl 3 Safety equipment for heating systems with lead temperatures up to 110 C ATV worksheet A 251 Feeding condensation water fr...

Page 11: ...specified in the general terms and conditions of EC POWER A S and EC POWER GmbH in the current version apply Should the XRGI system be defective in fact or law hereinafter defective at the time of de...

Page 12: ...gas from areas you cannot access immediately call the police and or fire brigade who are authorised to gain access immediately and inform your gas supplier at the same time If you suspect there is a...

Page 13: ...the Power Unit starts and is running Touching these parts while the Power unit is running is potentially life threatening Only authorised and instructed personnel may touch components under the hood W...

Page 14: ...Perchlorethylene methyl chloroform trichloroethylene methylene chloride car bon tetrachloride hydrochloric acid Chlorinated hydrocarbons Hydrofluorocarbons Frigen 1 2 8 Filling and top up water The he...

Page 15: ...are using pro pane gas as fuel observe TRF 2008 requirements The Power Unit must not be set up in the immediate vicinity of air inlets freezing risk when turned off The minimum footprint required to s...

Page 16: ...e client when the XRGI system is handed over to the shipper or carrier or when it leaves the works or dispatch warehouse whichever is the sooner even if Carriage Paid To destination is agreed T Cs sec...

Page 17: ...the flue gas pipe accordingly they cannot be compared with the even flue gas flow from boilers Although the Power Unit is well insulated against airborne and solid borne noise additional measures may...

Page 18: ...RGI 20G TO IQ20 Control Panel Fig 2 0 Fig 2 1 Fig 2 2 Functions Generates heat Generates electricity Safety functions Power control Q60 Heat Distributor Functions Connects to the grid Electrical safet...

Page 19: ...generator 3 Exhaust cooler not visible 4 Oil sump 5 Toyota gas engine 4 cylinder engine 6 Oil separator patented 7 Oxidising catalytic converter not visible 8 Primary circuit return 1 PT 9 Primary ci...

Page 20: ...rol cable to IQ Control Panel 1 x 2 x 0 75 mm shielded ground connection 1 x 4 x 0 75 mm shielded ground connection 1 x 10 x 0 75 mm shielded ground connection 5 Gas connection PT 4 1 PT flow to Q60 H...

Page 21: ...oning 2 1 1 4 Settings 2 1 1 5 Technical data Noise level Dimensions L x W x H Weight Service interval Primary energy factor Fuels Power output modulating Electrical efficiency Thermal output excludin...

Page 22: ...r control system Electricity meter output Hardware and software for the operating strategy Data recording and analysis Communications with service database Interfaces for external connections 2 1 2 IQ...

Page 23: ...Functions The settings for the IQ Control Panel are made on control field at the front of the device The IQ Control Panel is started with the switch on its left side IQ20 XRGI 17ELD1008 IQ20 XRGI 17E...

Page 24: ...nergy flows 2 1 3 Q60 Heat Distributor 2 1 3 1 Structure Fig 2 11 Fig 2 12 FLOW ENGINE COLD STORAGE TOP STORAGE BOTTOM ENGINE HOT Q NETWORK 230 V Key 1 Expansion vessel 2 Two connections for Q Network...

Page 25: ...allation plate 2 Cover insulated 3 Grid feed 1 PT 4 Storage tank connection top 1 PT 5 Storage tank connection bottom 1 PT 6 Power Unit flow 1 PT 7 Power Unit return 1 PT 2 1 3 2 Dimensions and connec...

Page 26: ...lled circulation pump The storage tank discharge group top right supplies the heating system with the desired heat The Q60 Heat Distributor is equipped with a self learning control system which monito...

Page 27: ...erything OK Continuous red Unit is connected to wrong network or there is no space for more Power Units Flashing red Error see relevant product specifications The control network consists of the IQ Co...

Page 28: ...how the storage tank is to be filled This optimizes the operation of the XRGI system so as to use the storage capacity to the full In order of priority the storage tanks are used to ensure that the X...

Page 29: ...ly be used in installations with an XRGI Power Unit connected as installation 3 Configuration The set point S of the flow temperature is adjusted in the IQ Control Panel Flow Control 01ELT2031 Scope o...

Page 30: ...ure and maximum heat generation Without a layer temperature the system is unable to maintain a stable flow temperature as long as the storage tank is not full With a cold start the Flow Control starts...

Page 31: ...stered as hot When that happens the Boiler Control blocks the boiler again If the heat con sumption continues to be greater than heat generation by the XRGI system the storage tank is cooled down and...

Page 32: ...the storage capacity that this mixing layer is kept as small as pos sible This is why the EC POWER system ensures that this layer is regenerated every time the storage tank is filled With the multi s...

Page 33: ...en mounted and the three control cables between the Power Unit the IQ Control Panel and the power installation have been established the network is completed by shielded computer cables LAN patch cabl...

Page 34: ...34 Version 1 0 2012 Manual XRGI 20G TO Q Network Cabling individual systems Q Network Cabling multiple systems Fig 2 29 Fig 2 30...

Page 35: ...mode In heat controlled mode the Load Sharer is used to start each XRGI system up separately A Load Sharer is installed as shown in Fig 1 Up to four XRGI systems can be connected to one Load Sharer C...

Page 36: ...anguage selected is saved Network setup Use to select from the menu The Load Sharer linked to the reference meter must be configured as the MASTER In installations with more than one Load Sharer those...

Page 37: ...s OK ESC the setting is saved stops flashing Select connected XRGI systems Up to four modular CHP units can be connected to one Load Sharer Each is configured the same way Press to select from the men...

Page 38: ...the next XRGI system that is ready for operation If neces sary it then starts up several XRGI systems The Load Sharer has a built in sequential start to ensure that each XRGI system starts separately...

Page 39: ...area clear Make sure also that there is sufficient space for the exhaust pipe tubes expansion vessel and other system components of the existing boiler system Please see fitting instructions with ass...

Page 40: ...approx 130 kg per hour i e approximately 100 m per hour The pressure drop in the exhaust system must not exceed 20 mbar The exhaust system must be designed to be pressure tight The power unit is not...

Page 41: ...set up in rooms where the air can be expected to be badly polluted with halogenated hydrocarbons e g hairdressing salons printers dry cleaners laboratories etc Adequate precautions must be taken to en...

Page 42: ...s MUST be fitted according to the instructions in section 3 5 3 Note flush the heating system out before connecting it in order to prevent foreign matter getting into the engine circuit Note if sludge...

Page 43: ...e natural gas family 2 H E L and LL gas The mixer device is preset for H and E gas as standard Ask your gas supplier what type of gas they supply The XRGI 20G TO can run on both natural gas H and liq...

Page 44: ...manual vent must then be fitted in the engine compartment instead of the safety valve The expansion vessel for the primary circuit is supplied in the Q60 Heat Distributor It has a capacity of 5 l and...

Page 45: ...ble as an accessory double walled aluminium tube DN 60 100 Exhaust and condensate pipes must not be laid horizontally they must slope at least 2 so the condensate can run off The exhaust with an inter...

Page 46: ...th the Q60 Heat Distributor engine side where the operating pressure is 1 5 bar and is already protected factory configuration Shutoff elements on the secondary side are essential to avoid the need to...

Page 47: ...ine X3 10 x 0 75 mm NSSH U J 12G0 75 shielded ground connection 6 Control line X4 4 x 0 75 mm NSSH U J 12G0 75 shielded ground connection 7 Control line X5 2 x 0 75 mm NSSH U J 12G0 75 shielded ground...

Page 48: ...not generate any reactive power at all This means the reactive current from machinery fluorescent tubes etc is deducted from the allowance and must be paid for If a power tariff includes reactive cur...

Page 49: ...ip X7 terminals 1 2 grounded 24 V AUX alarm interlocking if contact closed 3 External standby 4 Terminal strip X7 terminals 3 4 non floating 24 V external standby if contact closed 5 Alarm 6 Auxiliary...

Page 50: ...the annual costs for Service Data base access If data cannot be e mailed by either of the means above a connection to a landline network can be set up in such exceptional cases Hydraulic connection D...

Page 51: ...the storage tank that makes it possible to use the XRGI control strategies see section 4 The storage tank must be suited to the size of the building the type of heating system used and individual circ...

Page 52: ...nators Sensors must be positioned as shown in Fig 3 14 Other positions will cause operation errors Fit the flow temperature sensor downstream of the XRGI flow connection T f Fit the return temperature...

Page 53: ...o 4 at the lowest measuring point The distance between all four temperature sensors must be identical If there is more than one storage tank in the system each must have its own Storage Control unit T...

Page 54: ...PEN NO contact the contact is open when the boiler is isolated or as a NORMALLY CLOSED NC the contact is closed when the boiler is isolated XRGI n XRGI 2 XRGI 1 Storage Control Storage Tank DHW storag...

Page 55: ...the Load Sharer The XRGI systems do not need to be connected to the Load Sharer in any particular order The reference meter not included is connected to the reference meter input on the Load Sharer T...

Page 56: ...n valve in the overflow header is needed to prevent temporary overflows on the primary side in case of major load fluctuations since such overflows might cause the XRGI to shut down at random The inst...

Page 57: ...ardless of the dimensions of the rest of the network This configuration is recommended if the XRGI system is to work with small storage tanks and small connections on the XRGI side It is only suitable...

Page 58: ...the flow to the boiler If this is the case heat from the XRGI system will be stored The XRGI systems are connected to the storage tank The circulation pumps of the Heat Distributor pass the heat prod...

Page 59: ...Heating return increase with Flow Control Installation 3 Installation with one Power Unit Installation 3 consists of one XRGI system and an additional heat source In installation 1 the XRGI system is...

Page 60: ...ergy systems in principle They cause circulating pumps to use current unnecessarily increase line losses reduce storage tank performance and make the heat sources less efficient They must therefore be...

Page 61: ...uires The building heat consumption is recorded by monitoring how the layers are built up and reduced This data is saved and analysed so the XRGI system learns the property s consumption patterns The...

Page 62: ...storage tank to discharge or via the Flow Control This operating mode does not require a reference meter The benefits of this operating mode are that it has the lowest specific maintenance costs and i...

Page 63: ...roduced is fed into the grid Electricity tariff periods can be entered in the LCD display of the user interface via a weekly schedule Tariff oriented operation is to be preferred when electricity dema...

Page 64: ...ffs are low the Power Unit can be switched out if required in which case the heat is produced by the boiler or heat pump or the Power Unit runs at minimum output until the top storage tank area is hot...

Page 65: ...ents are at times e g in summer lower than the heat production of the Power Unit and Electricity costs are high This operating strategy is forward looking It works like a virtual power station but doe...

Page 66: ...l the supply point a protected output immediately behind the electricity meter utility company s meter upstream of the reference meter and all other outputs Install the reference meter electronic mete...

Page 67: ...1 x 0 75 15 m Cu 4 x 0 75 shielded 15 m Cu 2 x 0 75 shielded 15 m Cu 3 x 0 5 shielded 250 m Conductor material Cable type recommended Number of conductors x Maximum length cross section mm advised Cu...

Page 68: ...ext menu item Start function Select function confirm input Graphic display of power production and consumption coverage in Current power production Current input to grid Select menu item function Powe...

Page 69: ...arted provided the storage tanks are not full If the system asks Stop the system and you answer No the system will ask whether you want to start the system The system will ask Automatic operation Not...

Page 70: ...n Mixture control and engine module flushed with fresh air Calibration Control system checks system is working Press any key for menu 9 58 22 9 10 2008 Production 0 0KW 10 1KW Consumption Status Stand...

Page 71: ...cally Alarm fault details Press the key and the system explains why the stop alarm was set off The system should not be restarted without consulting a service engineer Consequential damage as a result...

Page 72: ...power output as 15 minute averages That is if the output shown at 14 00 is 130 kW that is the average for 13 45 14 00 i e 1 45 p m to 2 00 pm Statistics are updated every 15 minutes Press ESC to retur...

Page 73: ...storage tank and grid to Q60 Heat Distributor Flow temperature set point to heating network adjustable Operational set point Flow temperature to heating network Return temperature from heating networ...

Page 74: ...otal Power consumption metered Power production metered Power sales metered Heat production calculated Fuel consumption calculated from GCV Press OK ESC to return to menu Press OK to display operating...

Page 75: ...e heat backup line Press OK to change settings Use the keys to select Yes No then ESC to end selection 4 1 7 Operating data online 4 1 8 1 Heat backup 4 1 8 Heat Tariff Press OK to display heat and po...

Page 76: ...control system optimises heat and power production based on the times entered Should the XRGI preferably be used to cover peak power loads at certain times of day these times can be programmed here a...

Page 77: ...hange settings Use the keys to select Yes No press ESC to end Load period In manual input operation you should enter the period when power consumption is highest There are three period options All wor...

Page 78: ...ursor now moves to the minutes figure Use the keys to change the minutes and press OK to complete Use the ESC key to go back from minutes to hours Use the same procedure to change all times that need...

Page 79: ...he control system optimises heat and power production based on the times entered Should the XRGI preferably be used to cover peak power loads at certain times of day these times can be programmed here...

Page 80: ...ays Saturdays Sundays Eingabebeispiele Start End 24 hour high tariff 0 00 23 59 HT during specific periods 6 00 21 00 No HT within 24 hours 0 00 0 00 The control system optimises heat and power produc...

Page 81: ...er login if this has been agreed with your specialist dealer It is possible to make modem calls manually to test the line or update the database 4 1 11 Modem calls Press OK Use the keys to move the cu...

Page 82: ...t covered by the warranty 4 1 12 Technician 5 Pre commissioning Before you can start using your XRGI 20G TO you need to register your XRGI system in the EC POWER Service Database at https service ecpo...

Page 83: ...te the form with the correct installation address and contact information fields marked with marked are mandatory If there are subgroups in your unit list please write in the comments field in which s...

Page 84: ...to EC POWER It may take up to two working days until you can see your new XRGI site in the Service Database If you have questions about your XRGI system correction please e mail to serviceitem ecpower...

Page 85: ...the Control Panel When all of these questions can be answered the system is ready for commissioning Commissioning dates will not be confirmed until the signed checklist has been returned to EC POWER...

Page 86: ...this monitoring data to determine whether faults arise in the engine or other areas In addition service codes are useful for troubleshooting If problems occur with your XRGI 20G TO a fault code will...

Page 87: ...xing problems The production meter in the IQ Control Panel or connection to the IQ Control Panel is faulty 10 Oil pressure probe defective The oil pressure is recorded while the engine is not running...

Page 88: ...than 0 4 of rated quantity of current meter a faulty current meter or signal cable 24 Power output too low The stepping engine is set to maximum output but the system is not producing enough power to...

Page 89: ...buted over at least 15 steps of the stepping engine If this service code is displayed the system ventilates and calibration restarts Should this alarm service code occur three times in an hour this wi...

Page 90: ...ard System has been set to alarm stop because there is a fault in the electronics of the main board in the 5 V supply The system stops at once alarm stop A fuse may have blown Before changing the fuse...

Page 91: ...ituation requires it to do so If this fault appears it means there is a Phase fault or break Overvoltage or undervoltage Overfrequency or underfrequency 86 No power output while calibrating Code 86 is...

Page 92: ...ve faulty One of the Flow Control valve limit switches is faulty The valve engine must be replaced The system is working but does not have full control over the engine valve This may cause operating p...

Page 93: ...is selected which allows it to start However if an electric heater is connected the storage tank can be heated up until T1 is hot 110 No network unit found This code appears if a required network unit...

Page 94: ...ng which the stepping engine is wound back to 0 and the generator is cut out The system then stops and restarts of its own accord if power and heat circumstances so allow 40 Standby The system is inte...

Page 95: ...the reason the call is made e g normal call alarm etc If the call is successful the eight hour cycle resumes Modem cannot get through Calls may appear to be successful but may still not appear in the...

Page 96: ...p with absorbent material and dispose of as toxic waste Change oil drenched shoes and clothing Do not put oily cloths in pockets Skin Wash off with soap and water or special hand cleaners using a nail...

Page 97: ...ill ensure your XRGI system is always ready to use reliable and long lasting A well maintained XRGI 20G TO system is more efficient and hence economical Maintenance requires a maintenance kit Order nu...

Page 98: ...98 Version 1 0 2012 Manual XRGI 20G TO...

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Page 131: ...131 Version 1 0 2012 Manual XRGI 20G TO...

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Page 145: ...ARTY WITHOUT OUR PERMISSION DRAWING NO EC POWER A S Sams vej 25 DK 8382 Hinnerup Print date PAGE 20 20 20 20 20 20 20 20 20 20 20 JHS 19 09 2011 06 10 2008 DRAW NO 53741T02 PROJECT FILENAME 53741T02_2...

Page 146: ...ARTY WITHOUT OUR PERMISSION DRAWING NO EC POWER A S Sams vej 25 DK 8382 Hinnerup Print date PAGE 21 21 21 21 21 21 21 21 21 21 21 JHS 19 09 2011 06 10 2008 DRAW NO 53741T02 PROJECT FILENAME 53741T02_2...

Page 147: ...CLOSED TO A THIRD PARTY WITHOUT OUR PERMISSION DRAWING NO EC POWER A S Sams vej 25 DK 8382 Hinnerup Print date PAGE 23 23 23 23 23 23 23 23 23 23 23 JHS 19 09 2011 06 10 2008 DRAW NO 53741T02 PROJECT...

Page 148: ...TO A THIRD PARTY WITHOUT OUR PERMISSION DRAWING NO EC POWER A S Sams vej 25 DK 8382 Hinnerup Print date PAGE 24 24 24 24 24 24 24 24 24 24 24 JHS 19 09 2011 06 10 2008 DRAW NO 53741T02 PROJECT FILENA...

Page 149: ...IRD PARTY WITHOUT OUR PERMISSION DRAWING NO EC POWER A S Sams vej 25 DK 8382 Hinnerup Print date PAGE 25 25 25 25 25 25 25 25 25 25 25 JHS 19 09 2011 06 10 2008 DRAW NO 53741T02 PROJECT FILENAME 53741...

Page 150: ...IRD PARTY WITHOUT OUR PERMISSION DRAWING NO EC POWER A S Sams vej 25 DK 8382 Hinnerup Print date PAGE 26 26 26 26 26 26 26 26 26 26 26 JHS 19 09 2011 06 10 2008 DRAW NO 53741T02 PROJECT FILENAME 53741...

Page 151: ...IRD PARTY WITHOUT OUR PERMISSION DRAWING NO EC POWER A S Sams vej 25 DK 8382 Hinnerup Print date PAGE 27 27 27 27 27 27 27 27 27 27 27 JHS 19 09 2011 30 08 2011 DRAW NO 53741T02 PROJECT FILENAME 53741...

Page 152: ...152 Version 1 0 2012 Manual XRGI 20G TO...

Page 153: ...153 Version 1 0 2012 Manual XRGI 20G TO...

Page 154: ...154 Version 1 0 2012 Manual XRGI 20G TO...

Page 155: ...155 Version 1 0 2012 Manual XRGI 20G TO...

Page 156: ...156 Version 1 0 2012 Manual XRGI 20G TO...

Page 157: ...157 Version 1 0 2012 Manual XRGI 20G TO...

Page 158: ...158 Version 1 0 2012 Manual XRGI 20G TO...

Page 159: ...159 Version 1 0 2012 Manual XRGI 20G TO...

Page 160: ...160 Version 1 0 2012 Manual XRGI 20G TO...

Page 161: ...161 Version 1 0 2012 Manual XRGI 20G TO...

Page 162: ...162 Version 1 0 2012 Manual XRGI 20G TO...

Page 163: ...ient maintenance space around the unit Has a minimum of 450 mm free space been left at rear for routine gas maintenance of the gas mix tray Mechanical checklist Is the heat distributor correctly conne...

Page 164: ...d and leak tested Has the gas isolation valve been fitted 1 m from the Power Unit Fuel gas system Has the flue gas system been installed according to regulations Has unit been installed with EC POWER...

Page 165: ...tions Have correct fuses been fitted Is there cable containment between EC POWER components Mount the PT100 sensors in the sensor pockets on the buffer storage tanks Mount a switched fuse 230 V outlet...

Page 166: ...166 Version 1 0 2012 Manual XRGI 20G TO Notes...

Page 167: ...167 Version 1 0 2012 Manual XRGI 20G TO...

Page 168: ......

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