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EC POWER XRGI 20G-TO Manual

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SyStem componentS & InStallatIon InStRUctIonS

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  • Page 1 SyStem componentS & InStallatIon InStRUctIonS...
  • Page 2 Manual XrGi 20G-To Version 1.0 - 2012...
  • Page 3 Manual XrGi 20G-To This manual informs you in detail about the system components and about how to install your new XRGI 20G-TO. It also gives important safety instructions that must adhered to when the XRGI system is used. The manual includes descriptions of the main XRGI system components, i.e.
  • Page 4 EC POWER. One of systems are sold in more than ten European countries. the goals of EC POWER is to make optimal use of primary energy in order to cover growing electricity requirements cost-effectively while lowering the environmental impact. In...

  • Page 5: Table Of Contents

    1.2.10.1. Alterations in system surroundings 1.2.10.2. Explosive and highly inflammable substances 1.2.11. Transportation and accommodation 1.2.12. Base 1.2.13. Soundproofing 2. XRGI 20G-TO system components 2.1. Main XRGI system components 2.1.1. Power Unit 20G-TO 2.1.1.1 Structure 2.1.1.2. Dimensions and connections 2.1.1.3. Functioning 2.1.1.4.
  • Page 6 3.3.5. Connecting Q-Network Modules and Load Sharer 3.3.5.1. Flow Control 3.3.5.2. Storage Control 3.3.5.3. Boiler Control 3.3.5.4. Load Sharer 3.4. Hydraulic integration of the XRGI 20G-TO 3.4.1. System temperatures 3.4.2. Selecting the right hydraulics 3.4.2.1. Basic hydraulic circuits of XRGI components 3.4.3. Integration into heating system 3.4.3.1 Parallel integration with or without Flow Control...
  • Page 7 5. Pre-commissioning 5.1. Registering new XRGI site in the Service Database 5.2. Checklist 6. Monitoring 6.1. Troubleshooting 6.1.1. Your XRGI 20G-TO system does not start 6.2. Service codes 6.2.1. Service 6.2.2. Operating modes 6.2.3. Reasons for calls 7. Care and maintenance 7.1.

  • Page 8: General Instructions

    Warning! EC POWER assumes no liability for any damage caused by non-compliance with these instructions. We reserve the right to make technical changes...

  • Page 9: Notes On Equipment Documentation

    This manual applies to the XRGI 20G-TO without accessories with additional storage tank Before assembling and installing the XRGI 20G-TO, read the assembly instructions carefully and follow the safety instructions there given. Note: please keep these documents for future reference.

  • Page 10: Handling The Equipment

    To take best advantage of all the benefits your XRGI 20G-TO offers, please read these instructions carefully. For your own safety, please note that your system must be set up and adjusted by an authorised EC POWER specialist only. The same ap- plies for inspection/maintenance, servicing and repairs of the device.

  • Page 11: Modifying Xrgi System Components

    The warranty provisions specified in the general terms and conditions of EC POWER A/S and EC POWER GmbH in the current version apply.

  • Page 12: What To Do In The Event Of An Emergency

    Manual XrGi 20G-To Version 1.0 - 2012 1.2.4. What to do in the event of an emergency 1.2.4.1. Gas smell In the event of gas smell, please proceed as follows: Do not operate any electrical switches or remove any power plugs.

  • Page 13: Frost Protection

    Any cover that can only be removed with keys or tools, etc. conceals components which can cause injuries when touched (hot and/or live components). Such covers must be removed by authorised EC POWER specialists only. The door of the IQ-Control Panel is there for your protection, and may only be opened by trained electricians.

  • Page 14: Filling And Top-Up Water

    Manual XrGi 20G-To Version 1.0 - 2012 Main known sources of incomplete combustion are the following: Industrial sources Chemical cleaners Trichloroethylene, a hydrofluorocarbon Degreasing baths Perchlorethylene, trichloroethylene, methylene chloride Printing works Trichloroethylene Cooling equipment Methyl chloride, trichlorofluoromethane, dichlordifluoromethane Domestic sources...

  • Page 15: Installation

    Before installing your XRGI system, you must consult your gas supply company and district master chimney sweep, and obtain your electricity supplier's consent. The system must only be installed by an authorised and trained EC POWER specialist, who will be responsible for proper installation and commissioning.

  • Page 16: Alterations In System Surroundings

    Safety valve or heating water runoff pipe, and to any structural components that could affect the reliability of the Unit. Note: XRGI system components must not be modified without EC POWER's prior consent in writing. 1.2.10.2. explosive and highly inflammable substances Do not use or store any explosive or highly inflammable substances, such as petrol, paper or inks, in the area where the unit is installed.

  • Page 17: Soundproofing

    Version 1.0 - 2012 Manual XrGi 20G-To 1.2.13. soundproofing The Power Unit comes with high-grade airborne and solid-borne soundproofing. (<49 [±2] dB (A), at 1 m distance with hood closed); but noise-sensitive areas should be taken into account when deciding where to install it. To avoid solid-borne noise carrying into building structures, all connections between the XRGI and building systems must be made via flexible connections (hoses) or suitable soundproofing expansion joints.

  • Page 18: Xrgi 20G-To System Components

    Manual XrGi 20G-To Version 1.0 - 2012 2. XrGi 20G-to SyStem componentS 2.1. Main XrGi sysTeM CoMponenTs The XRGI 20G-TO system consists of three main components: poWer uniT XrGi 20G-To Functions: Generates heat Generates electricity Safety functions Power control Fig. 2.0.

  • Page 19: Power Unit 20G-To

    Version 1.0 - 2012 Manual XrGi 20G-To 2.1.1. power unit 20G-To 2.1.1.1 structure Fig. 2.3. The main Power Unit components are: Engine Mixture control Generator Cooling circuit Engine electronics The Power Unit turns gas into electricity and heat. Key: Electrical components and safety circuit...

  • Page 20: Dimensions And Connections

    Manual XrGi 20G-To Version 1.0 - 2012 2.1.1.2. Dimensions and connections Fig. 2.6. Fig. 2.7. Fig. 2.8. Key: Space for the installation of a control board, a safety circuit and the electrical ignition Space for the installation of an air filter, a gas pressure controller, a stepping engine and a gas mixture control Control cable to IQ-Control Panel (1 x 2 x 0.75 mm²...

  • Page 21: Functioning

    Version 1.0 - 2012 Manual XrGi 20G-To 2.1.1.3. Functioning The generator is attached directly to the engine, thus minimising the required maintenance. The gas safety circuit, engine con- trol and temperature control relay are integrated in the Power Unit. 2.1.1.4. settings Gas settings may only be made by authorised persons.

  • Page 22: Iq-Control Panel

    Manual XrGi 20G-To Version 1.0 - 2012 2.1.2. iQ-Control panel 2.1.2.1. structure The IQ-Control Panel provides: Fig. 2.9. Controller Power control system Electricity meter (output) Hardware and software for the operating strategy Data recording and analysis Communications with service database Interfaces for external connections 2.1.2.2.

  • Page 23: Functions

    Fuses: surge protection Output meter: measures the generator’s electricity production. Modem power supply (12 V) Modem: sends data to EC POWER Service Database Automatically operating circuit breaker: network monitoring device 10. Main board power supply (12 V) 11. Main board: communication interface with system 12.

  • Page 24: Q60-Heat Distributor

    Manual XrGi 20G-To Version 1.0 - 2012 2.1.3. Q60-Heat Distributor 2.1.3.1. structure The Q60-Heat Distributor plays an important role in the XRGI 20G-TO Fig. 2.11. system: Separates (primary) engine circuit from the heating network Protects primary circuit Controls the engine temperature...

  • Page 25: Dimensions And Connections

    Version 1.0 - 2012 Manual XrGi 20G-To 2.1.3.2. Dimensions and connections   Fig. 2.15. Fig. 2.16. Fig. 2.17. Right Front Left Key: Installation plate Cover (insulated) Grid feed (1 ¼“ PT) Storage tank connection top (1 ¼“ PT). Storage tank connection bottom (1 ¼“ PT) Power Unit flow (1 ¼“...

  • Page 26: Function

    Manual XrGi 20G-To Version 1.0 - 2012 2.1.3.3. Function The Q60-Heat Distributor separates the engine circuit (Power Unit cooling water circuit) from the heating system via a plate heat exchanger. The expansion vessel thus protects the engine circuit. The circulation pump for the engine circuit is fitted to the bottom left of the primary and secondary Q60-Heat Distributor circuits and is equipped with a specially modified connection on the pump housing for the Q60-Heat Distributor.

  • Page 27: Xrgi System Accessories

    Version 1.0 - 2012 Manual XrGi 20G-To 2.2. XrGi SyStem acceSSorieS 2.2.1. Q-network The XRGI control system is based on two logical networks: Control network Q-Network Both systems use the conventional hierarchical master/slave strategy, with the master controller alone being able to access the common resource of its own accord.

  • Page 28: Storage Control

    It is essential for the storage capacity that this mixing layer is kept as small as possible. This is why the EC POWER system ensures that this layer is regenerated every time the storage tank is filled. With the multi-sensor system it is therefore possible to use the mixing layer to determine very precisely how the storage tank is to be filled.

  • Page 29: Flow Control

    Version 1.0 - 2012 Manual XrGi 20G-To The optimum position of the cooling and thermal reserves varies over time. If the XRGI system is to cover the average heat consumption (typically in spring/autumn), the optimum positions of the sensors are at the bottom of the storage tank.

  • Page 30: Boiler Control

    Manual XrGi 20G-To Version 1.0 - 2012 Note: if a boiler is connected, its thermostat temperature must be set at least 5°C lower than the Flow Control set point to make sure the XRGI system is prioritized in the provision of heat.

  • Page 31: Storage Tank

    Version 1.0 - 2012 Manual XrGi 20G-To Fig. 2.23. FUNCTION WIRING Boiler NORMALLY OPEN Brown NORMALLY OPEN COMMON White 230 V COMMON NORMALLY CLOSED Green NORMALLY CLOSED Function The Boiler Control is used to control the boiler depending on the heat consumption. If more heat is consumed than the XRGI system can generate, the boiler is started.
  • Page 32 It is essential for 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-sensor system it is therefore possible to use the mixing layer to determine very precisely how the Storage Tank is to be filled.

  • Page 33: Q-Network Wiring

    Power Unit, the IQ-Control Panel and the power installation have been established, the network is completed by shielded computer cables (LAN patch cable 1:1, twisted pair, SFTP Cat 6) with RJ45 plugs. EC POWER can supply cables at the re- quired lengths.
  • Page 34 Manual XrGi 20G-To Version 1.0 - 2012 Q-Network Cabling (individual systems) Fig. 2.29. Q-Network Cabling (multiple systems) Fig. 2.30.

  • Page 35: Power-Controlled Operation

    Version 1.0 - 2012 Manual XrGi 20G-To 2.2.2. power-controlled operation 2.2.2.1. load sharer Load Sharer (01ELT2006) Scope of supply: Load Sharer Box Size (H x W x D): 90 x 260 x 160 mm Weight: 2 kg Fig. 2.31. The Load Sharer divides the required system output between the existing XRGI systems in power-controlled mode. It ensures that each XRGI system is started individually.
  • Page 36 Manual XrGi 20G-To Version 1.0 - 2012 Menu structure Select language Press the key to select language:   Press and the selected language flashes. Press to select the desired language. Now press OK/ESC: the LCD display stops flashing, and the language selected is saved.
  • Page 37 Version 1.0 - 2012 Manual XrGi 20G-To Network statistics This function is used to monitor RS485 traffic and assess the network stability. It is only relevant in installations with more than one Load Sharer. Use OK/ESC to scroll through statistics.
  • Page 38 Manual XrGi 20G-To Version 1.0 - 2012   Slave unit The menu displays the number of the secondary XRGI, which the master unit allocated automatically. Press OK/ESC to scroll through the secondary Load Sharer's four XRGIs:   Function In installations with 2 to 4 XRGI systems the Load Sharer ensures that the load is shared between the XRGI systems. The requi- red output is covered with a minimum of systems.

  • Page 39: Installation Instructions

    Version 1.0 - 2012 Manual XrGi 20G-To 3. inStallation inStructionS 3.1. insTallinG XrGi sysTeM CoMponenTs When installing your system, please observe the measures given in the figures below. The setup is merely an example and can of course be changed if required.

  • Page 40: General Installation Instructions

    (electronics). If temperatures are expected to be higher, the room must be ventilated to control the tempera- ture. The XRGI 20G-TO may not be set up in dusty areas or in areas with high humidity levels, e.g. laundry rooms. The area should be completely dust-free, so the Power Unit inlet filter does not clog up.

  • Page 41: Noise/Vibration

    The system as a whole must not be exposed to corrosive gases such as ammonia, chlorine, etc. which can be found in swim- ming pool water systems. Here, systems must be set up in a separate room. If an XRGI 20G-TO is set up in rooms where the air can be expected to be badly polluted with halogenated hydrocarbons, e.g. hairdressing salons...

  • Page 42: Installing Your Xrgi 20G-To

    Manual XrGi 20G-To Version 1.0 - 2012 3.3. inStallinG your XrGi 20G-to The main steps involved in the technical setup are the following: Set up Power Unit. Install Q60-Heat Distributor and IQ-Control Panel. Set up storage tank. Fit tubes between Q60-Heat Distributor and storage tank (min. tube size 1 ¼” PT, DN32).

  • Page 43: Gas Connection

    10 mbar (low pressure). A gas pressure regulator must be used if the pressure is higher. The XRGI 20G-TO is designed for gas type I2R natural gas, i.e. natural gas family 2 (H, E, L and LL gas). The mixer device is preset for H and E gas as standard.

  • Page 44: Exhaust Connection

    Manual XrGi 20G-To Version 1.0 - 2012 Primary connection (side view) (Front view) Fig. 3.4. Fig. 3.5. No ball valves are required between the Power Unit and the Q60-Heat Distributor. The Q60-Heat Distributor does not contain a great deal of water. However, if shutoff elements are fitted, at least one of these must be secured to prevent unauthorised persons from shutting them (remove handle, use fitting with hood, etc.).

  • Page 45: Exhaust Gas Heat Exchanger

    Version 1.0 - 2012 Manual XrGi 20G-To The fresh air supply and the exhaust lines must meet installation type B rules (depending on air space). Connections may only be carried out by a specialist. The Power Unit is not designed for condensing operation. However, a condensate drain must be fitted to trap the condensate which develops when the system is started up.

  • Page 46: Q60-Heat Distributor Connections

    Manual XrGi 20G-To Version 1.0 - 2012 3.3.2. Q60-Heat Distributor connections Variable volume flow rate – top stable diameter (1¼” PT) – only if Fig. 3.6. Flow Control is connected. Storage tank connection, top–centre stable diameter (1¼” PT). Q-NETWORK Storage tank connection, bottom stable diameter (1¼” PT).

  • Page 47: Iq-Control Panel Connections

    Version 1.0 - 2012 Manual XrGi 20G-To 3.3.3. iQ-Control panel connections Mains connection 5 x 16 mm² – 5 m Q-Network Cable (SFTP (CAT 6) network cable). Power Unit generator connections 4 x 10 mm² Impulse line from Load Sharer 2 x 2 x 0.8 mm²...

  • Page 48: Reactive Current Compensation

    If a power tariff includes reactive current, it would therefore be advisable to include the whole property in a viable reactive current compensation strategy. If reactive current compensation is only required for the XRGI 20G-TO, having considered the matters above, this is available as an accessory.

  • Page 49: External Connections

    Version 1.0 - 2012 Manual XrGi 20G-To 3.3.3.3. external connections A number of messages are provided for the connection to external regulation and control systems: External alarm Terminal strip X7, terminals 1/2, grounded 24 V (AUX alarm, interlocking if contact closed) External standby Terminal strip X7, terminals 3/4, non-floating 24 V (external standby if contact closed).

  • Page 50: Remote Data Transmission

    Manual XrGi 20G-To Version 1.0 - 2012 3.3.3.4. remote data transmission The IQ-Control Panel is equipped with a wireless modem for the transmission of data. The IQ-Control Panel and its antenna must therefore be installed in an area with mobile phone coverage. An adequate location can be found and tested using a mobile phone.
  • Page 51 Cable; the sensors are already mounted in the right positions in the Storage Tank. The storage tank makes it possible to separate the generated heat from the electrical power and to prevent the EC POWER system from cycling (switching constantly on and off). If the demand for electricity is high and also at high tariff times, the sur- plus heat generated can be accumulated in the storage tank and released to the heating system later on.

  • Page 52: Connecting Q-Network Modules And Load Sharer

    Version 1.0 - 2012 3.3.5. Connecting Q-network Modules and load sharer Q-Network Modules and Load Sharer may only be installed by authorised EC POWER specialists. Q-Network Module Cables must not be shortened, extended or cut off. Q-Network Modules are networked with other Q-Network Modules and the Load Sharer with other Load Sharers via a Q- Network Cable (SFTP (CAT 6) network cable).

  • Page 53: Storage Control

    Version 1.0 - 2012 Manual XrGi 20G-To 3.3.5.2. storage Control Fig. 3.15. Q-Network Heat sToraGe ConTrol sToraGe ConTrol Termination Endwiderstand The sensors must be positioned as shown in Fig. 3.15. Other positions will cause operation errors! The Storage Control Temperature Sensors must be fitted to the storage tank in immersion sleeves; sensor No. 1 must be installed at the topmost measuring point and sensor No.

  • Page 54: Boiler Control

    Manual XrGi 20G-To Version 1.0 - 2012 3.3.5.3. Boiler Control Fig. 3.16. sToraGe ConTrol Boiler ConTrol Heating circuit XRGI n reg. XRGI 2 sToraGe TanK Header additional DHW storage heat source XRGI 1 Temperature sensor Signal cable for sensor Pump...

  • Page 55: Load Sharer

    Version 1.0 - 2012 Manual XrGi 20G-To 3.3.5.4. load sharer Fig. 3.17. Reference meter max. 4 XRGI max. 20 m 230 VAC max. 4 XRGI max. 1200 m max. 20 m 230 VAC max. 10 x Load Sharer A Load Sharer must be installed as shown in 3.17. Incorrect installation will cause operation errors! The Load Sharer is connected to the IQ-Control Panels via CHP 1-4 connections.

  • Page 56: Hydraulic Integration Of The Xrgi 20G-To

    Manual XrGi 20G-To Version 1.0 - 2012 3.4. hydraulic inteGration oF the XrGi 20G-to 3.4.1. system temperatures The return temperature of the heating system should not normally exceed 65 °C. Return temperatures may be as high as 70 °C, but this affects the commercial viability and the storage capacity of the system. If other heat sources are included in the sys- tem, such as heat pumps or a condensing boiler, their demands on system temperatures must also be taken into account when designing the system.

  • Page 57: Parallel Integration With Flow Control (Installation 1)

    Version 1.0 - 2012 Manual XrGi 20G-To Parallel integration with Flow Control (Installation 1) Installation with one Power Unit Installation 1 consists of one XRGI system, a DHW storage and an additional heat source. Operation of the installation assumes that the building's heating circuit is regulated, i.e. that hot water is not led back to the XRGI system.

  • Page 58: Parallel Integration Without Flow Control For Multiple Systems (Installation 2)

    Manual XrGi 20G-To Version 1.0 - 2012 Parallel integration without Flow Control for multiple systems (Installation 2) Installation with more than one Power Unit Installation 2 consists of multiple XRGI systems, a DHW storage and an additional heat source. Operation of the installation assumes that the building's heating circuit is regulated, i.e.

  • Page 59: Heating Return Increase With Flow Control (Installation 3)

    Version 1.0 - 2012 Manual XrGi 20G-To 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 equipped with a Flow Control (not included). The Flow Control regulates how much heat is fed in the building's heating system and how much is stored in the storage tank.

  • Page 60: Transmitting Heat To The Consumer Side

    Manual XrGi 20G-To Version 1.0 - 2012 Installation diagram 4 Temperature sensor Signal cable for sensor Fig. 3.21. Pump Valve (manual) 3-way valve Regulator Heat consumption Installation pipe XRGI n Q-Network Cable (heat circuit) Q-Network Cable (control circuit) sToraGe ConTrol...

  • Page 61: Indications Of Lack Of Hydraulic Equalization

    Version 1.0 - 2012 Manual XrGi 20G-To 3.4.5. indications of lack of hydraulic equalization Radiators do not warm up, while other system components are over-supplied ('hydraulic short circuit'). Radiator valves and/or pipes make noises. Thermostat control is poor. Heating system is being operated at temperatures that are too high.

  • Page 62: Heat-Controlled Operation

    Manual XrGi 20G-To Version 1.0 - 2012 3.5.1. Heat-controlled operation The device produces the maximum amount of electricity based on the property's heat consumption. How much heat the pro- perty needs is recorded via the storage tank level. The point at which the XRGI cuts in varies between sensors 1 and 2 of the storage tank depending on how much output the heating system requires.

  • Page 63: Tariff-Oriented Operation

    Version 1.0 - 2012 Manual XrGi 20G-To 3.5.2. Tariff-oriented operation The Power Unit produces the set output preferably in high-tariff periods. This operating mode is thus guided by the electricity tariff and the property's heat requirements as follows: maximum electricity production during the high tariff periods entered...

  • Page 64: Power-Controlled Operation

    Manual XrGi 20G-To Version 1.0 - 2012 3.5.3. power-controlled operation This operating mode is guided by the electrical output required, electricity tariffs and the property's heat requirements. The output required here can either be entered in the LCD display of the user interface via a weekly schedule or metered via a reference meter.

  • Page 65: Heat-Controlled, Power-Controlled Operation

    Version 1.0 - 2012 Manual XrGi 20G-To 3.5.4. Heat-controlled, power-controlled operation This operating mode is guided by the property’s heat and electricity requirements, the electrical load profile for the past week and the electricity tariff. The XRGI system uses the load profiles saved to try to cover both heat and electricity demand optimally. High-tariff periods take priority.

  • Page 66: Electrical Installation Of The Xrgi 20G-To

    Manual XrGi 20G-To Version 1.0 - 2012 3.6. electrical inStallation oF the XrGi 20G-to The electrical installation must be large enough for a protected output with 63 A gl/gG fuses to be available for the XRGI sys- tem. With multi-module systems, each XRGI system must have its own output.
  • Page 67 Cable dimension tables: Please note! All cable lengths and dimensions are recommended by EC POWER; factors such as parallel lines, ambient temperatures, mechanical and chemical effects, etc. must also be taken into account for each XRGI system individually. Conductor material...

  • Page 68: Operating Instructions

    Manual XrGi 20G-To Version 1.0 - 2012 4. operatinG inStructionS 4.1. user interface on iQ-Control panel 4.1.1. Control keys Use the four keys of the control field to work through the menus as follows: Select menu item/function Back one menu item...

  • Page 69: Starting And Stopping Automatic Operation

    Version 1.0 - 2012 Manual XrGi 20G-To 4.1.3. starting and stopping automatic operation If the XRGI is operating in fully automatic operation, the control system ensures that the electricity and heat requirements are always covered at the best and most financially viable terms at the time.

  • Page 70: Automatic Operation

    Manual XrGi 20G-To Version 1.0 - 2012 4.1.3.3. automatic operation In automatic operation, the system monitors electricity and heat consumption constantly and covers them as economically as possible. In normal automatic operation, the system starts and stops automatically, as shown here: Standby: Waits for power/heat consumption to rise.

  • Page 71: Alarm Stop

    Version 1.0 - 2012 Manual XrGi 20G-To 4.1.3.4. alarm stop If a fault occurs during operation, the system stops automatically. The LED on the IQ-Control Panel illuminates red to indicate a fault. The control system reports the problem to the central database automatically via the integrated modem.

  • Page 72: 24-Hour Statistics

    Manual XrGi 20G-To Version 1.0 - 2012 4.1.4.1. 24-hour statistics The menu items are shown below: Power Press to show 24-hour statistics. Production WEEK Power Consumption Storage Status Info. Production last 24 hours Service The calendar week axis is scaled automatically to display the statistics as precisely as possible.

  • Page 73: Storage Tank And Heat Production

    Version 1.0 - 2012 Manual XrGi 20G-To 4.1.5. storage tank and heat production Power Production Power Consumption Press OK, select Storage Status, Storage the system overview with storage Status status is displayed. Info. Q60-Heat Distributor valve control Service 64.66ºC 97.21º C 93.00ºC...

  • Page 74: Operating Data

    Manual XrGi 20G-To Version 1.0 - 2012 Valve markings   Valves in standby position   Close valves   Open valves   Valves closed Valves open Press to return to menu. 4.1.6. operating data The menu items are shown below: Power...

  • Page 75: Operating Data Online

    Version 1.0 - 2012 Manual XrGi 20G-To 4.1.7. operating data online You can also find your system operating data online at www.ecpower.de by entering your username and password. You will need to agree to connect your system with your specialist dealer separately.

  • Page 76: Ht Period

    Manual XrGi 20G-To Version 1.0 - 2012 4.1.8.2. HT period If the installation has only one power tariff, select high tariff for all 24 hours in the day, as shown below. If there is more than one tariff, enter the start and end times for the HT periods (HT).

  • Page 77: Load Profiles

    Version 1.0 - 2012 Manual XrGi 20G-To 4.1.9.1. load profiles Menu items as shown below: Power Production Power Consumption Storage Status Info. Start/Stop Service Modem call Heat & Tariff Power load profile Press to display load profile settings. Power Sales...

  • Page 78: Heat-Controlled

    Manual XrGi 20G-To Version 1.0 - 2012 The 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 as high tariff periods.
  • Page 79 Version 1.0 - 2012 Manual XrGi 20G-To POWER LOAD PROFILE Stop in Low Load period: Select if you wish to enter periods manually. High load period: Start: End: 17:00 Mo - Fr: 7:00 7:00 23:59 Displays high load periods 7:00...

  • Page 80: Power Sales

    Manual XrGi 20G-To Version 1.0 - 2012 4.1.10. power sales The menu items are shown below: Power Production Power Consumption Storage Status Info. Service Start/Stop Modem call Heat & Tariff Power load profile Power Sales Press to display input settings.

  • Page 81: Modem Calls

    4.1.11. Modem calls The built-in modem connection is used to send service and operating data to EC POWER A/S and/or the relevant partner company at regular intervals (e.g. twice a day). You can access this information using you customer login if this has been agreed with your specialist dealer.

  • Page 82: Technician

    5. pre-commiSSioninG 5.1. registering new XrGi site in the service Database 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.ecpower.dk. Fig. 5.0.
  • Page 83 Version 1.0 - 2012 Manual XrGi 20G-To Fig. 5.2. Click on Edit CHP unit (mail). Fig. 5.3. Complete 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 subgroup you wish the unit to be listed. Then...
  • Page 84 When the changes have been saved properly, you will receive a confirmation and a correction number. The form is e-mailed to EC POWER. It may take up to two working days until you can see your new XRGI site in the Service Database.

  • Page 85: Checklist

    Pre-Commissioning Checklist The commissioning checklist ensures the units are ready for commissioning. The form must be returned at least 5 working days prior to the provisional commissioning date supplied by EC POWER A/S so that the date can be confirmed.

  • Page 86: Monitoring

    Your XRGI system uses 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 appear in the LCD display and in the Service Database.

  • Page 87: Service

    Version 1.0 - 2012 Manual XrGi 20G-To 6.2.1. service 1: Manual stop The operator has stopped automatic operation of the system, i.e. by pressing a key. 3: Manual stop while calibrating The operator has stopped the system, i.e. by pressing a key, while it was being calibrated.
  • Page 88 Manual XrGi 20G-To Version 1.0 - 2012 19: Production failed while calibrating Production failure was recorded while calibrating. However, production has started, otherwise service code 86 would be dis- played. When this service code is displayed, the system ventilates and calibration restarts. If there is another alarm service code within one hour of this alarm, this will cause an alarm stop.
  • Page 89 Version 1.0 - 2012 Manual XrGi 20G-To 49: Low priority (night standby position) During night tariff periods, the system stops and displays this service code if storage tank 1 is hot, independent of the amount of power used at that time, but only after it has operated for at least 20 minutes. During night tariff periods, the system also only runs if power consumption is high or no additional heat sources is available.
  • Page 90 Manual XrGi 20G-To Version 1.0 - 2012 66: Q60-Heat Distributor temperature high System has stopped (alarm stop). The gas safety circuit has detected that the Q60-Heat Distributor is too hot, so it has stopped the engine and displayed a fault.
  • Page 91 Version 1.0 - 2012 Manual XrGi 20G-To 78: Startup, all tanks cold When the control system starts the engine, the LCD display shows the start time (also appears in Service Database later). This code (78) means that all the storage tanks were cold when the engine started (no heat in storage). If there is heat in storage when the engine starts, code 79 “Start under other circumstances”...
  • Page 92 The system has suffered an alarm stop because there is no 5 V supply on the Q60-Heat Distributor network board. 99: Reduced output This code is ONLY used when test runs are conducted at EC POWER, not for a system on the customer's premises. 100: Q60-Heat Distributor engine valve faulty One of the engine valve limit switches is faulty.
  • Page 93 Version 1.0 - 2012 Manual XrGi 20G-To 108: VPP-Modus 4 This code appears when switching to mode 4 on the VPP gateway. In mode 4, the system does not operate. It remains on standby until another mode is selected which allows it to start. However, the storage tank can be heated up completely if an electric heater is connected.

  • Page 94: Operating Modes

    Manual XrGi 20G-To Version 1.0 - 2012 6.2.2. operating modes 8: Calibrating radiators In this operating mode, the system checks to see if its internal radiators are working properly when production starts. (The internal radiators are in the engine/generator compartment in older systems and in the water tank in newer ones). If everything is OK, the operating mode switches to 10 “Normal operation”.

  • Page 95: Reasons For Calls

    Version 1.0 - 2012 Manual XrGi 20G-To 6.2.3. reasons for calls 1: Normal (8/24) The system sends a modem call every eight hours (will only be every 24 hours at a later date). These calls are made whether the system is operating, in a normal alarm stop or some other mode. Continue reading here if the call does not get through.

  • Page 96: Care And Maintenance

    Version 1.0 - 2012 7. care and maintenance Maintenance must only be carried out by authorised EC POWER specialists. Warning! Do not carry out any maintenance unless and until the XRGI system has shut down and cooled down. Otherwise there is a risk of getting burned on hot components and scalded if media escape.

  • Page 97: Maintenance

    30,000 hours or at least every 120 months The XRGI 20G-TO system needs care and maintenance after 6,000 operating hours or at least every two years if it is to keep working safely and reliably. Regular maintenance will ensure your XRGI system is always ready to use, reliable and long lasting.
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  • Page 99: Xrgi Control Panel

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  • Page 131: Xrgi External Connections

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  • Page 161: Declaration Of Conformity

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  • Page 162: Certificate Of No Objection 11030

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  • Page 163: Pre - Commissioning Checklist

    Pre-Commissioning Checklist The commissioning checklist ensures the units are ready for commissioning. The form must be returned at least 5 working days prior to the provisional commissioning date supplied by EC POWER A/S so that the date can be confirmed.
  • Page 164 Fuel gas system: Has the flue gas system been installed according to regulations? Has unit been installed with EC POWER supplied flue? If not then please provide make and specification: Has a condensate drain been installed (or more if required)?
  • Page 165 Has the remaining supply, control and signal cables routed and connected according to instructions? 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 for the Heat Distributor Power cable between the Power Unit and the Control Panel (with 63 A CEE female connector).
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