HYDRAULIC SOLUTIONS

01DOC1089-01

VERSION 1.1 2019

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TA B L E O F C O N T E N T S

OBJECTIVES AND REQUIREMENTS FOR INSTALLATION		

3

EFFICIENCY LABEL FOR HEATING SYSTEMS		4OVERVIEW OF HYDRAULIC SOLUTIONS

5HYDRAULIC SOLUTIONS

6-9

SERIES CIRCUIT WITH INJECTION – BOILER WITH HEADER		

6

SERIES CIRCUIT – BOILER WITH HEADER		

7

INSTALLATION

9 - 11INSTALLATION OF TEMPERATURE SENSOR AND INJECTION LINE FROM FLOW MASTER

9HEATING PIPE DIMENSIONS		10

INTEGRATION OF BW4+ / BW8+ (CONDENSING EXHAUST GAS HEAT EXCHANGER)		

11

KEY XRGI® COMPONENT FUNCTIONS		

12 -17

FLOW MASTER CONTROL 		

12

FLOW MASTER

13

STORAGE TANK		14

STORAGE TANK AND FLOW MASTER QUICK SIZING GUIDE		

15

STORAGE CONTROL 		

16

BOILER CONTROL 		17

HYDRAULIC PLANNING CHECKLIST		18

O B J E C T I V E S A N D R E Q U I R E M E N T S F O R I N S TA L L AT I O N
OBJECTIVES:
Optimum operation and interaction between the XRGI® and boiler system.
Cost-effective integration of the XRGI® into existing or new central heating systems.
Use of the manufacturer’s standard settings (non-use of higher-level settings).

REQUIREMENTS FOR INSTALLATION:
The hydraulic circuit diagrams are schematic diagrams. Design and install any necessary hydraulic, safety and control fittings inaccordance with DIN standards and local regulations.
Only install the Storage Tank with two hydraulic connections (apart from the additional cost, additional connections will lead tosupply and return water mixing in the Storage Tank and hence to inefficiency and malfunctions).
High return temperatures can cause malfunctions. Avoid excessive flow in the heating system.
Operate the heating system at the lowest possible return temperatures.
Refer to the instructions for information on hydraulic and electrical connections.
Proper hydraulic integration (and prevention of start/stop operation) is necessary to comply with the warranty conditions.
Only the current version of this document, which can be found at www.ecpower.eu, is applicable.

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HYDRAULIC SOLUTIONSVERSION 1.1 2019

E F F I C I E N C Y L A B E L F O R H E AT I N G S Y S T E M S

P R O D U C T L A B E L A N D PA C K A G E L A B E L :Refrigerators, televisions and washing machines have carried an energy efficiency label for several years now – appliances that we can’t
imagine being without. This now also includes the XRGI®.
This label has been mandatory on space heaters since 26 September 2015. The individual components of a heating system carry a product label. The XRGI® carries the highest efficiency class label: A+++.
As heating systems consist of several components and all components affect the efficiency of the overall system, package labels are now
being added to product labels.

Example: S E R I E S C I R C U I T W I T H I N J E C T I O N – B O I L E R W I T H H E A D E R
STORAGE CONTROL

iQ-CONTROL PANELFLOW MASTER CONTROLQ-HEAT DISTRIBUTORTs
FLOW MASTER

T-At

C

BOILER

DHW

DW

Tf
BW 4+ / BW 8+Tb

XRGI® POWER UNITHEADERTrSTORAGE TANK

Please observe boiler manufacturer‘s specifications!

PRODUCT LABELManufacturer

PAC K AG E L A B E L

XRGI® 20

Example:XRGI® 20 with Flow MasterModel

E C P OWE R A/S XRGI® 20

EC POW ER A/SHeating function
A+++
A++
A+
A
B

A+++

Efficiency class

63 dB

A+++

A+++

A

Solar collector

A+
A

Thermal storage

39 kW

Heating capacity

B
C
D

Temperature control

E

Additional power
generating function

Additional
heating appliance
2019

A+++
++

C
D

Sound power level

Heating

X R G I® 20

811/2013

FG
2019

811/2013

IMPORTANT:
If products from other companies are used in systems in addition to products from EC POWER, EC POWER excludes all liability forthe correct calculation of the energy efficiency class for the overall system.
The calculations are prescribed by the European Commission (Delegated Regulation (EU) no. 811/2013)

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HYDRAULIC SOLUTIONSVERSION 1.1 2019

OVERVIE W OF HYDR AULIC SOLUTIONSHYDRAULICTYPE OF CIRCUITFLOW MASTER INJECTION

BOILER TYPENUMBER OF XRGI®

PAGE

1H O

SERIESYES

WITH HEADER

1

6

1H M

SERIESYES

WITH HEADER

>1

6

2HO

SERIESNO

WITH HEADER

1

7

2HM

SERIESNO

WITH HEADER>1

7IMPORTANT:All hydraulic solutions use the boiler functions to control the heating circuits and domestic hot water (DHW) as well as all possibleenergy-saving measures within the secondary heating system.
This avoids expensive control redundancies and there is not need for higher-level external control.

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HYDRAULIC SOLUTIONSVERSION 1.1 2019

SERIES CIRCUIT WITH INJECTION – BOILER WITH HEADER

1H O Hydraulic – O N E X R G I®

1H M Hydraulic – M O R E T H A N O N E X R G I®

IMPORTANT:
Always set Tf higher than the maximum flow temperature in the control settings to give
the XRGI® priority over the boiler, so that the XRGI® always supplies the base load heat(Δ 5 K is sufficient).
Select the Flow Master type/size based on the discharge capacity you require.
Use a minimum of 2 Storage Controls (= 8 temperature sensors) with multi-module systems.
Possible use of condensing technology in the boiler is slightly reduced by raising the return 		water temperature. However, the achieved efficiency improvement of the XRGI® production 		
more than covers this minor loss.

LEGEND
Temperature sensor
Signal cable for sensor / controls
Signal cable for external components
Flow, return water
Q-Network cable (heating circuit)
Q-Network cable (control circuit)
Pump
Heat consumer

MAIN COMPONENTS FOR OPERATION OF THE XRGI®:Power Unit, Q-Heat Distributor, iQ-Control Panel, Flow Master, Flow Master Control, Storage Control,
Storage Tank

6

2-way valve
3-way valve

HYDRAULIC SOLUTIONSVERSION 1.1 2019

SERIES CIRCUIT – BOILER WITH HEADER

2 H O Hydraulic – O N E X R G I®

2 H M Hydraulic – M O R E T H A N O N E X R G I®

IMPORTANT:Use a minimum of 2 Storage Controls (= 8 temperature sensors) with multi-module systems.
Possible use of condensing technology in the boiler is slightly reduced by raising the return
water temperature. However, the achieved efficiency improvement of the XRGI® production
more than covers this minor loss.

MAIN COMPONENTS FOR OPERATION OF THE XRGI®:Power Unit, Q-Heat Distributor, iQ-Control Panel, Storage Control, Storage Tank

LEGEND
Temperature sensor
Signal cable for sensor / controls
Signal cable for external components
Flow, return water
Q-Network cable (heating circuit)
Q-Network cable (control circuit)
Pump
Heat consumer
2-way valve
3-way valve

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HYDRAULIC SOLUTIONSVERSION 1.1 2019

INSTALLATION( P. 9 – 11 )K E Y X R G I® - C O M P O N E N T

FUNCTIONS( P. 1 2 – 1 7 )HYDR AULIC PLANNINGCHECKLIST( P. 1 8 )8HYDRAULIC SOLUTIONSVERSION 1.1 2019

I N S TA L L AT I O N O F T H E T E M P E R AT U R E S E N S O R A N D I N J E C T I O N L I N E F R O M F L O W M A S T E R

I N S TA L L AT I O N I N V E R T I C A L P I P E W O R K ( U P W A R D F L O W ) :Flow Master injection pipe

No obstructions

Return to Storage Tank
Main return

I N S TA L L AT I O N I N H O R I Z O N TA L P I P E W O R K ( C O N N E C T T O U N D E R S I D E O F M A I N ) :Main return
No obstructions
Return to Storage Tank

Flow Master injection pipe

Ensure that there are absolutely no obstructions to the flow (e.g. check valve) on the main pipe between the Flow Masterand Storage Tank. The Flow Master will automatically maintain the correct direction of flow between these connections.

Note the following when installing the (Pt100) temperature sensor:
Install temperature sensors in immersion sleeves to obtain better and faster results.
Ensure that the heating water in vertical pipework flows upwards (ascending).
Ensure that the temperature sensors (in immersion sleeves) in horizontal pipework are fitted from above and “flow” and“return” connections from below.
Distance from Tf to the injection line of the XRGI®/Storage Tank: minimum 5 x D (pipe diameter)
Distance from Tb to the injection line of the XRGI®/Storage Tank: minimum 5 x D (pipe diameter)
Distance from Tr to the return line of the XRGI®/Storage Tank: maximum 5 x D (pipe diameter)
When installing in horizontal pipework, ensure that the 85 °C hot water injected from the XRGI® is well mixed with the main
flow of heating water and that there is no temperature stratification in the pipe (particularly at low flow rates).

EC POWER RECOMMENDS INSTALLING THE TEMPERATURE SENSOR AND INJECTION LINE FROM THE FLOWMASTER IN VERTICAL PIPEWORK (UPWARD FLOW).

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H E AT I N G P I P E D I M E N S I O N S

X R G I® S E C T I O N

FM SECTION

BUILDING SECTION

Pipe diameter sized according to type and number of XRGI®

Pipe diameter according totype of Flow Master

Pipe diameter sized according toheat requirements in the building to be heated

RECOMMENDED DIAMETER(FOR 10M AND 5 x 90° BENDS)X R G I® S E C T I O N

XRGI® 6

Number of XRGI®
1
2
3
4
DN 25 DN 32 DN 32 DN 40

XRGI® 9DN 25 DN 32 DN 40 DN 50

XRGI® 15

DN 32 DN 40 DN 50 DN 65

XRGI® 20

DN 32 DN 50 DN 65 DN 65

XRGI® typeI M P O R TA N T :If the entire heating water supply forthe building runs through the Storage
Tank (cf. Hydraulic solution 2HO and2HM on p. 7), design the pipes to andfrom the Storage Tank, as well as theStorage Tank connections, according to
the heat requirements of the building to
be heated.

FM SECTION
FM type

10

FM 50

DN 25

FM 150

DN 32

FM 250

DN 40

FM 350DN 50

HYDRAULIC SOLUTIONSVERSION 1.1 2019

I N T E G R AT I O N O F B W 4 + / B W 8 + ( C O N D E N S I N G E X H A U S T G A S H E AT E X C H A N G E R )/ Wärmespeicher
tozum
the Verbrauchernetz
Storage Tank

XRGI® POWER UNIT

vomtheVerbrauchernetz
fromStorage Tank / Wärmespeicher

Connect the BW4+ / BW8+ (condensing exhaust gas heat exchanger) to the return line from the consumer network/hot water Storage
Tank to the Q-Heat Distributor.
Note the following when connecting:Route all return water to the Q-Heat Distributor through the BW4+ / BW8+.
Only integrate (connect) the BW4+ / BW8+ without causing significant pressure loss.

MAIN COMPONENTS FOR OPERATION OF THE XRGI®:Power Unit, Q-Heat Distributor, iQ-Control Panel, Flow Master, Flow Master Control, Storage Control, Storage Tank

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HYDRAULIC SOLUTIONSF LOW MA S T E R CO N T R O L

FUNCTIONAL DESCRIPTION
The Flow Master Control regulates the delivery of heat from the XRGI® system to the central heating/site supply system– via the Flow Master valve and variable speed pump – to maintain the required flow temperature (Tf ) set on theiQ Control Panel. The Flow Master Control also protects the XRGI® system from excessively high return temperatures,
automatically prevents reverse flow between XRGI®/Flow Master connections and ensures minimal consumption ofelectricity by the pump.
The Flow Master maintains the set temperature at Tf by mixing in 80 - 85°C hot water from the XRGI® system into the
supply system water. Variations in heat loads and flow rates are compensated for by the Flow Master valve opening
and closing and the pump speed; the supply temperature Tf is therefore maintained regardless of the heat load. The
pump will stop if the Flow Master valve closes completely (i.e. no heat load).
The heat store will fill up if the heat load is lower than the heat produced by the XRGI®. The XRGI® will stop production
once the heat store is full. During periods of peak demand, it will wait until there is sufficient cooling capacity in theheat store before it restarts, otherwise it will wait until the minimum heat reserve has been reached before starting.
None of this affects the steady supply from the Flow Master.
If the heat load is greater than the heat produced by the XRGI®, the heat store will discharge. When the heat store
has fully discharged, the supply temperature Ts for the Flow Master will fall and the Flow Master Control accordingly
calculates a maximum supply temperature Tf as basis for control.
The Flow Master Control automatically adjusts to actual flow rates and return temperature conditions to achieve
stable and precise control. Abrupt changes in supply loads and flow rates are compensated for by special functions to
immediately recover and maintain steady control under all circumstances.

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F LOW MA S T E R

Figure shows FM type 350

FUNCTIONAL DESCRIPTION
The Flow Master is a motorised valve and variable speed pump unit, controlled by the Flow Master Control module.
The heat store enables the XRGI® system to service short-term peak loads way beyond the nominal output of thePower Unit. This minimises the need for supplementary heat from back-up boilers and maximises the number ofoperational hours and electricity production by the Power Unit. The Flow Master should therefore always be able todeliver at least twice the nominal Power Unit heat output, and generally significantly more. Ideally, it should be sized
to service all peak loads whenever average loads (e.g. 24 hours) are below the nominal Power Unit output.
The nominal heat outputs are based on a delta T of 20 K between the XRGI® flow and main return, corresponding toa main return temperature of 60 - 65°C. The Flow Master heat outputs will increase proportionally with lower returntemperatures.
Flow Master offers steady regulation down to approx. 2% of max. load (provided it has been installed correctly).
THE FM-TYPE DEPENDS ON THE CHP’S THERMAL OUTPUT.
SIZING GUIDE SEE QUICK SIZING GUIDE PAGE 15.

∆T

FM-TypThermal output(at a return of 60 to 65 °C)(Distributor flow - object return)Maximum
flow rate

FM 50

50 kW

20 °C

2,2 m³/h

FM 150150 kW20 °C

6,5 m³/h

FM 250250 kW

20 °C

10,8 m³/h

FM 350350 kW

20 °C

15,1 m³/h

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HYDRAULIC SOLUTIONSS T O R A G E TA N K

FUNCTIONAL DESCRIPTIONThe Storage Tank forms an integral part of the XRGI® system and is required for proper operation of the system. It ensures that any temporary falls in heat loads below the output of the Power Unit do not cause the Power Unit to stop,and enables the XRGI® system to service temporary heat loads way beyond the nominal output of the Power Unit.
When the heat load on site is permanently below the output of the Power Unit, the Storage Tank allows the XRGI®
system to operate the Power Unit for longer and to schedule operation according to power load patterns on site.
The way in which the Storage Tank is integrated determines its efficiency and effective storage capacity. It must be
installed hydraulically with only two connections – regardless of the hydraulic system selected. Installing the Storage
Tank with four connections (i.e. as a header) allows the cold return to mix with the hot flow. This reduces storage
capacity and, as a result, can cause the control to malfunction, leading to the XRGI® system shutting down and shortening its service life.

If multiple Storage Tanks are used, they must
be installed in series. Experience has shownthat parallel or reverse return circuits do not
operate satisfactorily and must not be used.

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S T O R A G E TA N K A N D F L O W M A S T E R Q U I C K S I Z I N G G U I D E

Site Return Temperature, Tr

CascadeUnits

Nominal Thermal
Output, kW)

Storage Capacity
Min. Litre

Storage Control
Min. Pcs *

30 °C

40 °C

50 °C

60 °C

XRGI® 6

1

12

500

1

FM 50

FM 50

FM 50

FM 50

XRGI® 9

1

20

500

1

FM 50

FM 50

FM 50

FM 50

XRGI® 15

1

31

800

1

FM 50

FM 50

FM 50

FM 150XRGI® 20

1

39

1000

2

FM 50

FM 50

FM 150FM 150XRGI® 15

2

62

1600

2

FM 50

FM 150FM 150FM 150XRGI® 20

2

77

2000

4

FM 150FM 150FM 150FM 250XRGI® 20

3

116

3000

6

FM 150FM 150FM 250FM 250XRGI® 20

4

155

4000

8

FM 150FM 250FM 250FM 350XRGI® type* EC POWER Storage Tanks include the minimum number of required Storage Controls.

STORAGE TANK AND FLOW MASTER
The above table is a Storage Tank and Flow Master quick sizing guide; the combinations shown cover most applications
efficiently. However, if the average thermal load (e.g. 24 hours) mostly is below the nominal XRGI® thermal output, you
should size the Storage Tank and Flow Master to cover thermal peak loads.

STORAGE CONTROLFor storage capacities below 1 m³, use at least one Storage Control with four temperature sensors. Improved operational
results can be achieved by using multiple storage controls.
For storage capacities above 1 m³, you can find the minimum number of Storage Controls in the table above.
EC POWER Storage Tanks already contain the minimum number of required Storage Controls.

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HYDRAULIC SOLUTIONSSTORAGE CONTROLFUNCTIONAL DESCRIPTIONThe Storage Control manages the Storage Tank. The temperature sensors detect the stratification layer between
hot flow water and cold return water. The clear separation of cold (return) water and hot (flow) water is crucial for
optimum operation of the system and thermal storage capacity: the EC POWER Storage Tank ensures this.
THE XRGI® SYSTEM REQUIRES AT LEAST ONE STORAGE CONTROL WITH FOUR TEMPERATURE SENSORS –OTHERWISE IT CANNOT OPERATE! USE A MINIMUM OF TWO STORAGE CONTROLS AND 8 SENSORS FOR
OPTIMUM OPERATION.

Fully automated Storage Tank management is based on the following sequence:
1.
2.

3.

Ensure a minimum run-time for each start:
Only start the Power Unit when there is sufficient cold water in the Storage Tank.
Maximum servicing of heat demand by the XRGI®system:
Start the Power Unit before the Storage Tank is empty. The heat reserve needed is continuously determined 		
based on the actual supply profile.
Ensure power-based operation (e.g. based on electrical demand and/or electricity cost):
Storing heat in the Storage Tank for subsequent use enables the Power Unit to operate even when no heatis needed.

The reserve capacities determined by the XRGI® system vary according to season and heat demand profiles. For
instance, in the colder months the system will try to maintain a very high heat reserve, whereas the “cold reserve”
requirement will be minimal. The situation will be reversed with low heat demand, with the system maintaining amuch smaller heat reserve along with a larger “cold reserve” to ensure sufficient periods of operation.

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BOILER CONTROLFUNCTIONAL DESCRIPTION
The Boiler Control ensures optimum operation of the XRGI® and the peak load boiler, when the XRGI® system is operated hydraulically via the Storage Tank parallel to the boiler. A potential-free contact in the Boiler Control activates theboiler to produce heat, when consumption exceeds the heat produced by the XRGI® and the Storage Tank is almost
empty. The boiler stops as soon as heat production by the XRGI® exceeds consumption.
THE BOILER CONTROL IS CONTROLLED BY THE TWO TOP STORAGE CONTROL TEMPERATURE SENSORS(INTERNAL EC POWER DESIGNATION S1 AND S2) IN THE STORAGE TANK

If the heat consumption is higher than the heat produced by the XRGI® over the long term, the top Storage Tank
sensor S1 becomes cold. Then the boiler control enables the boiler to produce heat until the second Storage Tank
sensor from the top (S2) registers a sufficient temperature. When this occurs, the boiler control stops the boiler again.
The additional installation of the Boiler Control ensures that the boiler is only switched on when it is needed in order
not to reduce the operating time of the XRGI®. This is particularly important with parallel circuits and domestic hotwater (DHW) systems, so that the boiler does not unnecessarily start up although heat production from the XRGI® andthe storage volume are sufficient to deliver heat.

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HYDR AULIC PLANNING CHECKLISTREQUIRED

SELECT EC POWER STANDARD HYDRAULIC SYSTEM 		

YES

SELECT STORAGE CONTROL 		

YES

SELECT BOILER CONTROLAFTER SELECTING HYDRAULIC SYSTEM

SPECIFY CONNECTING POINTS TO HEATING SYSTEM		YES

SELECT FLOW MASTER TYPE WITH FLOW MASTER CONTROLAFTER SELECTING HYDRAULIC SYSTEM

SELECT XRGI® TYPE AND QUANTITY		YES

DIMENSION PIPEWORK IN THE XRGI® SECTION 		YES

DIMENSION PIPEWORK IN THE FM SECTION

AFTER SELECTING HYDRAULIC SYSTEMINTEGRATE CONDENSING EXHAUST GAS HEAT EXCHANGEROPTIONALPOSITION FLOW MASTER TEMPERATURE SENSOR (TF, TB, TR)

AFTER SELECTING HYDRAULIC SYSTEMPOSITION INJECTION LINE AND RETURN LINE

AFTER SELECTING HYDRAULIC SYSTEMXRGI® AND BOILER SYSTEM CONTROL SETTINGS

YES

DEFINE TF AND MAXIMUM BOILER TEMPERATURE

AFTER SELECTING HYDRAULIC SYSTEMCHECK HEATING CIRCUITS AND HW PRODUCTION AT BOILER SYSTEM		

NOTES

18

YES

COMPLETED10/2019

VERSION 1.1 2019