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EC POWER XRGI 6 Maintenance Instruction

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M A I N T E N A N C E I N S T R U C T I O N S
01DOC1077-03
01.2025

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  • Page 1 M A I N T E N A N C E I N S T R U C T I O N S 01DOC1077-03 01.2025...

  • Page 4: Table Of Contents

    XRGI® MAINTENANCE INSTRUCTIONS C O N T E N T SYSTEM AND DOCUMENTATION INFORMATION 1.1 VALIDITY OF THE INSTRUCTION 1.2 RATING PLATE SAFETY INSTRUCTIONS 2.1 INFORMATION, SAFETY, AND WARNING SYMBOLS 2.2 INTENDED USE 2.3 GENERAL SAFETY INFORMATION 2.3.1 HANDLING COOLANT AND ENGINE OIL 2.3.2 ACTIONS IN CASE OF GAS SMELL INSIDE BUILDINGS 2.3.3...
  • Page 5 XRGI® MAINTENANCE INSTRUCTIONS C O N T E N T 5.1.4 REPLACING USED SPARK PLUGS 5.1.5 AIR FILTER 5.1.6 VACUUM HOSE 5.1.7 OIL FILTER 5.1.8 PLUG FOR MEASURING POINT 5.1.9 LAMBDA SENSOR 5.1.10 FASTENING NEW SPARK PLUGS 5.1.11 EXHAUST COMPENSATOR & SPRING BAND CLAMPS 5.1.12 NEW OIL 5.1.13...

  • Page 6: System And Documentation Information

    XRGI® system, read the maintenance instructions carefully, especially the safety instructions. If you have any problems under- standing the contents, contact your EC POWER dealer before starting work. V A L I D I T Y O F T H E I N S T R U C T I O N This maintenance instruction only applies to XRGI®...

  • Page 7: Safety Instructions

    Read the following section carefully and observe the safety instructions. If you are unsure about any matters or information, contact your EC POWER dealer. The XRGI® system was constructed according to the current applicable rules and standards for technical equipment and in compliance with recognised, conventional safety measures. To achieve the maximum possible safety, it is essential that all the safety information contained in this maintenance manual is adhered to and fully implemented.

  • Page 8: General Safety Information

    G E N E R A L S A F E T Y I N F O R M AT I O N Only a certified, skilled installer who has undergone special training for the XRGI® system through EC POWER may conduct mainte- nance on the XRGI®...

  • Page 9: Handling Coolant And Engine Oil

    2. SAFETY INSTRUCTIONS 2.3.1 H A N D L I N G C O O L A N T A N D E N G I N E O I L Always wear safety gloves and safety glasses when handling coolant and engine oil. I N T H E E V E N T O F C O N TA C T W I T H C O O L A N T A N D E N G I N E O I L : PROPERTY ■...

  • Page 10: Actions In Case Of Fire Or Ingress Of Water

    The installation of an equipotential bonding between the CHP and all metal parts near the XRGI® system, gas pipes, water pipes, ven- tilation, etc. must comply with applicable regulations and ordinances and is strongly recommended by EC POWER. The equipotential bonding must be calculated and carried out professionally and depends on the type of grounding protection used (TN-s, TT, etc.).

  • Page 11: Explosive And Easily Flammable Materials

    XRGI® system without consulting your authorised EC POWER specialist. Check with your authorised EC POWER specialist to ensure that there is still a sufficient supply of combustion air to the XRGI® system before fitting moisture-tight windows.

  • Page 12: Filling And Refilling Liquid

    Use EC POWER Engine Coolant, supplied with every new XRGI® system, to fill and refill the engine circuit to avoid expensive repairs due to corrosion in the pipes of XRGI® systems. Only use the heated EC POWER Engine Coolant for heating purposes in the closed circuit and do not drain it off for other purposes.

  • Page 13: Operation With Biogenic Gases

    2. SAFETY INSTRUCTIONS 2.3.14 O P E R AT I O N W I T H B I O G E N I C G A S E S Biogenic gas can be odourless. When operating with biogenic gases the applicable gas detectors and shut-off devices for gas detec- tors must be installed.

  • Page 14: Safety Equipment On The Xrgi® System

    Sound insulation cladding on the Power Unit Make sure that the warning information labels (stickers) on the XRGI® system are always clearly visible, undamaged and complete. Replace damaged or dirty warning labels. The information labels are available from EC POWER. 2 . 3 .17 S A F E T Y A N D W A R N I N G L A B E L S O N T H E X R G I ®...

  • Page 15: Warranty Information

    R E T U R N O B L I G AT I O N S EC POWER is obliged to take back XRGI® systems after their use. XRGI® systems must be reused or recycled following their return. Components that cannot be recycled must be disposed of in an environmentally friendly manner.

  • Page 16: Maintenance Instructions

    Maintenance is required after fixed intervals to ensure that the XRGI® system always operates safely and reliably. ■ The maintenance interval is indicated on the iQ-Control Panel display and in the EC POWER service database. ■ Maintenance is performed after the number of operational hours listed below or no later than after 2 years (for XRGI® 15 BIOGE- NIC no later than one year).

  • Page 17: Online Check

    C H E C K I N G T H E S E R V I C E D ATA B A S E https:// Check the runtime of the XRGI® system in the EC POWER service database - service.ecpower.dk ■...

  • Page 18: On Site Check

    3.1.3 H Y D R A U L I C C H E C K Make sure that the XRGI® system is installed according to the EC POWER regulations: ■ Use the commissioning protocol to check which hydraulic has been applied.
  • Page 19 4. MAINTENANCE XRGI® 6 M A I N T E N A N C E X R G I ® 6 S E R V I C E K I T - S TA N D A R D C O M P O N E N T S QTY.

  • Page 20: Service Kit - Component Replacement

    XRGI® MAINTENANCE INSTRUCTIONS S E R V I C E K I T – C O M P O N E N T R E P L A C E M E N T Suitable protective clothing i.e. goggles, gloves, and shoes shall be ■...

  • Page 21: Torque Wrench

    4. MAINTENANCE XRGI® 6 4.1.3 V A L V E C L E A R A N C E A D J U S T M E N T ■ Remove the oil separator hose from the valve cover. torque wrench 16 mm spark plug ■...

  • Page 22: Replacing Used Spark Plugs

    XRGI® MAINTENANCE INSTRUCTIONS 4.1.4 R E P L A C I N G U S E D S P A R K P L U G S Feeler gauge new spark ■ Check the electrode gap using a before inserting the plugs (5) and adjust if necessary.

  • Page 23: Oil Filter

    4. MAINTENANCE XRGI® 6 vacuum hose (7) onto the vacuum sensor and the air filter box. ■ Push the new 4.1.7 O I L F I LT E R oil filter spanner. ■ Dismantle the used oil filter using an Used oil filters must be disposed in accordance with the applicable country regulations.

  • Page 24: Exhaust Compensator & Spring Band Clamps

    XRGI® MAINTENANCE INSTRUCTIONS 4.1.10 E X H A U S T C O M P E N S AT O R & S P R I N G B A N D C L A M P S spring ■ Loosen the spring band clamps on the exhaust compensator using a band clamp pliers and put them aside.

  • Page 25: Coolant & Bleeding

    4. MAINTENANCE XRGI® 6 4.1.12 C O O L A N T & B L E E D I N G ■ Check whether all four valves on the manifold are open on the Q-Heat Distributor. Open any closed valves. Q - H E AT D I S T R I B U T O R ■...

  • Page 26: Software Update

    ■ Once all parts of the service kit have been replaced on the XRGI® system, the software must be updated. Follow the EC POWER software update instructions. If your XRGI® system already has the latest software installed, please pro- ceed to section 4.3.

  • Page 27: Regulation Of Emissions

    4. MAINTENANCE XRGI® 6 R E G U L AT I O N O F E M I S S I O N S L A M B D A A D J U S T M E N T TECHNICIAN MENU ▲▼...

  • Page 28: Maintenance Xrgi® 6 Lownox And Xrgi

    XRGI® MAINTENANCE INSTRUCTIONS M A I N T E N A N C E X R G I ® 6 L o w N O x A N D X R G I ® 9 S E R V I C E K I T - S TA N D A R D C O M P O N E N T S QTY.

  • Page 29: Service Kit - Component Replacement

    5. MAINTENANCE XRGI® 6 LowNOx AND XRGI® 9 S E R V I C E K I T – C O M P O N E N T R E P L A C E M E N T ■ Suitable protective clothing i.e.

  • Page 30: Valve Clearance Adjustment

    XRGI® MAINTENANCE INSTRUCTIONS 5.1.3 V A L V E C L E A R A N C E A D J U S T M E N T ■ Remove the oil separator hose from the valve cover. torque wrench 16 mm spark plug ■...
  • Page 31 5. MAINTENANCE XRGI® 6 LowNOx AND XRGI® 9 5.1.4 R E P L A C I N G U S E D S P A R K P L U G S Feeler gauge new spark ■ Check the electrode gap using a before inserting the plugs (5) and adjust if necessary.
  • Page 32 XRGI® MAINTENANCE INSTRUCTIONS 5.1.7 O I L F I LT E R oil filter spanner. ■ Dismantle the used oil filter using an Used oil filters must be disposed in accordance with the applicable country regulations. Improper disposal of used filters endangers the environment! oil filter (4), put a little oil onto the rubber seal and tighten the oil ■...
  • Page 33 5. MAINTENANCE XRGI® 6 LowNOx AND XRGI® 9 5.1.10 F A S T E N I N G N E W S P A R K P L U G S The temperatures of the spark plugs and the cylinder head have now equalised. torque wrench 16 mm spark plug insert ■...

  • Page 34: Water Pump

    XRGI® MAINTENANCE INSTRUCTIONS 5.1.12 NEW O I L ■ XRGI® Engine Oil (2). Fill a maximum of 40 litres Fill the engine with of oil through the filler neck. ■ Check the fill level on the oil dipstick to ensure that the engine is not overfilled. To do this, briefly screw on the oil cap and then remove it again.
  • Page 35 5. MAINTENANCE XRGI® 6 LowNOx AND XRGI® 9 P O W E R U N I T ■ Bleed the engine circuit at the air pot on the Power Unit. Attach a hose to the 11 mm bleed screw to divert any leaking XRGI® Engine Coolant and then use an wrench to loosen the bleed screw.
  • Page 36 ■ Once all parts of the service kit have been replaced on the XRGI® system, the software must be updated. Follow the EC POWER software update instructions. If your XRGI® system already has the latest software installed, please pro- ceed to section 5.3.
  • Page 37 6. MAINTENANCE XRGI® 15 AND XRGI® 15 BIOGENIC M A I N T E N A N C E X R G I ® 1 5 A N D X R G I ® 1 5 B I O G E N I C S E R V I C E K I T - S TA N D A R D C O M P O N E N T S QTY.
  • Page 38 XRGI® MAINTENANCE INSTRUCTIONS S E R V I C E K I T – C O M P O N E N T R E P L A C E M E N T ■ Suitable protective clothing i.e. goggles, gloves, and shoes shall be worn during maintenance of the XRGI®...
  • Page 39 6. MAINTENANCE XRGI® 15 AND XRGI® 15 BIOGENIC 6.1.3 R E P L A C I N G U S E D S P A R K P L U G S ■ torque wrench 20.8 mm spark plug Remove the old spark plugs using a with a insert.
  • Page 40 XRGI® MAINTENANCE INSTRUCTIONS 6.1.7 O I L ■ XRGI® Engine Oil (2). Fill a maximum of 30 litres Fill the engine with of oil through the filler neck. ■ Check the fill level on the oil dipstick to ensure that the engine is not overfilled. ■...
  • Page 41 6. MAINTENANCE XRGI® 15 AND XRGI® 15 BIOGENIC P O W E R U N I T ■ Bleed the engine circuit at the air pot on the Power Unit. Attach a hose to the 11 mm bleed screw to divert any leaking XRGI® Engine Coolant and then use an wrench to loosen the bleed screw.
  • Page 42 ■ Once all parts of the service kit have been replaced on the XRGI® system, the software must be updated. Follow the EC POWER software update instructions. If your XRGI® system already has the latest software installed, please pro- ceed to section 6.3.
  • Page 43 7. MAINTENANCE XRGI® 15 LowNOx AND XRGI® 20 M A I N T E N A N C E X R G I ® 1 5 L o w N O x A N D X R G I ® 2 0 S E R V I C E K I T - S TA N D A R D C O M P O N E N T S QTY.
  • Page 44 XRGI® MAINTENANCE INSTRUCTIONS S E R V I C E K I T – C O M P O N E N T R E P L A C E M E N T Suitable protective clothing i.e. goggles, gloves, and shoes shall be ■...
  • Page 45 7. MAINTENANCE XRGI® 15 LowNOx AND XRGI® 20 7.1.3 R E P L A C I N G U S E D S P A R K P L U G S torque wrench 20.8 mm spark plug ■ Remove the old spark plugs using a with a insert.
  • Page 46 XRGI® MAINTENANCE INSTRUCTIONS oil filter (4), put a little oil onto the rubber seal and tighten the oil ■ Take the new filter manually. Do not use any tools to fit the oil filter to avoid damage to the filter. 7.1.7 NEW O I L XRGI®...
  • Page 47 7. MAINTENANCE XRGI® 15 LowNOx AND XRGI® 20 7.1.9 V A C U U M H O S E 3 mm Allen ■ Loosen the 8 bolts from the electronics compartment using a screwdriver and remove the cover. ■ In the electronics compartment remove the vacuum hose from the vacuum sensor.
  • Page 48 XRGI® MAINTENANCE INSTRUCTIONS 7.1.12 C O O L A N T & B L E E D I N G ■ Check whether all four valves on the manifold are open on the Q-Heat Distributor. Open any closed valves. Q - H E AT D I S T R I B U T O R ■...
  • Page 49 ■ Once all parts of the service kit have been replaced on the XRGI® system, the software must be updated. Follow the EC POWER software update instructions. If your XRGI® system already has the latest software installed, please pro- ceed to section 7.3.
  • Page 50 XRGI® MAINTENANCE INSTRUCTIONS R E G U L AT I O N O F E M I S S I O N S L A M B D A A D J U S T M E N T TECHNICIAN MENU ▲▼...
  • Page 51 8. PREVENTIVE MAINTENANCE OF WEAR PARTS P R E V E N T I V E M A I N T E N A N C E O F W E A R PA R T S Once the maintenance service has been completed, check wear parts of the XRGI® system components and, if necessary, replace components in order to ensure a long service life and safe operation of the XRGI®...
  • Page 52 XRGI® MAINTENANCE INSTRUCTIONS iQ - C O N T R O L PA N E L With the iQ-Control Panel switched on: S U R G E P R O T E C T I O N ■ Inspect the surge protection for correct function. D I S P L AY ■...
  • Page 53 8. PREVENTIVE MAINTENANCE OF WEAR PARTS X R G I ® A C C E S S O R I E S Q - N E T W O R K ■ Inspect all Q-Network modules for correct function. AFTER P O W E R FA C T O R C O R R E C T O R Q-NETWORK SALES...

  • Page 54: Maintenance

    XRGI® MAINTENANCE INSTRUCTIONS R E C O R D I N G Once all maintenance tasks have been carried out, they must be recorded in the ser- vice booklet and in the iQ-Control Panel on site. S E R V I C E B O O K L E T ■...
  • Page 55 9. RECORDING N O T E S...
  • Page 56 M A I N T E N A N C E I N S T R U C T I O N S 01DOC1077-03 01.2025...

This manual is also suitable for:

Xrgi 6 lownoxXrgi 9Xrgi 15Xrgi 15 biogenicXrgi 15 lownoxXrgi 20

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