EC POWER XRGI 6 Maintenance Instruction Download

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01DOC1077

VERSION 17/1.0

M A I N T E N A N C E I N S T R U C T I O N

For professionals

Summary of Contents for XRGI 6

Page 1: ...01DOC1077 VERSION 17 1 0 M A I N T E N A N C E I N S T R U C T I O N For professionals...

Page 2: ...data 14 SCHRITT 2 Data transmission 14 SCHRITT 3 Network cables 15 SCHRITT 4 Software update XRGI system 15 SCHRITT 5 Software update Q network modules 15 SCHRITT 6 Data recovery 16 4 3 Regulation of...

Page 3: ...eplacement 37 SCHRITT 1 Used oil 37 SCHRITT 2 Used spark plugs 37 SCHRITT 3 Injector 37 SCHRITT 4 Air filter 38 SCHRITT 5 Plug for measuring point 39 SCHRITT 6 Oil filter 39 SCHRITT 7 Oil 39 SCHRITT 8...

Page 4: ...he XRGI system for its intended use 2 Install the XRGI system on a stable foundation 3 Before commissioning the system ensure that the on site mains voltage matches the line voltage specified on the m...

Page 5: ...Replace clothing and shoes contaminated with oil Do not put any oily rags and or cloths in your pockets 19 Skin Wash off with water and soap or special hand cleaning agents where necessary use a nail...

Page 6: ...ge every maintenance with a signature Maintenance is required after fixed intervals to ensure that the XRGI system always operates safely and reliably The maintenance interval display on the iQ Contro...

Page 7: ...tention to the following Is the TMV set point compensated displayed as an operational set point below the actual value Are all temperatures shown in the service database and are the figures viable Is...

Page 8: ...op glands Check the ball siphon for leaks While the XRGI system is running check whether condensate is present in the ball siphon and whether condensate can run freely from the ball siphon Check the c...

Page 9: ...0x1 5 1 pc oil filter 1 pc plug for measuring point REQUIRED TOOLS Engine oil suction pump 16 mm spark plug wrench Oil filter spanner 17 mm socket insert Torque wrench 10 mm socket insert Water pump p...

Page 10: ...e applicable coun try regulations Improper disposal of used oil represents a hazard to the environment Mixing foreign substances such as solvents brake fluid coolant and chlorinated oil in used oil is...

Page 11: ...11 Nm With No 1 piston at TDC of the compression stroke check and adjust the valve clearances for the cylinders shown in the chart to the right Rotate the crankshaft one complete turn 360 clockwise t...

Page 12: ...e plug from the vacuum sensor and the zero pressure hose from the air filter box Unscrew the vacuum sensor by a 5 mm Allen screwdriver and remove it from the zero pressure hose Remove the 2 hose clamp...

Page 13: ...dance with the applicable country regulations Improper disposal of used filters represents a hazard to the environment Take the new oil filter put a little oil onto the rubber seal and tighten the oil...

Page 14: ...pensator including the two hose clamps and fix the exhaust gas compensator with the 2 hose clamps by a hose clamp pliers STEP 10 OIL Add oil to the engine Fill a maximum of 40 litres of oil through th...

Page 15: ...nder Settings Press any key on the user interface to activate the display and enter the menu Move the cursor to Info by using the buttons and press OK on the user interface Press ESC on the user inter...

Page 16: ...requires that the boards of all XRGI components must be updated otherwise the XRGI system may malfunc tion Update the heat control PCB of the Q Heat Distributor the central control PCB of the iQ Cont...

Page 17: ...card than an EC POWER Telia SIM card please contact the SIM card provider for the APN address An incorrect APN address causes data transfer problems Move the cursor to Request by using the buttons and...

Page 18: ...by 1 NOX ADJUST Lambda adjustment increase by 1 When reducing CO and or NOx values it takes a couple of minutes before the change stabilises on your flue gas analyser Only make small adjust ments at a...

Page 19: ...engine oil 1 pc oil filter 2 pcs zero pressure hose 2 0x1 5 REQUIRED TOOLS Oil suction pump 16 mm spark plug wrench Oil filter spanner 17 mm socket insert Torque wrench 10 mm socket insert Water pump...

Page 20: ...applicable coun try regulations Improper disposal of used oil represents a hazard to the environment Mixing foreign substances such as solvents brake fluid coolant and chlorinated oil in used oil is...

Page 21: ...e 11 Nm With No 1 piston at TDC of the compression stroke check and adjust the valve clearances for the cylinders shown in the chart to the right Rotate the crankshaft one complete turn 360 clockwise...

Page 22: ...et insert Torque 5 Nm STEP 5 INJECTOR ZERO PRESSURE HOSE VACUUM FILTER VACUUM SENSOR Remove the plug from the injector and vacuum sensor Unscrew the vacuum sensor by a 5 mm Allen screwdriver and pull...

Page 23: ...il separator hose back into their positions and fix the air filter box bolts by a 10 mm open end spanner Push the gas hose onto the new injector and insert the injector into the intake socket Use 2 Al...

Page 24: ...exhaust gas pipe consider replacing the plug in the exhaust gas opening on the exhaust gas pipe upstream of the Power Unit STEP 8 LAMBDA SENSOR Separate the lambda sensor cable from the cable tree at...

Page 25: ...ompensator including the 2 hose clamps and fix the exhaust gas compensator with the 2 hose clamps by a hose clamp pliers STEP 11 OIL Add oil to the engine Fill a maximum of 40 litres of oil through th...

Page 26: ...nder Settings Press any key on the user interface to activate the display and enter the menu Move the cursor to Info by using the buttons and press OK on the user interface Press ESC on the user inter...

Page 27: ...m requires that the boards of all XRGI components must be updated otherwise the XRGI system may malfunc tion Update the heat control PCB of the Q Heat Distributor the central control PCB of the iQ Con...

Page 28: ...card than an EC POWER Telia SIM card please contact the SIM card provider for the APN address An incorrect APN address causes data transfer problems Move the cursor to Request by using the buttons and...

Page 29: ...by 1 NOX ADJUST Lambda adjustment increase by 1 When reducing CO and or NOx values it takes a couple of minutes before the change stabilises on your flue gas analyser Only make small adjust ments at a...

Page 30: ...g for measuring point 4 pcs spark plugs 1 pc oil filter REQUIRED TOOLS Oil suction pump Torque wrench Oil filter spanner 17 mm socket insert Water pump pliers 20 8 mm spark plug wrench Funnel 3 mm All...

Page 31: ...k plugs and adjust if necessary Standard gap 0 4 0 5 mm Insert the new spark plugs loosely to allow the temperature to balance out between the cylinder head and spark plugs STEP 3 AIR FILTER Loosen th...

Page 32: ...lter as they could damage it STEP 6 OIL Add oil to the engine Fill a maximum of 30 litres of oil through the filler neck Use a funnel to fill the engine Check the oil level on the dipstick to ensure t...

Page 33: ...e main menu under Info and in the technician menu under Settings Press any key on the user interface to activate the display and enter the menu Move the cursor to Info by using the buttons and press O...

Page 34: ...m requires that the boards of all XRGI components must be updated otherwise the XRGI system may malfunc tion Update the heat control PCB of the Q Heat Distributor the central control PCB of the iQ Con...

Page 35: ...guration may only be used when commissioning new XRGI systems not during the software update of existing XRGI sys tems The data from the XRGI system will now be recovered and visible on the display af...

Page 36: ...played on all components close the Power Unit and reinstall the rear cover of the Power Unit Recommission the XRGI system by Connecting the Q Heat Distributor to the power supply Opening the gas supp...

Page 37: ...sensor 1 pc injector 1 pc vacuum filter 1 pc lambda sensor 4 pcs spark plugs 1 pc air filter 1 pc oil filter EXTRA 1 pc Power Wrap 1 pc Rubber plug REQUIRED TOOLS Oil suction pump Flue gas analyser Oi...

Page 38: ...g insert Use a feeler gauge to check the electrode gap before inserting the new spark plugs and adjust if necessary Standard gap 0 4 0 5 mm Insert the new spark plugs loosely to allow the temperature...

Page 39: ...ntake socket Fix the injector with the 2 Allen screw by a 5 mm Allen screwdriver Fix the gas hose with the hose clamp on the injector and plug the injector plug back on the injector Replace the engine...

Page 40: ...ubber seal and tighten the oil filter manually Do not use any tools to fit the oil filter as they could damage it STEP 7 OIL Add oil to the engine Fill a maximum of 50 litres of oil through the filler...

Page 41: ...e Replace the exhaust gas compensator including the 2 hose clamps and fix the exhaust gas compensator with the 2 hose clamps by a hose clamp pliers STEP 10 LAMBDA SENSOR Separate the lambda sensor cab...

Page 42: ...e main menu under Info and in the technician menu under Settings Press any key on the user interface to activate the display and enter the menu Move the cursor to Info by using the buttons and press O...

Page 43: ...m requires that the boards of all XRGI components must be updated otherwise the XRGI system may malfunc tion Update the heat control PCB of the Q Heat Distributor the central control PCB of the iQ Con...

Page 44: ...guration may only be used when commissioning new XRGI systems not during the software update of existing XRGI sys tems The data from the XRGI system will now be recovered and visible on the display af...

Page 45: ...by 1 NOX ADJUST Lambda adjustment increase by 1 When reducing CO and or NOx values it takes a couple of minutes before the change stabilises on your flue gas analyser Only make small adjust ments at a...

Page 46: ...ess 6 Temperature sensor Check the sensor values of the temperature sensors of the Q Heat Distributor in the iQ Control Panel display Verification of the temperatures 1 The XRGI system is started and...

Page 47: ...hten all terminals in the iQ Control Panel STEP 3 POWER UNIT XRGI 6 9 Power Unit XRGI 15 20 Power Unit POS COMPONENT DESCRIPTION 1 Safety temperature limiter Inspect the safety temperature limiter for...

Page 48: ...the protection in the power factor corrector for correct function STEP 5 CLEANING POS COMPONENT DESCRIPTION 1 Gas water filter Clean the gas and water filter on the secondary circuit 2 XRGI system com...

Page 49: ...e menu Move the cursor to Technician by using the buttons and press OK on the user interface Log on In the technician menu move the cursor to Maintenance by using the buttons and press OK on the user...

Page 50: ...W W W E C P O W E R E U M A I N T E N A N C E I N S T R U C T I O N...

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EC POWER XRGI 6, Maintenance Instruction

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