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ABB HT608602 manual available for free PDF download: Operation Manual
ABB HT608602 Operation Manual (200 pages)
Brand:
ABB
| Category:
Battery Charger
| Size: 34.18 MB
Table of Contents
Operation Manual / A150-M - A155-M
3
Table of Contents
3
Operation Manual / A150-M
6
Introduction
6
Purpose of the Manual
6
Fig. 1: Serial Number (01) on the Rating Plate
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
Safety
15
Introduction
15
CE Conformity
15
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Fig. 10: Attachment Angle
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Lifting of Loads
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Removing and Installing
31
Turbocharger Weight and Transportation
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Table 4: Weight of Complete Turbocharger Unit
31
Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Fig. 13: Removing the Turbocharger
33
Fig. 14: Loosening the Clamping Nut
34
Fig. 15: Turbocharger Centre of Gravity
35
Installing the Turbocharger
36
Fig. 16: Inserting the Gasket
36
Fig. 17: Fitting the Turbocharger 1
37
Fig. 18: Fitting the Turbocharger 2
38
Table 5: Fitting the Turbocharger, Value X, L
38
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
39
Table 6: Torque-Controlled Tightening of the Pressure Screws
40
Fig. 20: Tightening Pressure Screws
40
Fig. 21: Connecting the Speed Sensor
41
Fig. 22: Connecting the Compressor Cooling Air Intake
41
Fig. 23: Attaching the Support
41
Commissioning
42
Oil Supply
42
Fig. 24: Oil Orifice
42
Inspection Procedures
44
Commissioning after Taking out of Operation
46
Table 7: Lubricating Oil Pressure at Oil Inlet before Turbocharger
47
Monitoring Operation
47
Oil Pressure, Oil Temperature
47
Table 8: Lubricating Oil Temperature at the Inlet
48
Table 9: Maximum Lubricating Oil Temperature at the Outlet
48
Exhaust Gas Temperature before Turbine
49
Turbocharger Speed
50
Fig. 25: Layout and Overview of Speed Measurement System
50
Fig. 26: Replacing the Speed Sensor
52
Table 10: Tightening Torque (86505)
52
Noise Emission
53
Operation and Service
53
Fig. 27: Noise Insulation, Bellows
54
Service Work
55
Expected Replacement Intervals
58
Table 11: Expected Replacement Intervals
58
Stopping the Engine
60
Periodic Maintenance Work
61
Foreword to Maintenance
61
Table 12: Maintenance Table
61
Cleaning the Compressor During Operation
62
Fig. 28: Carrying out Wet Cleaning of Compressor
64
Table 13: Parameters for Wet Cleaning of Compressor
64
Cleaning the Turbine During Operation
65
Fig. 29: Turbine Cleaning Devices
67
Table 14: Turbine Wet Cleaning, Recommended Operating State
67
Fig. 30: Carrying out Wet Cleaning of Turbine
68
Table 15: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
68
Cleaning Components Mechanically
69
Table 16: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
69
Fig. 31: Cleaning the Filter Silencer
70
Fig. 32: Cleaning the Filter Silencer
72
Fig. 33: Cleaning the Filter Silencer (2)
74
Table 17: Tightening Torque (81272)
74
Table 18: Tightening Torque (81273)
74
Fig. 34: Compressor-End, Non-Rotating Parts
75
Fig. 35: Turbine End, Non-Rotating Parts
76
Fig. 36: Soaking the Turbine End
79
Table 19: Value Table for Soaking
79
Changing the Absorption Element
82
Fig. 37: Disassembling the Absorption Element
82
Table 20: Tightening Torque (81152 / 81154)
83
Fig. 38: Installing the Absorption Element
83
Eliminating Malfunctions
84
Malfunctions When Starting
84
Table 21: Malfunctions When Starting - Delayed Start-Up
84
Table 22: Malfunctions When Starting - Vibrations
84
Table 23: Malfunctions When Starting - Rubbing of Rotating Parts
84
Malfunctions During Operation
85
Table 24: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 25: Malfunctions During Operation - Speed Reduces
85
Table 26: Malfunctions During Operation - Speed Increases
85
Table 27: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 28: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 29: Malfunctions During Operation - Charge Air Pressure too High
87
Table 30: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 31: Malfunction - Turbocharger Pumping
88
Table 32: Malfunction - Sporadic Surge Blows
88
Malfunctions When Stopping
89
Table 33: Malfunctions When Stopping - Runout Noises
89
Table 34: Malfunctions When Stopping - Runout Time too Short
89
Table 37: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Table 35: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 36: Malfunction of the Speed Measurement System - Measured Speed too High
90
Speed Measurement System
90
Dismantling and Fitting, General
91
Introduction
91
Material Required
92
Fig. 39: Swivel Lifting Eyes
92
Table 38: Swivel Lifting Eyes
92
Table 40: Dismantling Screw
93
Table 39: Press-Off Screws
93
Fig. 41: Dismantling Screw
93
Fig. 40: Press-Off Screws
93
Disassembly and Assembly Concepts
95
Fig. 42: Removing the Cartridge Group with Compressor and Turbine Casing
95
Fig. 43: Cartridge Concept
96
Fig. 44: Optional Spanner Holder
97
Weights of Individual Parts
98
Fig. 45: Weights of Assemblies
98
Table 41: Weights of Assemblies
98
Table 42: Tightening Torques
99
Fig. 46: Overview of Tightening Torques
99
Table of Tightening Torques
99
Fig. 47: Tightening Torques for Insulation
100
Table 43: Tightening Torques for Insulation
100
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
101
Removing Air Inlets
101
Fig. 48: Removing the Air Inlets
101
Fig. 49: Removing the Uncoupled Filter Silencer
102
Removing the Gas Outlet Casing
103
Fig. 50: Remove Gas Outlet Casing Without Support
103
Fig. 51: Removing Gas Outlet Casing with Support 1
104
Fig. 52: Removing Gas Outlet Casing with Support 1
105
Removing the Gas Outlet Flange
106
Fig. 53: Dismantling the Gas Outlet Flange
107
Table 44: 3 Press-Off Screws
107
Fig. 54: Removing the Gas Outlet Flange
108
Table 45: 6 Press-Off Screws
108
Removing the Cartridge Group with Compressor and Turbine Casing
109
Fig. 55: Turbine Cleaning Nozzle
109
Fig. 56: Remove Insulation
109
Fig. 57: Removing the Cartridge Group with Compressor and Turbine Casing
110
Fig. 58: Setting down the Cartridge Group with the Compressor and Turbine Casing
110
Removing the Compressor Casing
111
Fig. 59: Removing the Compressor Casing
111
Fig. 60: Dismantling the Diffuser and the Wall Insert
112
Removing the Cartridge Group
113
Fig. 61: Removing Cartridge Group 1
113
Table 46: Tightening Torque (90012-01)
113
Fig. 62: Removing Cartridge Group 2
114
Fig. 63: Removing Cartridge Group 3
115
Installing the Cartridge Group on the Service Support
116
Fig. 64: Installing the Cartridge Group on the Service Support
116
Removing the Nozzle Ring
117
Fig. 65: Removing the Nozzle Ring
117
Measuring Clearance a and B
118
Fig. 66: Measuring Clearance a and B
118
Table 47: Permissible Clearances a and B
118
Nozzle Ring Compression PD
119
Fig. 67: Nozzle Ring Compression PD
119
Table 48: Nozzle Ring Compression PD
119
Installing Nozzle Ring
120
Fig. 68: Installing the Nozzle Ring
120
Installing the Cartridge Group
121
Fig. 69: Lifting the Cartridge Group and Rotating It
121
Fig. 70: Turning the Cartridge Group
122
Table 49: Tightening Torque (90012-01)
122
Fig. 71: Installing the Cartridge Group
123
Table 50: Tightening Torque (51007)
123
Installing the Compressor Casing
124
Fig. 72: Fitting the Wall Insert and the Diffuser
124
Table 51: Tightening Torque (79041)
124
Table 52: Tightening Torque (72011)
125
Fig. 73: Installing the Compressor Casing
125
Turning the Cartridge Group with Compressor and Turbine Casing
126
Fig. 74: Turning the Cartridge Group with Compressor and Turbine Casing
126
Installing the Gas Outlet Flange
127
Fig. 75: Installing the Gas Outlet Flange
127
Radial Clearances N and R
128
Fig. 76: Measuring Clearances N and R
128
Table 53: Permissible Clearances N and R
128
Fitting the Insulation
129
Fig. 77: Fitting the Insulation
129
Fig. 79: Installing the Cartridge Group with Compressor and Turbine Casing
130
Fig. 78: Installing the Cartridge Group with Compressor and Turbine Casing
130
Installing the Cartridge Group with Compressor and Turbine Casing
130
Installing the Gas Outlet Casing
131
Fig. 80: Fitting Gas Outlet Casing Without Support
131
Table 54: Tightening Torque (51009)
131
Fig. 81: Installing Gas Outlet Casing with Support 1
132
Table 55: Tightening Torque (51009)
132
Fig. 82: Installing Gas Outlet Casing with Support 2
133
Table 56: Tightening Torque (72051)
134
Fig. 83: Installing the Air Inlets
134
Installing Air Inlets
134
Fig. 84: Installing the Uncoupled Filter Silencer
135
Table 57: Tightening Torque (72054)
135
Dismantling and Fitting, Cartridge Concept
136
Removing Air Inlets
136
Fig. 85: Removing the Air Inlets
136
Fig. 86: Removing the Uncoupled Filter Silencer
137
Removing the Compressor Casing
138
Fig. 87: Removing the Compressor Casing
138
Fig. 88: Pressing off Compressor Casing
139
Fig. 89: Remove the Diffuser
139
Fig. 90: Dismantling the Diffuser and the Wall Insert
140
Fig. 91: Removing Insulation Sheets
141
Fig. 92: Removing Cartridge Group 1
141
Table 58: Threaded Rod, Value X
141
Fig. 93: Removing Cartridge Group 2
142
Fig. 94: Removing Cartridge Group 2
143
Fig. 95: S_05180
144
Fig. 96: Measuring Clearance a and B
145
Table 59: Permissible Clearances a and B
145
Fig. 97: Nozzle Ring Compression PD
146
Table 60: Nozzle Ring Compression PD
146
Fig. 98: Installing the Nozzle Ring
147
Fig. 99: Installing the Cartridge Group 1
148
Fig. 100: Installing the Cartridge Group 2
149
Table 61: Threaded Rod, Value X and L
149
Table 62: Tightening Torque (51007)
149
Fig. 101: Fitting the Wall Insert and the Diffuser
150
Table 63: Tightening Torque (79041)
150
Fig. 102: Installing the Compressor Casing
151
Table 64: Tightening Torque (72011)
151
Fig. 103: Measuring Clearances N and R
152
Table 65: Permissible Clearances N and R
152
Fig. 104: Fitting the Insulation
153
Fig. 105: Installing the Air Inlets
154
Table 66: Tightening Torque (72051)
154
Fig. 106: Installing the Uncoupled Filter Silencer
155
Table 67: Tightening Torque (72054)
155
Dismantling and Fitting, Special Tools for Fastening Strips
156
Fig. 107: Customer Tool
156
Fig. 108: Customer Tool
156
Table 68: Customer Tool
156
Table 69: Customer Tool
156
Fig. 110: Removing the Fastening Strips
157
Fig. 109: Positioning the Collection Tub
157
Application, Special Tools
157
Fig. 111: Fitting the Upper Fastening Strips
158
Fig. 112: Fitting the Bottom Fastening Strip
158
Table 70: Tightening Torque (51007)
158
Fig. 113: Fitting the Bottom Fastening Strip
159
Table 71: Tightening Torque (51007) with Spanner Holder
159
Fig. 114: Fitting the Cartridge Group
160
Table 72: Tightening Torque (51007)
160
Fig. 115: Positioning the Fastening Strip
161
Fig. 116: Clamping Piece
162
Fig. 117: Attach Nut
163
Table 73: Tightening Torque (51007) with Spanner Holder
163
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
164
Disassembly
164
Fig. 118: Initial Situation
164
Fig. 119: Disassembly of the Elbows
164
Fig. 120: Disassembly of the Elbows
165
Fig. 121: Pipe Disassembly
165
Table 74: Dismantling Screw
166
Fig. 123: Disassembly of the Cleaning Nozzle
166
Fig. 122: Disassembly of the Connecting Pieces
166
Assembly
167
Fig. 124: Assembly of the Cleaning Nozzle
167
Fig. 125: Assembly of the Connecting Pieces
167
Table 75: Dismantling Screw
167
Fig. 126: Pipe Assembly
168
Fig. 127: Elbow 1 Assembly
168
Fig. 128: Elbow 2 Assembly
169
Table 76: Tightening Torque (51314 / 51316)
169
Fig. 129: Fit the Cleaning Nozzles
170
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
170
Taking out of Operation at Short Notice
171
Possible Emergency Repairs
171
Installing the Replacement Turbocharger
172
Installing the Replacement Cartridge Group
172
Fitting the Cover Plate
173
Fig. 130: Fitting the Cover Plate
173
Table 77: Cover Plate Dimensions [MM]
174
Fig. 131: Cover Plate Drawing
174
Cover Plate Drawing
174
Table 78: Cover Plate Dimensions [MM]
175
Fig. 132: Dimensions for Cover Plate
175
Mothballing the Turbocharger
176
Taking the Engine out of Operation for up to 12 Months
176
Taking the Engine out of Operation for more than 12 Months
177
Material and Disposal
178
REACH and Rohs Compliance Declaration for Products
178
Disposing of Turbocharger Components
179
Required Customer Spare Part Set (97070)
180
Table 79: Customer Spare Part Set 97070
180
Ordering Spare Parts
180
Spare Parts
180
Spare Part - Illustrations
181
Table 80: Spare Parts - Cartridge, Oil Cooled
181
Table 81: Spare Parts - Bearing, Casing Oil Cooled
182
Table 82: Spare Parts - Rotor and Bearing Parts
183
Table 83: Spare Parts - Turbine Casing, 1 Inlet
184
Table 84: Spare Parts - Turbine Casing, 2 Inlets
185
Table 85: Spare Parts - Turbine Casing, 3 Inlets
186
Table 86: Spare Parts - Cleaning Device
187
Table 87: Spare Parts - Gas Outlet Casing, Radial
188
Table 88: Spare Parts - Compressor Casing
189
Table 89: Spare Parts - Filter Silencer
191
Table 90: Spare Parts - Air Suction Branch Axial
191
Table 91: Spare Parts - Air Suction Branch Radial
192
Table 92: Spare Parts - Speed Measurement System
193
Tools
194
Fig. 133: Special Tool
194
Table 93: Customer Tool Set 90000
194
Table 94: Special Tool (90160)
194
Fig. 134: Special Tool
195
Table 95: Special Tool (90160)
195
Figures
196
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