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ASSEMBLY INSTRUCTIONS
Turbocharger / Power2 500-M
Original assembly instructions – English
This document is valid for the
Power2 series:
Power2 550-M
Purpose
The assembly instructions explain how the low-
and high-pressure stage of ABB Turbocharging
is fitted to the engine correctly and without any
health and safety risks.
Target group
The assembly instructions are intended for
engineers and mechanics responsible for fitting
the low- and high-pressure stage on the engine.
Power2 performance package
Two-stage turbocharging solution for highest
turbocharging efficiency
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Table of Contents
Related Manuals for ABB Power2 Series
Summary of Contents for ABB Power2 Series
- Page 1 Power2 550-M Purpose Power2 performance package The assembly instructions explain how the low- Two-stage turbocharging solution for highest and high-pressure stage of ABB Turbocharging turbocharging efficiency is fitted to the engine correctly and without any health and safety risks. Target group...
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Page 3: Table Of Contents
Steps for fastening the high-pressure stage............22 Tightening the clamping nut ..................24 Completion work, if required ................... 25 Storage of new low-pressure and high-pressure stages........ 26 Further information..................... 28 © Copyright 2020 ABB. All rights reserved. HZTL455311P0009_EN Rev.A July 2020... -
Page 4: Introduction
Introduction Purpose of the assembly instructions The assembly instructions explain how the low- and high-pressure stage of ABB Turbochar- ging is fitted to the engine correctly and without any health and safety risks. This element of the documentation is supplied with the product, as is required for partly completed ma- chinery in accordance with machinery directive 2006/42/EC. - Page 5 ABB Switzerland Ltd, Turbocharging is identified as ABB Turbocharging in this document. Official service stations of ABB Turbocharging Official service stations are identified in this document as ABB Turbocharging Service Sta- tions. They are regularly audited and certified by ABB Turbocharging. See "Contact Informa- tion"...
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Page 6: Definition Of Warning, Caution, Note
- Mechanical hazard - Dusts - Chemical hazard - Gases - Thermal hazard Safety helmet Ear protection Table 3: Personal protective equipment to be worn specific to the respective task © Copyright 2020 ABB. All rights reserved. HZTL455311P0009_EN Rev.A July 2020... -
Page 7: Safety
All further safety instructions contained and specifically identified in every chapter of this document (see section Definition of safety instructions) must also be observed. Information Low-pressure and high-pressure stages from ABB Turbocharging comply with the machinery directive 2006/42/EC and are partly completed machinery as defined by Article 2 g. Responsibility of the operating company... -
Page 8: Lifting Of Loads
Use a suitable edge guard if there are sharp edges. The assembly devices must be completely screwed in and must not unscrew during use. Use assembly devices only for the described applications. © Copyright 2020 ABB. All rights reserved. HZTL455311P0009_EN Rev.A... -
Page 9: Occupational Safety
Keep the floor, equipment and the low-pressure and high-pressure stage clean. Have oil binding agents ready and provide or keep oil pans at hand. Welding work Wear personal protective equipment (PPE) for welding operations. © Copyright 2020 ABB. All rights reserved. HZTL455311P0009_EN Rev.A July 2020... - Page 10 Only perform operations for which you have previously received instruc- tion or training. Hazards due to operating materials and supplies Operating materials and supplies can include: Oils, greases, coolants, cleaning agents and solvents, acids or similar substances. © Copyright 2020 ABB. All rights reserved. HZTL455311P0009_EN Rev.A July 2020...
- Page 11 Observe the information in the material safety data sheet for the operat- ing materials and supplies. Comply with local legislation. Wear safety goggles. Wear safety gloves to protect against mechanical hazards. Wear a respiratory mask to protect against gases. © Copyright 2020 ABB. All rights reserved. HZTL455311P0009_EN Rev.A July 2020...
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Page 12: Weight And Transportation Of The Low-Pressure And The High-Pressure Stages
Two swivel lifting eyes are required for the safe lifting of loads. These are not included in the ABB scope of delivery. Swivel lifting eyes Power2 Thread Length Minimum load limit 550 HP 20 ... 30 400 kg mm Table 5: Swivel lifting eyes © Copyright 2020 ABB. All rights reserved. HZTL455311P0009_EN Rev.A July 2020... -
Page 13: Installing The Low-Pressure Stage
Assembly Instructions / Power2 500-M 4 Installing the low-pressure stage / Installing the low-pressure stage The fixing screws for fastening the low-pressure stage are not included in the ABB scope of delivery and must be provided by the enginebuilder. General information... -
Page 14: Placing The Low-Pressure Stage On The Bracket And Aligning
Adjust the low-pressure stage on the engine. Tighten the fixing screws at the foot. For a one-piece foot, see One-piece foot →13 For a two-piece foot, see Two-piece foot →15 © Copyright 2020 ABB. All rights reserved. HZTL455311P0009_EN Rev.A July 2020... -
Page 15: Steps For Fastening The Low-Pressure Stage
(recessed). To ensure that the screws still have the same high pre-tensioning force, the tightening angle must be in- creased by the specified amount for every 10 mm of additional screw length. © Copyright 2020 ABB. All rights reserved. HZTL455311P0009_EN Rev.A... - Page 16 Completion work, if required: Attach all gas, air, water and oil pipes in accordance with the enginebuilder's instructions. Fit insulation components. Fit speed sensor and plug in cable connector. © Copyright 2020 ABB. All rights reserved. HZTL455311P0009_EN Rev.A July 2020...
- Page 17 We recommend contacting ABB Turbocharging for new applications of the low-pressure stage with horizontally-mounted gas outlet NB090 or NB270. Step 1: Check screws in accordance with the General Information table Power2 500 LP –...
- Page 18 NB000 (045 / 315) 3, 4, 5, 6 NB090 3, 6, 5 NB270 4, 5, 6 Table 9: Pre-tightening torque sequence Power2 Thread size [mm] Pre-tightening torque [Nm] 550 LP Table 10: Pre-tightening torque © Copyright 2020 ABB. All rights reserved. HZTL455311P0009_EN Rev.A July 2020...
- Page 19 NB000 (045 / 315) 1, 2, 7, 8 NB090 1, 8, 7 NB270 2, 7, 8 Table 11: Pre-tightening torque sequence Power2 Thread size [mm] Pre-tightening torque [Nm] 550 LP Table 12: Pre-tightening torque © Copyright 2020 ABB. All rights reserved. HZTL455311P0009_EN Rev.A July 2020...
- Page 20 Completion work, if required: Attach all gas, air, water and oil pipes in accordance with the enginebuilder's instructions. Fit insulation components. Fit speed sensor and plug in cable connector. © Copyright 2020 ABB. All rights reserved. HZTL455311P0009_EN Rev.A July 2020...
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Page 21: Installing The High-Pressure Stage
Bearing casing 42198 O-ring 42199 O-ring Oil supply Oil drains The oil is supplied (01) and drained (02) through the bracket. Insert the O-rings (42198 and 42199) into the slots of the bearing casing. © Copyright 2020 ABB. All rights reserved. HZTL455311P0009_EN Rev.A July 2020... -
Page 22: Placing The High-Pressure Stage On The Bracket
4. Lead threaded rod (42191) with screwed-on clamping nut through thrust washer, expan- sion bush and bearing casing. 5. Screw the centering bush (42193) flush onto the threaded rod from below. © Copyright 2020 ABB. All rights reserved. HZTL455311P0009_EN Rev.A... - Page 23 Step 1. Observe the steps for fastening the high-pressure stage (see following section). Value X Value L 135 ±2 mm 70 mm Table 15: Values X and L © Copyright 2020 ABB. All rights reserved. HZTL455311P0009_EN Rev.A July 2020...
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Page 24: Steps For Fastening The High-Pressure Stage
When using a radial gas outlet casing, only operate the high-pressure stage with a completely fitted support (61300). © Copyright 2020 ABB. All rights reserved. HZTL455311P0009_EN Rev.A July 2020... - Page 25 3. Fit the support (61300) using the fixing screws (01). Observe tightening torque. 4. Tighten the screw (61003) of the connection between gas outlet casing (61001) and sup- port (61300). Connect all gas pipes and air lines. © Copyright 2020 ABB. All rights reserved. HZTL455311P0009_EN Rev.A July 2020...
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Page 26: Tightening The Clamping Nut
4. Tighten clamping nut (03) by hand. 5. Unscrew clamping nut (03) by ¼ of a turn (90°). The distance between the thrust washer and the clamping nut is now about 1 mm. © Copyright 2020 ABB. All rights reserved. HZTL455311P0009_EN Rev.A... -
Page 27: Completion Work, If Required
Completion work, if required Attach all gas, air, water and oil pipes in accordance with the enginebuilder's instructions. Fit insulation components. Fit speed sensor and plug in cable connector. © Copyright 2020 ABB. All rights reserved. HZTL455311P0009_EN Rev.A July 2020... -
Page 28: Storage Of New Low-Pressure And High-Pressure Stages
Storage of new low-pressure and high-pressure stages and cartridge groups for up to 6 months New low-pressure and high-pressure stages and cartridge groups from ABB Turbocharging can be stored in their closed packages for 6 months from the date of delivery without addi- tional mothballing measures (indicated by the VCI label on the package). - Page 29 Check the package for damage. If the package is damaged, the low-pressure or high- pressure stage or the cartridge group must be checked and repackaged by an ABB Tur- bocharging Service Station. After every 3 years, the following steps must be carried out by an ABB Turbocharging Service Station: ¡...
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Page 30: Further Information
Online Operation Manual The Operation Manual for the low-pressure and high-pressure stage with the relevant serial number is available online on our website www.abb.com/turbocharging. Fig. 19: Serial number of the low-pressure and high-pressure stage on the rating plate Low-pressure stage... - Page 31 Assembly Instructions / Power2 500-M 7 Further information / Fig. 20: Finding the Operation Manual online © Copyright 2020 ABB. All rights reserved. HZTL455311P0009_EN Rev.A July 2020...
- Page 32 Phone: +41 58 585 7777 Station”). Fax: +41 58 585 5144 Find and download the Operation Manual of E-mail: turbocharging@ch.abb.com your product on our website (see “Operation Manuals“). www.abb.com/turbocharging © Copyright 2020 ABB. All rights reserved. Visit our website by scanning the QR code.