ABB XAC24083 Manuals

Manuals and User Guides for ABB XAC24083. We have 1 ABB XAC24083 manual available for free PDF download: Operation Manual

ABB XAC24083 Operation Manual (140 pages)

Brand: ABB | Category: Industrial Equipment | Size: 22 MB

Table of Contents
3
Introduction
4
Purpose of the Manual
4
Symbols, Definitions
5
Storage of New Turbochargers and Spare Parts
7
Contact Information
9
Safety
12
Introduction
12
CE Conformity
12
Definition of Mandatory Signs
13
Definition of Safety Instructions
13
Intended Use
14
Deflagration on Gas Engines
15
Warning Plates on the Turbocharger
16
Turbocharger Rating Plate
17
Periodic Check of the Pressure Vessels
18
Lifting of Loads
19
Prerequisites for Operation and Maintenance
20
Hazards During Operation and Maintenance
21
Safe Operation
23
Safe Maintenance
24
Introduction
34
Essential Information
34
Registered Trademarks
34
Related Documents
34
Table 1: Related Documents
34
Layout and Function of the Turbocharger
35
Fig. 1: Layout and Function of the Turbocharger
35
Warning Plates on the Turbocharger
37
Fig. 2: Warning Plate Locations
37
Locations of the Rating Plates
38
Fig. 3: Locations of the Rating Plates
38
Removal and Installation
39
Turbocharger Weight
39
Removing the Turbocharger
39
Table 2: Total Weight
39
Fig. 4: Fitting the Lifting Gear
40
Installing the Turbocharger
41
Fig. 5: Placing the Turbocharger
41
Fig. 6: Compressor-End Foot
42
Fig. 7: Turbine-End Foot
42
Table 3: General Information about Fastening the Turbocharger
42
Table 4: Tightening Torques (Foot Screws)
43
Table 5: Tightening Angle (Foot Screws)
43
Commissioning
44
Oil Supply
44
Inspection Procedures
44
Commissioning after Taking out of Operation
46
Monitoring During Operation
47
Oil Pressure, Oil Temperature
47
Table 6: Lubricating Oil Pressure, Oil Inlet
47
Fig. 8: Oil Temperature at the Outlet
48
Table 7: Lubricating Oil Temperature at the Inlet
48
Table 8: Lubricating Oil Temperature at the Outlet
48
Admissible Air Inlet Temperature
50
Turbocharger Speed
50
Fig. 9: Layout and Overview of the Speed Measurement System
50
Fig. 10: Replacing the Speed Sensor
52
Table 9: Tightening Torques (86505)
52
Low Pressure Measurement at the Filter Silencer
53
Fig. 11: U-Tube Manometer at the Filter Silencer
53
Operation and Service
54
Noise Emission
54
Service Work
55
Fig. 12: Noise Insulation, Bellows
55
Expected Replacement Intervals
59
Table 10: Expected Replacement Intervals for Turbocharger Parts
59
Table 11: Recommended Replacement Intervals for Turbocharger Parts
59
Flexible Turbocharger Cut-Out
60
Stopping the Engine
61
Periodic Maintenance
62
Foreword to Maintenance
62
Cleaning the Filter Silencer
63
Fig. 13: Layout and Overview of Filter Silencer
63
Changing the Filter Strip on the Filter Silencer Casing
65
Fig. 14: Dismantling Filter Ring Circumferential Part
65
Fig. 15: Opening Filter Ring Lock
65
Fig. 16: Attaching New Filter Ring
66
Fig. 17: Fitting New Filter Ring
66
Cleaning the Compressor During Operation
67
Fig. 18: Overview of Wet Cleaning of Compressor
69
Fig. 19: Filter Plug View
70
Table 12: Volume of Water Per Cleaning Process
70
Table 13: Tightening Torques (81125)
70
Cleaning the Turbine During Operation
71
Fig. 20: Overview of Dry Cleaning Device
72
Table 14: Amount of Granulate
74
Draining the Gas Outlet Casing
75
Fig. 21: Drain Pipe Diagram
75
Troubleshooting
76
Malfunctions When Starting
76
Table 15: Malfunctions When Starting - Delayed Start-Up
76
Table 16: Malfunctions When Starting - Vibrations
76
Table 17: Malfunctions When Starting - Rubbing of Rotating Parts
76
Malfunctions During Operation
77
Table 18: Malfunctions During Operation - Lubricating Oil Pressure too Low
77
Table 19: Malfunctions During Operation - Drop in Speed
77
Table 20: Malfunctions During Operation - Exhaust Gas Temperature too High
78
Table 21: Malfunctions During Operation - Charge Air Pressure too Low
78
Surging of the Turbocharger
79
Table 22: Malfunctions During Operation - Charge Air Pressure too High
79
Table 23: Surging of the Turbocharger
79
Malfunctions When Stopping
80
Table 24: Malfunctions When Stopping - Runout Noises
80
Table 25: Malfunctions When Stopping - Shortened Runout Time
80
Speed Measurement System
81
Table 26: Malfunctions of the Speed Measurement System
81
Disassembly and Assembly
82
Introduction
82
Material Required
83
Weights of Assemblies
84
Fig. 22: Weights of Assemblies
84
Table 27: Weights of Assemblies [Kg]
84
Table 28: Weight of Wall Insert [Kg]
84
Disassembly and Assembly of the Filter Silencer Casing
85
Fig. 23: Dismantling the Filter Silencer Casing
85
Fig. 24: Fitting the Filter Silencer Casing
86
Fig. 25: Fitting the Filter Silencer Casing
87
Fig. 26: Fitting the Filter Silencer Casing
87
Fig. 27: Fitting the Filter Silencer Casing
88
Fig. 28: Fitting the Filter Silencer Casing
88
Fig. 29: Fitting the Bellows
89
Table 29: Tightening Torques (Filter Silencer Screws)
89
Dismantling the Filter Silencer
90
Fig. 30: Dismantling the Filter Silencer
90
Fig. 31: Dismantling the Filter Silencer
91
Dismantling the Filter Silencer with Noise Package
92
Fig. 32: Dismantling the Filter Silencer with Noise Package
92
Dismantling Wall Insert and Diffuser
93
Fig. 33: Dismantling the Wall Insert
93
Fig. 34: Moving out Wall Insert
94
Fig. 35: Putting down Wall Insert
94
Fig. 36: Putting down Wall Insert
95
Fig. 37: Dismantling the Diffuser
96
Axial Clearance a Prior to Disassembly
97
Fig. 38: Measuring Axial Clearance a
97
Table 30: Axial Clearance a
97
Dismantling the Insulation (≤ A175-L)
98
Fig. 39: Removing the Insulation (A175-L and Smaller)
98
Dismantling the Gas Inlet Casing (≤ A175-L)
99
Fig. 40: Dismantling the Gas Inlet Casing (A175-L and Smaller)
99
Table 31: Maximum Admissible Loosening Torque (51087)
99
Dismantling the Nozzle Ring (≤ A175-L)
100
Fig. 41: Dismantling the Nozzle Ring (A175-L and Smaller)
100
Dismantling the Gas Inlet Casing (≥ A180-L)
101
Fig. 42: Dismantling the Gas Inlet Casing (180-L and Larger)
101
Table 32: Maximum Admissible Loosening Torque (51087)
101
Dismantling the Nozzle Ring (≥ A180-L)
102
Fig. 43: Fitting the Nozzle Ring Holder
102
Fig. 44: Dismantling the Nozzle Ring
103
Fig. 45: Put down the Nozzle Ring
103
Fitting the Nozzle Ring (≤ A175-L)
104
Fig. 46: Fitting the Nozzle Ring (A175-L and Smaller)
104
Table 33: Tightening Torque (56014)
104
Fitting the Gas Inlet Casing (≤ A175-L)
105
Fig. 47: Fitting the Gas Outlet Casing (A175-L and Smaller)
105
Table 34: Tightening Torque (51087)
105
Fitting the Insulation (≤ A175-L)
106
Fig. 48: Fitting the Insulation (A175-L and Smaller)
106
Fitting the Nozzle Ring (≥ A180-L)
107
Fig. 49: Looping Around the Nozzle Ring (A180-L and Larger)
107
Fig. 50: Fitting the Nozzle Ring (A180-L and Larger)
108
Table 35: Tightening Torque (56014)
108
Fitting the Gas Inlet Casing (≥ A180-L)
109
Fig. 51: Fitting the Gas Inlet Casing (A180-L and Larger)
109
Table 36: Tightening Torque (51087)
109
Axial Clearance a after Assembly
110
Fig. 52: Measuring Axial Clearance a
110
Table 37: Axial Clearance a
110
Fitting the Diffuser
111
Fig. 53: Fitting the Diffuser
111
Table 38: Tightening Torque (77015)
111
Fitting Wall Insert
112
Fig. 54: Positioning Wall Insert
112
Fig. 55: Fitting Wall Insert
113
Table 39: Tightening Torque (72011)
113
Fitting the Filter Silencer
114
Fig. 56: Fitting the Filter Silencer
115
Table 40: Tightening Torque (72004)
115
Fig. 57: Fitting the Filter Silencer
116
Table 41: Tightening Torque (72004)
116
Fitting the Filter Silencer with Noise Package
117
Fig. 58: Fitting the Filter Silencer with Noise Package
117
Table 42: Tightening Torque (51087)
117
Table of Tightening Torques
119
Fig. 60: Tightening Torques of Speed Sensor
119
Fig. 59: Overview of Tightening Torques
120
Table 43: Overview of Tightening Torques
120
Table 44: Tightening Torque, Insulation
120
Taking a Turbocharger out of Operation
121
Possible Emergency Repairs
121
Taking Defective Turbochargers out of Operation
122
Table 45: Bypass Procedure
122
Fig. 61: Locking the Rotor
123
Table 46: Tightening Torque
124
Fig. 62: Ensuring Clamping of the Cover Ring
125
Table 47: Required Washers (01)
125
Table 48: Tightening Torque (57005)
125
Fig. 63: Position of Cover Plates
126
Mothballing the Turbocharger
128
Taking the Engine out of Operation for up to 12 Months
128
Taking the Engine out of Operation for more than 12 Months
129
Disposing of Turbocharger Components
130
Spare Parts
131
Ordering Spare Parts
131
Table 49: Customer Spare Part Set (97070)
131
Table 50: Customer Spare Part Set (97071)
132
View of Turbocharger with Part Numbers
133
Fig. 64: View of Turbocharger with Part Numbers
133
Table 51: Turbocharger with Part Numbers
134
View of Cartridge Group with Part Numbers
135
Fig. 65: View of Cartridge Group with Part Numbers
135
Table 52: Cartridge Group with Part Numbers
136
Tools
137
Table 53: Customer Tool Set 90000
137

ABB Categories

Industrial Equipment Controller Measuring Instruments Battery Charger DC Drives

More ABB Manuals

ABB XAC24083 Manuals

ABB XAC24083 Operation Manual (140 pages)

Table of Contents

Related Products

ABB Categories