ABB TPS44-H32 Bedienungsanleitung

ABB Turbocharging

Operation Manual

TPS44-H32

HT577639 English

Original Operation Manual

Chapter Document-ID

1 Introduction HZTL4005_EN_F

2 Safety HZTL4026_EN_D

3 Safety data sheet HT577639

4 Product description HZTL4037_EN_E

Operating limits and replacement intervals

The recommended replacement intervals and the corresponding operating limits in chapter 3 are jointly defined

with the enginebuilder. This information is specific to the product.

Non-observance of the recommended replacement intervals and the operating limits increases the risk of unpre-

dictable component failures.

Operation Manual / 1 Introduction

Table of contents

Introduction

1 Introduction............................................................................................................ 2

1.1 Purpose of the manual.................................................................................................. 2

1.2 Symbols, definitions...................................................................................................... 3

1.3 Storage of new turbochargers and spare parts...................................................... 5

1.4 Contact information...................................................................................................... 7

Operation Manual / 1 Introduction

1 Introduction / 1.1 Purpose of the manual

1 Introduction

1.1 Purpose of the manual

Fig.1: Serial number (01) on the rating plate

This Operation Manual belongs to the turbocharger with the identical serial number (01), see

chapter 3 (Safety data sheet) and the rating plate on the turbocharger.

Operation Manual

The Operation Manual explains the turbocharger and contains instructions for safe opera-

tion.

The Operation Manual is a complement to and expansion of existing national regulations for

occupational safety, accident prevention and environmental protection.

Target group

The Operation Manual is aimed at engineers and trained mechanics responsible for the

proper operation of the engine and for the turbocharger connected to it.

Availability of the Operation Manual

The Operation Manual must be available where the turbocharger is used.

All persons operating or working on the turbocharger must have read and fully understood

the Operation Manual.

Page 2 / 7

Operation Manual / 1 Introduction

1 Introduction / 1.2 Symbols, definitions

1.2 Symbols, definitions

Symbols

The following symbols are used in this document:

uIndicates an action step.

1. Indicates a numbered action step.

→ Refers to a page number.

Definition of Note

NOTICE

Note

The note provides advice which facilitates the work.

Definition of mandatory signs

Mandatory signs show the protective equipment to be worn for a task. The mandatory signs

are described in chapter Safety and must be complied with.

Definition of Caution / Warning

Caution and warning signs are described in chapter Safety.

ABB Turbo Systems

ABB Turbo Systems Ltd is identified as ABB Turbo Systems in this document.

Official service stations of ABB Turbo Systems

Official service stations are identified in this document as ABB Turbocharging Service Sta-

tions. They are regularly audited and certified by ABB Turbo Systems. Also see chapter Con-

tact information →7.

Page 3 / 7

Operation Manual / 1 Introduction

1 Introduction / 1.2 Symbols, definitions

Definition of pictograms

The following pictograms can occur in this document. These point out actions that must be

taken in accordance with the meaning of the relevant pictogram.

Pictogram Meaning Pictogram Meaning

Tighten with specified torque Affix

Tighten over specified tighten-

ing angle

Measure

Hand-tight, tighten without

tools

Note

Oil Visually inspect

Apply screw locking paste (e.g.

Loctite)

Please note text for numbered

work step

Apply high-temperature grease See document

Apply other paste in accord-

ance with specifications

Dispose of in an environmentally

compatible, professional way and

in compliance with locally applic-

able regulations

Oil free, grease free and dry

Table1: Definition of pictograms

Page 4 / 7

Operation Manual / 1 Introduction

1 Introduction / 1.3 Storage of new turbochargers and spare parts

1.3 Storage of new turbochargers and spare parts

Storage of new turbochargers and spare parts for up to 6 months

New turbochargers and spare parts can be stored in their closed packages for 6 months

from the date of delivery without additional mothballing measures, indicated by the VCI la-

bel on the package.

Fig.2: Volatile Corrosion Inhibitor (VCI)

Only dry rooms with 40...70 % atmospheric humidity, in which no water condensation can

form, are suitable as storage locations.

Storage of new turbochargers and spare parts for more than 6 months

WARNING

Health protection when handling VCI

VCI products are not hazardous in terms of the Ordinance on Hazardous

Substances. Nevertheless, the following points must be observed when

handling VCI:

uObserve information in material safety data sheet

uEnsure proper space ventilation.

uDo not eat, drink or store food at the workplace while working with VCI.

uClean hands and face after working with VCI.

uFor more information, see www.branopac.com.

Wear safety gloves to protect against mechanical hazards.

Every 6 months, the following mothballing measures are required:

uOpen package.

uRemove VCI corrosion protection emitter from package and replace with a new VCI corro-

sion protection emitter of the same kind. New VCI corrosion protection emitters can be

obtained from www.branopac.com.

uOld VCI corrosion protection emitters must be disposed of in an environmentally compat-

ible, professional way and in compliance with locally applicable regulations.

uClose package. The more tightly the package is sealed, the longer the protection dura-

tion.

Page 5 / 7

Operation Manual / 1 Introduction

1 Introduction / 1.3 Storage of new turbochargers and spare parts

Long-term storage of replacement turbochargers or spare parts

The turbochargers or cartridge groups will be prepared for long-term storage if requested in

the purchase order. The package is equipped with a hygrometer (see illustration).

Fig.3: Package with hygrometer

Every 6 months, the following measures are required:

uCheck the hygrometer(02) in the sight-glass. There is an opening(01) in the wooden

crate to enable you to perform this check. If the 70% indicator field has changed colour,

the maximum admissible atmospheric humidity has been exceeded. In this case, the tur-

bocharger or cartridge group must be checked and repackaged by an ABB Turbocharging

Service Station.

uCheck the package for damage. If the package is damaged, the turbocharger or cartridge

group must be checked and repackaged by an ABB Turbocharging Service Station.

After every 3 years, the following steps must be carried out by an ABB Turbocharging Service

Station:

¡Checking the component

¡Replacing the desiccant

¡Repackaging the component.

NOTICE

Replacement components which are ready for operation

If the 70% field of the hygrometer(02) has not changed colour and the pack-

age is not damaged, the replacement turbocharger or replacement cartridge

group can be put into operation without previously having been checked by

an ABB Turbocharging Service Station.

Unpackaging replacement turbochargers or spare parts

Once the material has been unpackaged from the VCI package, the corrosion protection is

no longer effective.

To prevent condensation, the temperature of the package contents must be the same as the

ambient temperature.

Page 6 / 7

Operation Manual / 1 Introduction

1 Introduction / 1.4 Contact information

1.4 Contact information

Contact information for the ABB Turbocharging Service Stations is available online.

uScan the QR code to access our website.

ABB Turbo Systems Ltd

Bruggerstrasse 71a

CH-5401 Baden

Switzerland

www.abb.com/turbocharging

Page 7 / 7

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