ABB A130-M65 Bedienungsanleitung

ABB Turbocharging

ABB Turbo Systems Ltd

Operation Manual

A130-M65

HT842062 English

Original Operation Manual

Chapter Document-ID

1 Introduction HZTL4005_EN_D

2 Safety HZTL4022_EN_B

3 Safety data sheet HT842062

4 Product description HZTL4031_EN_C

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.

ABB Turbo Systems AG

Bruggerstrasse 71a

CH-5401 Baden

Switzerland

We herewith confirm that this Operation Manual has been drawn up in compliance with the "EU Product Liability

Directive" 85/374/EEC as well as with the "EU Machinery Directive" 2006/42/EC.

Design and specifications are subject to change without notice.

Printed on naturally white paper, bleached free from chlorine and environmentally acceptable.

The CD is made of polycarbonate and contains in addition aluminium, lacquer, dye stuffs and materials of the adhesive label.

The CD-cover is made of recycled cardboard.

These materials may be disposed with the domestic wastes or at a specialised collecting centre.

Operation Manual / 1 Introduction

Table of contents

Page 1 /

HZTL4005_EN

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September 2015

Introduction

Introduction ................................................................................................

1.1

Purpose of the manual ................................................................................

1.2

Symbols, definitions ....................................................................................

1.3

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

1.4

Contact information .....................................................................................

Operation Manual / 1 Introduction

Introduction

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September 2015

1 Introduction

1.1 Purpose of the manual

Figure 1: Serial number (01) on the rating plate

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

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

Operation Manual

The Operation Manual explains the turbocharger from ABB Turbo Systems and contains

instructions for safe operation.

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.

Operation Manual / 1 Introduction

Introduction

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1.2 Symbols, definitions

Symbols

The following symbols are used in this document:

Shows an action.

1. Shows a numbered action.

Enumeration, first level

– Enumeration, second level

[➙ ] 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

Stations. They are regularly audited and certified by ABB Turbo Systems. Also see chapter

Contact information [➙ 8].

Operation Manual / 1 Introduction

Introduction

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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 tightening

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 accordance

with specifications

Dispose of in an environmentally

compatible, professional way and

in compliance with locally

applicable regulations.

Oil free, grease free and dry

Table 1: Definition of pictograms

Operation Manual / 1 Introduction

Introduction

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September 2015

1.3 Storage of new turbochargers and spare parts

Storage of new turbochargers and spare parts up to 6 months

New turbochargers and spare parts from ABB Turbo Systems can be stored in sealed

packaging without additional mothballing measures for up to 6 months from the date of

delivery (marked by the VCI label on the package).

Figure 2:

olatile

orrosion

nhibitor (VCI)

Only dry rooms in which the relative humidity is between 40…70 % and no condensation can

form are suitable for storage.

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

WARNING

Protection of health when handling VCIs

VCI products are not hazardous in the sense of the Hazardous Substances

Ordinance. Nevertheless, the following points are to be observed when

handling VCIs:

Observe specifications in the safety data sheet

Ensure good room ventilation.

Do not eat, drink or keep food at the workplace while working with VCIs.

Clean hands and face after working with VCIs.

For further information refer to www.branopac.com.

Wear safety gloves against mechanical risks.

The following mothballing measures are required every 6 months:

Open the package.

Remove the VCI corrosion protection emitter from the package and replace it with a new,

identical VCI corrosion protection emitter. New VCI corrosion protection emitters can be

obtained at www.branopac.com.

Dispose of the old VCI corrosion protection emitter in an environmentally compatible

manner, professionally and in accordance with local regulations.

Seal the package. The better the external seal is designed, the more permanent the

protection.

Operation Manual / 1 Introduction

Introduction

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September 2015

Long-term storage of replacement turbochargers or spare parts

Per order, turbochargers or cartridge groups will be prepared by ABB Turbo Systems for

prolonged storage. The package is equipped with a hygrometer (see illustration).

Figure 3: Package with hygrometer

The following measures are required every 6 months:

Check the hygrometer (2) in the sight-glass. There is an opening (1) in the wooden crate

which allows this check to be carried out. When the display field has changed colour at the

70% level, the maximum permissible humidity has been exceeded. In this case the

turbocharger or cartridge group must be inspected by an ABB Turbocharging Service

Station and repacked.

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

group must be inspected by an ABB Turbocharging Service Station and repacked.

After every 3 years the following work steps must be performed by an ABB Turbocharging

Service Station:

Inspect the components

Exchange the desiccant agent

Repackage the components.

NOTICE

Replacement components ready for operation

If the 70% display field of the hygrometer (2) has not changed colour and the

package is undamaged, the replacement turbocharger or replacement

cartridge group can be placed into operation without any prior testing by an

ABB Turbocharging Service Station.

Unpacking replacement turbochargers or spare parts

The corrosion protection effect ends after the material is unpacked from the VCI package.

To avoid the formation of condensation, the surroundings and the content of the package must

have the same temperature during unpacking.

Operation Manual / 1 Introduction

Introduction

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HZTL4005_EN

Revision D

September 2015

1.4 Contact information

Contact information for the official service stations of ABB Turbo Systems is available online.

Scan the QR code to access our website.

ABB Turbo Systems AG

Bruggerstrasse 71a

CH-5401 Baden

Switzerland

www.abb.com/turbocharging

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