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ASSEMBLY INSTRUCTIONS
Power2 800-M
Original assembly instructions – English
This document is valid for the Power2
series:
Power2 850-M
Purpose
The assembly instructions explain how the low- and high-
pressure stage of ABB Turbo Systems 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 800-M
Summary of Contents for ABB Power2 800-M
- Page 1 Power2 performance package The assembly instructions explain how the low- and high- Two-stage turbocharging solution for highest pressure stage of ABB Turbo Systems is fitted to the turbocharging efficiency engine correctly and without any health and safety risks. Target group...
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Page 3: Table Of Contents
Gaskets .......................... 12 Assembly procedure....................13 Installing the high-pressure stage..............14 Gaskets .......................... 15 Assembly procedure....................16 Storage of new low-pressure and high-pressure stages........ 17 Further information..................... 20 © Copyright 2019 ABB. All rights reserved. HZTL455311P0010_EN Revision A March 2019... -
Page 4: Introduction
Introduction Purpose of the assembly instructions The assembly instructions explain how the low- and high-pressure stage of ABB Turbo Sys- tems 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 2006/42EC. - Page 5 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. See "Contact Informa- tion" on our website at www.abb.com/turbocharging.
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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 2019 ABB. All rights reserved. HZTL455311P0010_EN Revision A March 2019... -
Page 7: Safety
Safety Introduction The two-stage turbocharging system (Power2) manufactured by ABB Turbo Systems is state of the art and complies with the respective health and safety standards in effect at the time the system was built. Thus Power2 is safe to operate. Nevertheless, there may be some re-... -
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 2019 ABB. All rights reserved. HZTL455311P0010_EN Revision A... -
Page 9: Occupational Safety
Keep flammable objects and substances out of the vicinity of flying sparks. Cover all connections on the low-pressure and high-pressure stage so that no foreign ob- jects can enter the low-pressure or high-pressure stage. © Copyright 2019 ABB. All rights reserved. HZTL455311P0010_EN Revision A... - Page 10 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 2019 ABB. All rights reserved. HZTL455311P0010_EN Revision A March 2019...
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Page 11: Weight And Transportation Of The Low-Pressure And The High-Pressure Stages
Fig. 3: Suspending the low-pressure and high-pressure stages Low-pressure stage High-pressure stage Power2 Product Weight [kg] 850 LP Low-pressure stage 1900 850 HP High-pressure stage Table 4: Weights of the low-pressure and high-pressure stages © Copyright 2019 ABB. All rights reserved. HZTL455311P0010_EN Revision A March 2019... - Page 12 / Swivel lifting eyes to be used Two swivel lifting eyes (S) are required for the safe lifting of loads. These are not included in the ABB Turbo Systems scope of delivery. Swivel lifting eye (S) Power2 Thread...
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Page 13: Installing The Low-Pressure Stage
Installing the low-pressure stage Fixing elements and installation forces The fixing screws for fastening the low-pressure stage are not included in the ABB Turbo Systems scope of delivery and must be designed by the enginebuilder in accordance with the following details. -
Page 14: Gaskets
Always use new gaskets and insert them carefully into the slot. Gas and air lines The gas and air line gaskets are not included in the ABB Turbo Systems scope of delivery and must be provided by the enginebuilder. © Copyright 2019 ABB. All rights reserved. -
Page 15: Assembly Procedure
Tighten the fixing elements on the foot (see Table 8: Fixing element requirements →11). Secure all gas, air, water and oil pipes. Attach cable connector to the speed sensor. © Copyright 2019 ABB. All rights reserved. HZTL455311P0010_EN Revision A March 2019... -
Page 16: Installing The High-Pressure Stage
Fixing elements and installation force The fixing screws and sleeves for fastening the high-pressure stage are not included in the ABB Turbo Systems scope of delivery and must be designed by the enginebuilder in accord- ance with the following details. -
Page 17: Gaskets
Always use new gaskets and insert them carefully into the slot. Gas and air lines The gas and air line gaskets are not included in the ABB Turbo Systems scope of delivery and must be provided by the enginebuilder. © Copyright 2019 ABB. All rights reserved. -
Page 18: Assembly Procedure
(see Table 11: Fixing element requirements →14). Connect the cable connector to the speed sensor. Install air suction branch together with bellows. Secure all gas, air, water and oil pipes. © Copyright 2019 ABB. All rights reserved. HZTL455311P0010_EN Revision A March 2019... -
Page 19: 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 Turbo Systems can be stored in their closed packages for 6 months from the date of delivery without addi- tional mothballing measures (indicated by VCI label on package). - Page 20 Check the package for damage. If the package is damaged, the low or high-pressure stage or the 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: ¡...
- Page 21 Assembly Instructions / Power2 850-M 6 Storage of new low-pressure and high-pressure stages / © Copyright 2019 ABB. All rights reserved. HZTL455311P0010_EN Revision A March 2019...
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Page 22: 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. Low-pressure stage Fig. 11: Serial number of low-pressure stage on rating plate High-pressure stage Fig. 12: Serial number of high-pressure stage on rating plate... - Page 23 Assembly Instructions / Power2 850-M 7 Further information / © Copyright 2019 ABB. All rights reserved. HZTL455311P0010_EN Revision A March 2019...
- Page 24 +41 58 585 5144 Find and download the Operation Manual of E-mail: turbocharging@ch.abb.com your product on our website (see “Need product information” / “Operating www.abb.com/turbocharging instructions“). © Copyright 2019 ABB. All rights reserved. Visit our website by scanning the QR code.