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A255-L35
ABB A255-L35 Manuals
Manuals and User Guides for ABB A255-L35. We have
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ABB A255-L35 manual available for free PDF download: Original Operation Manual
ABB A255-L35 Original Operation Manual (144 pages)
Brand:
ABB
| Category:
Battery Charger
| Size: 22.74 MB
Table of Contents
Introduction
3
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
11
CE Conformity
12
Introduction
12
Safety
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
Product Description
31
1 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
2 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
3 Commissioning
44
Oil Supply
44
Inspection Procedures
44
Commissioning after Taking out of Operation
46
4 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
5 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
6 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: Cleaning Parameters
74
Draining the Gas Outlet Casing
75
Fig. 21: Drain Pipe Diagram
75
7 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
8 Disassembly and Assembly
83
Introduction
83
Material Required
84
Weights of Assemblies
85
Fig. 22: Weights of Assemblies
85
Table 27: Weights of Assemblies [Kg]
85
Table 28: Weight of Wall Insert [Kg]
85
Disassembly and Assembly of the Filter Silencer Casing
86
Fig. 23: Dismantling the Filter Silencer Casing
86
Fig. 24: Fitting the Filter Silencer Casing
87
Fig. 25: Fitting the Filter Silencer Casing
88
Fig. 26: Fitting the Filter Silencer Casing
88
Fig. 27: Fitting the Filter Silencer Casing
89
Fig. 28: Fitting the Filter Silencer Casing
89
Fig. 29: Fitting the Bellows
90
Table 29: Tightening Torques (Filter Silencer Screws)
90
Dismantling the Filter Silencer
91
Fig. 30: Dismantling the Filter Silencer
91
Fig. 31: Dismantling the Filter Silencer
92
Dismantling Wall Insert and Diffuser
93
Fig. 33: Moving out Wall Insert
94
Fig. 34: Putting down Wall Insert
94
Fig. 36: Moving out Wall Insert
96
Fig. 37: Putting down Wall Insert
96
Fig. 38: Putting down Wall Insert
97
Fig. 39: Dismantling the Diffuser
98
Axial Clearance a Prior to Disassembly
99
Fig. 40: Measuring Axial Clearance a
99
Table 30: Axial Clearance a
99
Dismantling the Insulation (≤ A275-L)
100
Fig. 41: Removing the Insulation (A275-L and Smaller)
100
Dismantling the Gas Inlet Casing (≤ A275-L)
101
Fig. 42: Dismantling the Gas Inlet Casing (275-L and Smaller)
101
Table 31: Maximum Admissible Loosening Torque (51087)
101
Dismantling the Nozzle Ring (≤ A275-L)
102
Fig. 43: Dismantling the Nozzle Ring (A275-L and Smaller)
102
Dismantling the Gas Inlet Casing (A280-L)
103
Fig. 44: Dismantling the Gas Inlet Casing (A280-L)
103
Table 32: Maximum Admissible Loosening Torque (51087)
103
Dismantling the Nozzle Ring (A280-L)
104
Fig. 45: Fitting the Nozzle Ring Holder
104
Fig. 46: Dismantling the Nozzle Ring
105
Fig. 47: Put down the Nozzle Ring
105
Fitting the Nozzle Ring (≤ A275-L)
106
Fig. 48: Fitting the Nozzle Ring (A275-L and Smaller)
106
Table 33: Tightening Torque (56014)
106
Fitting the Gas Inlet Casing (≤ A275-L)
107
Fig. 49: Fitting the Gas Outlet Casing (A275-L and Smaller)
107
Table 34: Tightening Torque (51087)
107
Fitting the Insulation (≤ A275-L)
108
Fig. 50: Fitting the Insulation (A275-L and Smaller)
108
Fitting the Nozzle Ring (A280-L)
109
Fig. 51: Fitting the Nozzle Ring (A280-L)
109
Fig. 52: Attaching the Nozzle Ring (A280-L)
110
Table 35: Tightening Torque (56014)
110
Fitting the Gas Inlet Casing (A280-L)
111
Fig. 53: Fitting the Gas Inlet Casing (A280-L)
111
Table 36: Tightening Torque (51087)
111
Axial Clearance a after Assembly
112
Fig. 54: Measuring Axial Clearance a
112
Table 37: Axial Clearance a
112
Fitting the Diffuser
113
Fig. 55: Fitting the Diffuser
113
Table 38: Tightening Torque (77015)
113
Fitting Wall Insert
114
Fig. 56: Positioning Wall Insert
114
Fig. 57: Fitting the Wall Insert (A255-L
115
Table 39: Tightening Torque (72002)
115
Table 40: Tightening Torque (72004)
115
Fig. 58: Fitting the Wall Insert (A265-L
117
Table 41: Tightening Torque (72011)
117
Fitting the Filter Silencer
118
Fig. 59: Fitting the Filter Silencer
119
Table 42: Tightening Torque (72004)
119
Fig. 60: Fitting the Filter Silencer
120
Table 43: Tightening Torque (72004)
120
Table of Tightening Torques
121
Fig. 62: Overview of Speed Sensor Tightening Torque
121
Fig. 61: Overview of Tightening Torques
122
Table 44: Overview of Tightening Torques
122
Table 45: Tightening Torque, Insulation
122
9 Taking a Turbocharger out of Operation
123
Possible Emergency Repairs
123
Taking Defective Turbochargers out of Operation
124
Table 46: Bypass Procedure
124
Fig. 63: Locking the Rotor
125
Table 47: Tightening Torque B
126
Fig. 64: Ensuring Clamping of the Cover Ring
127
Table 48: Required Washers (01)
127
Table 49: Tightening Torque (57005)
127
Fig. 65: Position of Cover Plates
128
10 Mothballing the Turbocharger
130
Taking the Engine out of Operation for up to 12 Months
130
Taking the Engine out of Operation for more than 12 Months
131
11 Disposing of Turbocharger Components
132
12 Spare Parts
133
Ordering Spare Parts
133
Table 50: Customer Spare Part Set (97070)
133
Table 51: Customer Spare Part Set (97071)
134
View of Turbocharger with Part Numbers
135
Fig. 66: View of Turbocharger with Part Numbers
135
Table 52: Turbocharger with Part Numbers
136
View of Cartridge Group with Part Numbers
137
Fig. 67: View of Cartridge Group with Part Numbers
137
Table 53: Cartridge Group with Part Numbers
138
13 Tools
139
Table 55: Customer Tool Set 90000 (A265-L
139
Figures
141
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