Sign In
Upload
Manuals
Brands
ABB Manuals
Industrial Equipment
XAC22451
ABB XAC22451 Manuals
Manuals and User Guides for ABB XAC22451. We have
1
ABB XAC22451 manual available for free PDF download: Operation Manual
ABB XAC22451 Operation Manual (140 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 22.75 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
Essential Information
33
Introduction
33
Registered Trademarks
33
Related Documents
33
Table 1: Related Documents
33
Fig. 1: Layout and Function of the Turbocharger
34
Layout and Function of the Turbocharger
34
Fig. 2: Warning Plate Locations
36
Warning Plates on the Turbocharger
36
Fig. 3: Locations of the Rating Plates
37
Locations of the Rating Plates
37
Removal and Installation
38
Removing the Turbocharger
38
Table 2: Total Weight
38
Turbocharger Weight
38
Fig. 4: Fitting the Lifting Gear
39
Fig. 5: Placing the Turbocharger
40
Installing the Turbocharger
40
Fig. 6: Compressor-End Foot
41
Fig. 7: Turbine-End Foot
41
Table 3: General Information about Fastening the Turbocharger
41
Table 4: Tightening Torques (Foot Screws)
42
Table 5: Tightening Angle (Foot Screws)
42
Commissioning
43
Inspection Procedures
43
Oil Supply
43
Commissioning after Taking out of Operation
45
Monitoring During Operation
46
Oil Pressure, Oil Temperature
46
Table 6: Lubricating Oil Pressure, Oil Inlet
46
Fig. 8: Oil Temperature at the Outlet
47
Table 7: Lubricating Oil Temperature at the Inlet
47
Table 8: Lubricating Oil Temperature at the Outlet
47
Admissible Air Inlet Temperature
49
Fig. 9: Layout and Overview of the Speed Measurement System
49
Turbocharger Speed
49
Fig. 10: Replacing the Speed Sensor
51
Table 9: Tightening Torques (86505)
51
Fig. 11: U-Tube Manometer at the Filter Silencer
52
Low Pressure Measurement at the Filter Silencer
52
Noise Emission
53
Operation and Service
53
Fig. 12: Noise Insulation, Bellows
54
Service Work
54
Expected Replacement Intervals
58
Table 10: Expected Replacement Intervals for Turbocharger Parts
58
Table 11: Recommended Replacement Intervals for Turbocharger Parts
58
Flexible Turbocharger Cut-Out
59
Stopping the Engine
60
Foreword to Maintenance
61
Periodic Maintenance
61
Cleaning the Filter Silencer
62
Fig. 13: Layout and Overview of Filter Silencer
62
Changing the Filter Strip on the Filter Silencer Casing
64
Fig. 14: Dismantling Filter Ring Circumferential Part
64
Fig. 15: Opening Filter Ring Lock
64
Fig. 16: Attaching New Filter Ring
65
Fig. 17: Fitting New Filter Ring
65
Cleaning the Compressor During Operation
66
Fig. 18: Overview of Wet Cleaning of Compressor
68
Fig. 19: Filter Plug View
69
Table 12: Volume of Water Per Cleaning Process
69
Table 13: Tightening Torques (81125)
69
Cleaning the Turbine During Operation
70
Fig. 20: Overview of Dry Cleaning Device
71
Table 14: Cleaning Parameters
73
Draining the Gas Outlet Casing
74
Fig. 21: Drain Pipe Diagram
74
Malfunctions When Starting
75
Table 15: Malfunctions When Starting - Delayed Start-Up
75
Table 16: Malfunctions When Starting - Vibrations
75
Table 17: Malfunctions When Starting - Rubbing of Rotating Parts
75
Troubleshooting
75
Malfunctions During Operation
76
Table 18: Malfunctions During Operation - Lubricating Oil Pressure too Low
76
Table 19: Malfunctions During Operation - Drop in Speed
76
Table 20: Malfunctions During Operation - Exhaust Gas Temperature too High
77
Table 21: Malfunctions During Operation - Charge Air Pressure too Low
77
Surging of the Turbocharger
78
Table 22: Malfunctions During Operation - Charge Air Pressure too High
78
Table 23: Surging of the Turbocharger
78
Malfunctions When Stopping
79
Table 24: Malfunctions When Stopping - Runout Noises
79
Table 25: Malfunctions When Stopping - Shortened Runout Time
79
Speed Measurement System
80
Table 26: Malfunctions of the Speed Measurement System
80
Disassembly and Assembly
82
Introduction
82
Fig. 22: Weights of Assemblies
84
Table 27: Weights of Assemblies [Kg]
84
Table 28: Weight of Wall Insert [Kg]
84
Weights of Assemblies
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 Wall Insert and Diffuser
92
Fig. 33: Moving out Wall Insert
93
Fig. 34: Putting down Wall Insert
93
Fig. 36: Moving out Wall Insert
95
Fig. 37: Putting down Wall Insert
95
Fig. 38: Putting down Wall Insert
96
Fig. 39: Dismantling the Diffuser
97
Axial Clearance a Prior to Disassembly
98
Fig. 40: Measuring Axial Clearance a
98
Table 30: Axial Clearance a
98
Dismantling the Insulation (≤ A275-L)
99
Fig. 41: Removing the Insulation (A275-L and Smaller)
99
Dismantling the Gas Inlet Casing (≤ A275-L)
100
Fig. 42: Dismantling the Gas Inlet Casing (275-L and Smaller)
100
Table 31: Maximum Admissible Loosening Torque (51087)
100
Dismantling the Nozzle Ring (≤ A275-L)
101
Fig. 43: Dismantling the Nozzle Ring (A275-L and Smaller)
101
Dismantling the Gas Inlet Casing (A280-L)
102
Fig. 44: Dismantling the Gas Inlet Casing (A280-L)
102
Table 32: Maximum Admissible Loosening Torque (51087)
102
Dismantling the Nozzle Ring (A280-L)
103
Fig. 45: Fitting the Nozzle Ring Holder
103
Fig. 46: Dismantling the Nozzle Ring
104
Fig. 47: Put down the Nozzle Ring
104
Fig. 48: Fitting the Nozzle Ring (A275-L and Smaller)
105
Fitting the Nozzle Ring (≤ A275-L)
105
Table 33: Tightening Torque (56014)
105
Fig. 49: Fitting the Gas Outlet Casing (A275-L and Smaller)
106
Fitting the Gas Inlet Casing (≤ A275-L)
106
Table 34: Tightening Torque (51087)
106
Fig. 50: Fitting the Insulation (A275-L and Smaller)
107
Fitting the Insulation (≤ A275-L)
107
Fig. 51: Fitting the Nozzle Ring (A280-L)
108
Fitting the Nozzle Ring (A280-L)
108
Fig. 52: Attaching the Nozzle Ring (A280-L)
109
Table 35: Tightening Torque (56014)
109
Fig. 53: Fitting the Gas Inlet Casing (A280-L)
110
Fitting the Gas Inlet Casing (A280-L)
110
Table 36: Tightening Torque (51087)
110
Axial Clearance a after Assembly
111
Fig. 54: Measuring Axial Clearance a
111
Table 37: Axial Clearance a
111
Fig. 55: Fitting the Diffuser
112
Fitting the Diffuser
112
Table 38: Tightening Torque (77015)
112
Fig. 56: Positioning Wall Insert
113
Fitting Wall Insert
113
Fig. 57: Fitting the Wall Insert (A255-L
114
Table 39: Tightening Torque (72002)
114
Table 40: Tightening Torque (72004)
114
Fig. 58: Fitting the Wall Insert (A265-L
116
Table 41: Tightening Torque (72011)
116
Fitting the Filter Silencer
117
Fig. 59: Fitting the Filter Silencer
118
Table 42: Tightening Torque (72004)
118
Fig. 60: Fitting the Filter Silencer
119
Table 43: Tightening Torque (72004)
119
Fig. 62: Overview of Speed Sensor Tightening Torque
120
Table of Tightening Torques
120
Fig. 61: Overview of Tightening Torques
121
Table 44: Overview of Tightening Torques
121
Table 45: Tightening Torque, Insulation
121
Possible Emergency Repairs
122
Taking a Turbocharger out of Operation
122
Table 46: Bypass Procedure
123
Taking Defective Turbochargers out of Operation
123
Fig. 63: Locking the Rotor
124
Table 47: Tightening Torque B
125
Fig. 64: Ensuring Clamping of the Cover Ring
126
Table 48: Required Washers (01)
126
Table 49: Tightening Torque (57005)
126
Fig. 65: Position of Cover Plates
127
Mothballing the Turbocharger
129
Taking the Engine out of Operation for up to 12 Months
129
Taking the Engine out of Operation for more than 12 Months
130
Disposing of Turbocharger Components
131
Ordering Spare Parts
132
Spare Parts
132
Table 50: Customer Spare Part Set (97070)
132
Table 51: Customer Spare Part Set (97071)
133
Fig. 66: View of Turbocharger with Part Numbers
134
View of Turbocharger with Part Numbers
134
Table 52: Turbocharger with Part Numbers
135
Fig. 67: View of Cartridge Group with Part Numbers
136
View of Cartridge Group with Part Numbers
136
Table 53: Cartridge Group with Part Numbers
137
Figures
138
Advertisement
Advertisement
Related Products
ABB XAC22682
ABB XAC22399
ABB XAC22125
ABB XAC22175
ABB XAC25762
ABB XAC24782
ABB XAC26064
ABB XAC25870
ABB XAC25130
ABB XAC25886
ABB Categories
Industrial Equipment
Controller
Measuring Instruments
Battery Charger
DC Drives
More ABB Manuals
Login
Sign In
OR
Sign in with Facebook
Sign in with Google
Upload manual
Upload from disk
Upload from URL