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Engine Builder Manual For A100-L and A200-L

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507 views118 pages

Engine Builder Manual For A100-L and A200-L

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Enginebuilder Manual / A100-L, A200-L

Inhaltsverzeichnis Seite 1 / 1

HZTL Revision

Preliminary remarks 91001 A

1
Safety 91002 A
2
Introduction 91003 A
3
Weights, dimensions and space required 91004 A
4
Turbocharger installation 91005 A
5
Oil supply 91022 A
6
Speed measurement at the turbocharger 91007 A
7
Compressor and turbine cleaning 91008 A
8

© 2013 ABB Turbo Systems Ltd HZTL90708_EN Revision A April 2013

Enginebuilder Manual / A100, A200
Table of contents Page 1 / 4

Preliminary remarks

1 Preliminary remarks ................................................................................ 3

1.1 Purpose of the manual ............................................................................... 3
1.2 Symbols, definitions, contact address ........................................................ 3

CONFIDENTIAL HZTL91001_EN Revision A March 2013

The Information contained in this document has to be kept strictly confidential. Any unauthorized use, reproduction, distribution or disclosure to third
parties is strictly forbidden. ABB reserves all rights regarding Intellectual Property Rights. © Copyright 2013 ABB. All rights reserved.
Enginebuilder Manual / A100, A200
1 Preliminary remarks Page 3 / 4

1 Preliminary remarks

1.1 Purpose of the manual

Enginebuilder Manual

The Enginebuilder Manual provides the information necessary for the intended installation and
operation of the turbocharger.

This avoids difficulties during operation, enables effective monitoring and facilitates mainte-
nance.

Target group

The Enginebuilder Manual is aimed at enginebuilders, engineers and persons who are
responsible for the proper installation of the turbocharger on the engine and the initial com-
missioning.

Documentation of outline drawings

The main dimensions and connection dimensions of the turbochargers are shown in the Out-
line drawings documentation.

1.2 Symbols, definitions, contact address

Symbols

The following symbols are used in the documents:

 Step of a procedure

 List, first level

– List, second level

[➙ ] see page

CONFIDENTIAL HZTL91001_EN Revision A March 2013

Definition of Note

Note
The note provides advice to facilitate working with the product.
NOTICE

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.

Contact address

ABB Turbo Systems AG

Bruggerstrasse 71a
CH-5401 Baden
Switzerland

www.abb.com/turbocharging

CONFIDENTIAL HZTL91001_EN Revision A March 2013

Safety

2 Safety..................................................................................................... 3
2.1 Introduction ................................................................................................ 3
2.2 Definition of safety instructions................................................................... 4
2.3 Warning plates on the turbocharger ........................................................... 5
2.4 Safe operation and maintenance ............................................................... 6
2.5 Hazards during operation and maintenance ............................................... 9
2.6 Lifting of loads............................................................................................ 14
2.7 Periodic check of the pressure vessels ...................................................... 15

CONFIDENTIAL HZTL91002_EN Revision A April 2013

2 Safety

2.1 Introduction
Turbochargers manufactured by ABB Turbo Systems are state of the art and comply with the
respective health and safety standards in effect at the time the turbocharger was built. This
ensures safe operation of the turbocharger. Nevertheless, there may be some residual risks
during operation of and work on the turbocharger which:

 Are caused by the turbocharger itself or its accessories.

 Are caused by the operating equipment used or supplies and materials.
 Are a consequence of insufficient compliance with safety instructions.
 Are a consequence of insufficient or inappropriate performance of maintenance and in-
spection work.

The operating company is responsible for the organisational measures that regulate the safe
handling of the turbocharger by its personnel.

All instructions contained in this chapter must be observed for safe and trouble-free operation
of the turbocharger and during all work on the turbocharger.

All further safety instructions contained and specifically identified in every chapter of this man-
ual (Definition of safety instructions [➙ 4]) must also be observed.

CONFIDENTIAL HZTL91002_EN Revision A April 2013

2.2 Definition of safety instructions

The following symbols and nomenclature are used in this manual, referring to safety or indicat-
ing potential hazards:

Definition of Warning
Non-compliance or inaccurate compliance with working or operating instruc-
tions indicated by this symbol and the word WARNING can lead to serious
WARNING
injuries to personnel and even to fatal accidents.
 Warning signs must always be observed.

Definition of Caution
Non-compliance or inaccurate compliance with working or operating instruc-
tions indicated by this symbol and the word CAUTION can lead to serious
CAUTION
damage to engine or property with grave consequences.
 Caution signs must always be observed.

CONFIDENTIAL HZTL91002_EN Revision A April 2013

2.3 Warning plates on the turbocharger

Warning plates are affixed at the following locations on the turbocharger:

Figure 1: A…-L

If warning plates are not present in the designated locations or not readable, proceed as fol-
lows:

 Order new warning plates from ABB Turbocharging Service Stations.

 Remove any warning plates that have become unreadable.
 Clean and degrease the areas designated for the warning plates.
 Attach the new warning plates.

Non-insulated turbochargers

Turbochargers supplied to the enginebuilder without insulation must be equipped later with
warning plates to be attached to the insulation. This is the responsibility of the enginebuilder.

CONFIDENTIAL HZTL91002_EN Revision A April 2013

2.4 Safe operation and maintenance

The instructions specified in this section are for the safety of personnel. Together with the in-
structions in section "Hazards during operation and maintenance" of this chapter, they allow
the user to safely use the turbocharger.

Occupational safety and safety at the workplace

Risk of falling
When working on the turbocharger, there is a risk of falling.
WARNING
 Do not climb onto the turbocharger or onto attached parts and do not use
them as climbing aids.
 Use suitable climbing aids and working platforms for work above body
height.

 Comply with the general accident prevention regulations.

 Only perform work on the turbocharger when you are in a physically and psychologically
stable condition.
 Wear appropriate protective equipment, such as:

 Helmet
 Hearing protection
 Safety goggles
 Safety gloves
 Safety boots
 Protective clothing
 Hair net (for long hair)
 Respirator mask

 Only work with suitable tools and with equipment and appliances that function properly.
 Power tools must be properly earthed and cables must be undamaged.
 Keep the workplace clean; clear away any loose objects and obstacles on the floor.
 Keep the floor, equipment, and turbocharger clean.
 Have oil binding agents ready and provide or keep oil pans at hand.
 Clean up any spills.
 Have fire protection means and extinguishing agents available.

CONFIDENTIAL HZTL91002_EN Revision A April 2013

Welding work

 When performing welding work above the turbocharger, always cover the filter silencer to
prevent the filter mat from being damaged.
 Keep flammable objects and substances out of the vicinity of flying sparks.
 Cover all connections on the turbocharger so that no foreign objects can enter the turbo-
charger.

Safety during commissioning and operation

 Visually inspect your working environment before starting work.

 Remove any obstacles and objects littering the workplace.
 Check all pipes to and from the turbocharger for damage and leaks before commissioning.
 Avoid all operational practice which could negatively affect safety at the turbocharger.
 Check turbocharger for recognisable damage or defects approximately every 12 hours of
operation or at least once a day.
 Report any damage and any alterations of operational characteristics to the responsible
department immediately.
 In case of damage, take the turbocharger out of operation immediately and safeguard
against accidental/unauthorised use.
 When switching on operating energy supplies (hydraulics, pneumatics, electricity, water),
pay attention to the risks that may occur as a consequence of this energy input.

CONFIDENTIAL HZTL91002_EN Revision A April 2013

Safety during cleaning

It is possible that detergents or solvents are used for cleaning. In this case, the safety instruc-
tions in section "Hazards due to operating materials and supplies" must always be observed.

 Protect the floor against unintentional penetration of detergents or solvents before starting
cleaning operations.
 Wear appropriate protective clothing.
 Inspect the electric cables for abrasion and damage before and after your cleaning work.

Safety during disassembly, assembly, maintenance and repair

 Observe the procedures for set-up, maintenance and inspection work and the inspection
intervals.
 Inform the operating staff before starting any maintenance or repair work.
 Before taking off any cover or removing any guard from the turbocharger, switch off the
engine and wait until the turbocharger has come to a standstill.
 Make sure that the oil supply is interrupted, especially with an external oil supply.
 Only restart the engine after all parts have been properly fitted again and oil supply is en-
sured.

Mechanical operations on the turbocharger

Components of the turbocharger can be damaged or destroyed.
CAUTION
 Only perform operations that are described in this manual.
 Only perform operations for which you have previously received instruc-
tion or training.

Safety when taking out of operation at short notice or preparing for mothballing

 Secure rotor against turning. The rotor can rotate due to the stack draught alone.
 Clean the turbocharger prior to mothballing.
 Wear appropriate protective clothing.

CONFIDENTIAL HZTL91002_EN Revision A April 2013

2.5 Hazards during operation and maintenance

Mechanical hazards during operation

During standard operation, no mechanical hazards are caused by the turbocharger itself if it
has been properly installed.

Physical hazards due to rotating parts

Contact with rotating parts can cause severe injury. The turbocharger must
never be used without the air-inlet casing or filter silencer, respectively. With
WARNING
the engine stopped, the rotor can rotate due to the stack draught alone.
 Operate the turbocharger in compliance with the specifications.

Mechanical hazards when working on the turbocharger

During maintenance, various risks may arise due to improper handling of components, non-
compliance with safety and health standards, carelessness, or as a consequence of inade-
quate qualification.

Mechanical hazards
Severe injuries to personnel or fatal accidents can be caused by mechanical
influences as a consequence of hazardous and inadequate operational pro-
WARNING
cedures.

 Secure rotor against turning.

 Observe the general rules for occupational safety and prevention of acci-
dents.
 Ensure workplace safety.
 Only perform operations that are described in this manual.
 Only perform operations for which you have previously received instruc-
tion or training.

CONFIDENTIAL HZTL91002_EN Revision A April 2013

Noise hazards

The noise emission during operation is influenced by its installation and operating conditions.
A noise level exceeding 85 dB(A) is harmful.

Danger due to noise

Exposure to noise can harm the hearing system. It can impair health and the
psychological state and may lead to irritation and lack of attention.
WARNING
 When the engine is running, always wear hearing protection.
 Always wear hearing protection if the noise level exceeds 85 dB(A).

Standard values for the maximum duration of exposure to areas of noise emission (source:
Unfallverhütungsvorschriften für Unternehmen der Seefahrt (UVV See) [Accident Prevention
Regulations for Enterprises engaged in Seafaring]):

Figure 2

x Noise level [dB(A)]

y Maximum duration of exposure [min] per working day

CONFIDENTIAL HZTL91002_EN Revision A April 2013

Hazards due to hot surfaces and substances

Surfaces of the turbocharger, attached parts and operating fluids (lubricating oil) get hot during
operation. The surface temperature depends on the efficacy of the existing insulation. The
temperature may rise to a level that can cause burns.

Danger of burns
Touching hot surfaces or contact with hot operating fluids can cause severe
burns.
WARNING
 Do not touch hot surfaces. Observe the warning plate on the turbo-
charger.
 Wear heat-resistant safety gloves and protective clothing.
 Wait for the turbocharger to cool down before carrying out any work.

Hot surfaces on the non-insulated turbocharger

Non-insulated turbochargers can cause serious injuries to personnel (burns).
WARNING ABB Turbo Systems supplies the turbocharger with or without insulation in
accordance with the purchase order received from the enginebuilder. If sup-
ply is without insulation, the enginebuilder is responsible for providing the
turbocharger with proper insulation and for providing protection against con-
tact with hot surfaces.
 Compliance with the instructions and specifications given by the en-
ginebuilder to protect against hot surfaces is compulsory.

Hazards due to operating materials and supplies

Operating materials and supplies are substances required for the operation or for the perfor-
mance of maintenance work. Oils, greases, coolants, detergents and solvents, acids and simi-
lar substances can be classified as hazardous substances. Operating materials and supplies
can be flammable and combustible.

Danger of poisoning or acid burns

Swallowing of or skin contact with toxic or caustic operating materials and
supplies or breathing of any such vapours can be harmful to health.
WARNING
 Do not breathe in these substances and avoid contact with the skin.
 Wear protective clothing and a breathing mask.

CONFIDENTIAL HZTL91002_EN Revision A April 2013

Danger of fire or explosion

Flammable and combustible operating materials and supplies can catch fire
or resulting vapours can lead to an explosion.
WARNING

 Open flames are forbidden when carrying out cleaning work.

 Carry out cleaning in the open or provide sufficient ventilation.

Danger of environmental damage

The emission of operating materials and supplies into the atmosphere or the
contamination of ground or water systems as a result of improper disposal
CAUTION
can cause damage to the environment.
 Handle operating materials and supplies with care.

 Observe all instructions for use, material safety data sheets and the hazard information
provided on the containers of the operating materials and supplies.
 Wear appropriate protective clothing.
 Do not breathe in these substances and avoid contact with the skin.
 Ensure sufficient ventilation of the workspace.
 After use, close containers hermetically and put them away.
 Collect used operating materials and supplies safely, store them separately in suitable con-
tainers and dispose of them properly and in an environmentally compatible manner in com-
pliance with the legal regulations.
 In the event of leaks or spillage, spread binding agents immediately and dispose of them
properly and in an environmentally compatible manner in compliance with the legal regula-
tions.

CONFIDENTIAL HZTL91002_EN Revision A April 2013

Hazards due to the handling of insulation materials

Danger from insulation materials

Dust or fibres from insulation materials can have adverse effects on the
health or cause irritations. Unsuitable and combustible insulation materials
WARNING
are a fire hazard.
 Handle insulation materials with care.

 Only use suitable and non-combustible insulation materials.

 Ensure good ventilation at the workplace.
 Wear suitable work clothing (safety goggles, dust mask).
 Avoid whirling up dust.
 Use dust-free tools and working methods.
 Remove package at the workplace only.
 Proceed with particular care when removing old insulation materials.
 Dispose of insulation materials properly and in an environmentally compatible manner in
compliance with the legal regulations.

Hazards due to electrical components

Danger due to electrical components

Electrical components work with electrical voltages that can be a danger to
humans.
WARNING
 Any work on or with electrical components must only be performed by
specifically qualified electricians.
 National regulations must be observed.

CONFIDENTIAL HZTL91002_EN Revision A April 2013

2.6 Lifting of loads

Figure 3

Suspended loads
Loads that are not attached according to regulations can cause physical inju-
ries with grave consequences or fatal accidents.
WARNING
 Fasten assemblies or individual parts above 25 kg carefully on properly
functional lifting gear with a sufficient load limit.
 Pay attention to the correct attachment of loads on the crane hook.
 No persons must remain under suspended loads.

Figure 4

If there are two or more suspension points, the attachment angle of 45° must not be exceed-
ed. This prevents excessive loading due to diagonal pull.

 Attach components of the turbocharger as described in the respective action steps.

 Before looping around the components of the turbocharger, let them cool down (maximum
80 °C).
 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.
 Put down dismantled components of the turbocharger in such a way that they cannot tip
over.

CONFIDENTIAL HZTL91002_EN Revision A April 2013

2.7 Periodic check of the pressure vessels

The pressure vessels used by ABB Turbo Systems, for example, in the wet or dry cleaning
process, are so-called simple pressure vessels.

 The locally applicable legal regulations regarding periodic checks of the pressure vessels
must be observed.
 The operating company is responsible for the safe operation of the pressure vessel.

Danger due to pressure vessels

The operating company must make sure the pressure vessels are in proper
working condition and monitor them. Necessary repair or maintenance work
WARNING
must be performed promptly, and the required safety measures must be tak-
en.
 Pressure equipment must not be operated if defects are present.

CONFIDENTIAL HZTL91002_EN Revision A April 2013

Introduction

3 Introduction ............................................................................................ 2
3.1 Layout and function of the turbocharger ..................................................... 2
3.2 Intended use .............................................................................................. 4
3.3 Turbocharger designs ................................................................................ 5
3.4 Turbocharger rating plate ........................................................................... 7

CONFIDENTIAL HZTL91003_EN Revision A March 2013

3 Introduction

3.1 Layout and function of the turbocharger

Figure 1

1 Filter silencer 8 Gas inlet casing

2 Thrust bearing 9 Bearing casing
3 Radial plain bearing 10 Diffuser
4 Radial plain bearing 11 Compressor wheel
5 Gas outlet casing 12 Compressor casing
6 Turbine wheel 13 Air-outlet silencer (option)
7 Nozzle ring

CONFIDENTIAL HZTL91003_EN Revision A March 2013

Mode of operation

The turbocharger is a turbo machine and consists of the following main components:

 Turbine
 Compressor

These components are installed on a common shaft and form the rotor (see Figure 1).

The exhaust gases of the internal combustion engine flow through the gas-inlet casing (8) and
the nozzle ring (7) onto the turbine wheel (6). The turbine wheel uses the energy contained in
the exhaust gas to drive the rotor and, hence, the compressor wheel (11).

The exhaust gases then reach the atmosphere through the exhaust gas pipe connected to the
gas-outlet casing (5).

The compressor wheel (11) sucks in fresh air and presses the compressed air into the cylin-
der.

The air passes through the filter silencer (1) to the compressor wheel (11). The air then flows
through the diffuser (10) and exits the turbocharger through the compressor casing (12). An
air outlet silencer (13) is available as an option. It reduces the noise emitted by the compo-
nents on the outlet side downstream of the compressor casing.

The rotor runs in two radial plain bearings (3/4) which are located in the bearing casing (9)
between compressor and turbine. The axial thrust bearing (2) is located on the compressor
end.

The plain bearings are connected to a central lubricating oil duct which is normally supplied by
the lubricating oil circuit of the engine. The oil outlet always lies at the deepest point of the
bearing casing (9).

The turbocharger is equipped with an oil tank which is integrated in the bearing casing (9).
This oil tank supplies the bearings of the rotor with oil until standstill in the event that a mal-
function of the lubrication oil system causes an emergency stop of the engine.

CONFIDENTIAL HZTL91003_EN Revision A March 2013

3.2 Intended use

Use on internal combustion engines

ABB turbochargers are intended for turbocharging internal combustion engines.

The A...-L turbochargers are designed for use on 2-stroke diesel engines.

The turbocharger supplies the engine with the air volume or air/gas mixture and the associa-
ted charging pressure required for operation.

The specific operating limits of the turbocharger were determined on the basis of information
from the enginebuilder about the intended use. These data are given on the rating plate.

ABB Turbo Systems accepts no liability and rejects all warranty claims for any non-intended
uses.

Approved operation
Any operation of the turbocharger outside of its operating limits can be ha-
zardous to personnel.
WARNING
 Only trained personnel must operate the turbocharger.

The intended use of the turbocharger includes compliance with all regulations and conditions.
The following points must be specifically observed:

 The operation manual

 The instructions of the enginebuilder

State of the art

The turbocharger is designed and built according to the state of the art and is safe to operate.

Flawless condition

The turbocharger must only be used when it is in a technically flawless condition and operated
in compliance with its intended use.

ABB Turbo Systems excludes any liability for damage resulting from unauthorized modifica-
tions to the turbocharger.

CONFIDENTIAL HZTL91003_EN Revision A March 2013

3.3 Turbocharger designs

3.3.1 General

Documentation of outline drawings

The main dimensions of the turbochargers, the connection dimensions (with contact surfaces)
as well as all available casing designs are shown in the Outline drawings documentation and
the 3D-step solids.

The various possibilities of the casing positions appear in the catalogue of outline drawings
(see chapter Outline drawings).

Air-inlet

The turbocharger is equipped with a filter silencer.

Gas-inlet

The turbocharger is equipped with a gas-inlet casing with single inlet.

CONFIDENTIAL HZTL91003_EN Revision A March 2013

3.3.2 Design series

Low Speed (= engine segment L)

A165-L A170-L A175-L A180-L A185-L A190-L

Table 1

A270-L A275-L
Table 2

3.3.3 Size and series

Figure 2

1 A for ABB
2 Turbocharger generation
3+4 Size
5 Hyphen
6 Engine segment (L, M, H)
7+8 Technical information
9 Options

CONFIDENTIAL HZTL91003_EN Revision A March 2013

3.4 Turbocharger rating plate

Figure 3

Operating limits

1 Turbocharger operating limits at engine overload (110 %).

In test rig operation only, unless otherwise agreed with the engine-
builder.
2 Turbocharger operating limits during operation

Recommended replacement intervals of turbocharger components

3 Replacement interval of plain bearings in 1000 h

4 Replacement interval of compressor in 1000 h
5 Replacement interval of turbine in 1000 h

Further data

6 Customer part number

7 Designation for special design
8 Weight of turbocharger in kg
9 Turbocharger type
10 Serial number
11 Year of construction of turbocharger

CONFIDENTIAL HZTL91003_EN Revision A March 2013

Explanations of the rating plate

The recommended replacement intervals and the corresponding operating limits are jointly
defined with the enginebuilder. This information is specific to the system.

Operation above the indicated values nBmax, tBmax can considerably shorten the recommended
replacement intervals. In such a case, we recommend that you contact the nearest official
service station of ABB Turbo Systems.

nMmax, tMmax normally apply only when running at overload (110 %) during trials on the engine
test bed. These limit values can also be permitted during operation for special applications.
Operation above nMmax and tMmax is not permitted.

Non-observance of the recommended replacement intervals increases the risk of unpredictab-

le component failures.

Locations of the rating plates

Figure 4

One rating plate (1) each is attached on the left and the right side of the turbocharger bearing
casing.

CONFIDENTIAL HZTL91003_EN Revision A March 2013

Weights, dimensions and space required

4 Weights, dimensions and space required ................................................. 2

4.1 Weights and dimensions ............................................................................ 2
4.2 Access to the engine room......................................................................... 6
4.3 Space required for service ......................................................................... 8
4.4 Toolbox dimensions ................................................................................... 12

CONFIDENTIAL HZTL91004_EN Revision A April 2013

4 Weights, dimensions and space required

4.1 Weights and dimensions

Lifting gear with a sufficient load limit must be used for removing and installing the turbo-
charger. The following weight specification applies to the heaviest variant possible. Depending
on the specification, the weight specified on the rating plate may be lower than the standard
value specified here.

Weight [kg]

A165-L A170-L A175-L A180-L A185-L A190-L

2300 3300 5600 7500 10500 13500
Table 1

Weight [kg]

A265-L* A270-L A275-L A280-L* A285-L*

2700 3800 6300 8600 12000
Table 2

* Preliminary

The specified weights of the individual parts or assemblies are rounded-up standard values.

CONFIDENTIAL HZTL91004_EN Revision A April 2013

Dimensions and assembly weights

Product Complete turbocharger Filter silencer

L B H Weight L Ø -- Weight
[mm] [mm] [mm] [kg] [mm] [mm] [kg]
A165-L 2340 1190 1220 2300 540 1110 -- 220
A170-L 2700 1370 1410 3300 630 1280 -- 280
A175-L 3250 1650 1690 5600 750 1540 -- 480
A180-L 3680 1870 1910 7500 850 1750 -- 620
A185-L 4100 2080 2130 10500 950 1950 -- 850
A190-L 4520 2300 2350 13500 1050 2150 -- 1050

A265-L* 2410 1290 1390 2700 580 1240 310

A270-L 2780 1490 1600 3800 670 1430 -- 420
A275-L 3340 1790 1930 6300 800 1720 -- 710
A280-L* 3780 2020 2180 8600 910 1940 -- 980
A285-L* 4210 2260 2430 12000 1010 2170 -- 1300
Table 3

1) Dimension L, with dry cleaning option: 120 mm longer.

* Preliminary

CONFIDENTIAL HZTL91004_EN Revision A April 2013

Product Gas outlet casing Gas inlet casing, with nozzle ring

L B H Weight L Ø H Weight
[mm] [mm] [mm] [kg] [mm] [mm] [mm] [kg]
A165-L 560 1100 1030 500 860 640 750 190
A265-L*
A170-L 640 1270 1190 750 980 740 860 260
A270-L
A175-L 770 1520 1430 1220 1160 880 1030 410
A275-L
A180-L 880 1730 1620 1700 1300 1000 1170 570
A280-L*
A185-L 980 1920 1800 2300 1430 1120 1310 770
A285-L*
A190-L 1080 2120 1990 2900 1570 1230 1440 900
Table 4

1) Dimension L, with dry cleaning option: 120 mm longer.

* Preliminary

CONFIDENTIAL HZTL91004_EN Revision A April 2013

Product Compressor casing Wall insert and diffuser

L B H Weight L Ø -- Weight
[mm] [mm] [mm] [kg] [mm] [mm] [kg]
A165-L 440 1130 1160 320 370 860 -- 280
A170-L 510 1300 1340 450 430 990 -- 400
A175-L 610 1560 1600 740 510 1190 -- 660
A180-L 690 1770 1820 960 580 1350 -- 960
A185-L 770 1970 2020 1360 650 1500 -- 1290
A190-L 850 2180 2230 1800 720 1660 -- 1770

A265-L* 470 1270 1370 420 410 960 -- 340

A270-L 540 1460 1580 620 470 1110 -- 510
A275-L 660 1760 1900 1030 560 1340 -- 870
A280-L* 740 1990 2150 1450 640 1510 -- 1240
A285-L* 830 2220 2400 2000 710 1680 -- 1700
Table 5

* Preliminary

Product Complete rotor

L Ø Weight
[mm] [mm] [kg]
A165-L 940 500 90
A170-L 1080 580 130
A175-L 1300 700 220
A180-L 1470 790 330
A185-L 1640 880 460
A190-L 1810 970 610

A265-L* 930 500 100

A270-L 1090 580 140
A275-L 1320 700 240
A280-L* 1490 790 350
A285-L* 1660 880 490
Table 6

* Preliminary

CONFIDENTIAL HZTL91004_EN Revision A April 2013

4.2 Access to the engine room

The installation of the turbocharger on the engine has an enormous influence on the time re-
quired for carrying out service and repair work.

Consistent implementation of the following recommendations forms the basis for efficient
maintenance work during the entire lifetime of the ship or system. If these recommendations
are not implemented, scheduled service work on the turbocharger can take longer, hence
causing additional costs.

The following figure shows the transport paths to the turbocharger and the engine in a ship's
engine room.

Figure 1

1 Lifting gear 4 Working platform

2 Exhaust gas pipes 5 Accessibility to engine room
3 Turbocharger installation 6 Storage space for components

CONFIDENTIAL HZTL91004_EN Revision A April 2013

Transport of turbocharger components into the engine room

 The hatch to the engine room must be dimensioned so it is big enough to allow the turbo-
charger assemblies to pass through.

Recommended hatch opening [mm]

A165-L A170-L A175-L A180-L A185-L A190-L

1400 x 1000 1600 x 1000 1800 x 1200 2000 x 1400 2200 x 1500 2500 x 1800
Table 7

A265-L* A270-L A275-L A280-L* A285-L*

1600 x 1000 1800 x 1000 2000 x 1200 2300 x 1400 2500 x 1500
Table 8

* Preliminary

 The transport of the largest assembly must be ensured:

With respect to the amount of space required from the hatch through the engine room to
the point of installation of the turbocharger.
 The efficient transport of the heaviest assembly must be assured:
With respect to the available, correctly dimensioned lifting devices with sufficient lifting ca-
pacity.
 For service work on the turbocharger, space must be planned on the working platform or in
the vicinity for putting down dismantled assemblies.

Access to the turbocharger

Access to the following turbocharger components must be assured when it is still attached:

 Filter silencer
 Compressor cleaning device
 Turbine cleaning device
 Speed sensor

Free access to the turbocharger must be assured in order to carry out the following checking
procedures:

 Monitoring the lubricating oil pressure and lubricating oil temperature

CONFIDENTIAL HZTL91004_EN Revision A April 2013

4.3 Space required for service

Space required for service and laying out the crane tracks

Figure 2

Figure 3

CONFIDENTIAL HZTL91004_EN Revision A April 2013

a Required minimum clearance to the crane hook

b Lateral distance for disassembling/assembling the insulation and the speed sensor
c Required minimum width of the corridor (at the top) for transporting assemblies (especially
filter silencer) to (and from) the turbocharger,
depending on the position of the gas outlet casing and the version of the transition piece
fitted on it
d Required minimum width of the corridor (at the bottom) for transporting assemblies (espe-
cially gas inlet casing) to (and from) the turbocharger,
depending on the position of the compressor casing
e Minimum axial clearance at compressor end and turbine end
f Required minimum height of the corridor for transporting assemblies (especially filter
silencer) to (and from) the turbocharger,
depending on the version of the transition piece on the gas outlet casing
g Opening in crane tracks (opening for gas outlet pipe)
P Working platform with sufficient load limit for dismantled assemblies
R1 , R2 Crane tracks
Table 9

Product a [mm] b [mm] c [mm] d [mm] e [mm] f [mm] g [mm]

A165-L 1800 500 650 800 400 1250 1000
A170-L 2100 500 750 950 450 1450 1100
A175-L 2500 500 850 1100 500 1700 1300
A180-L 2850 600 900 1250 600 1950 1400
A185-L 3150 600 1000 1400 650 2150 1600
A190-L 3500 700 1100 1600 700 2400 1800
Table 10

Product a [mm] b [mm] c [mm] d [mm] e [mm] f [mm] g [mm]

A265-L* 2100 500 700 800 400 1400 1000
A270-L 2500 500 800 950 450 1650 1100
A275-L 2850 500 850 1100 500 1900 1300
A280-L* 3150 600 950 1250 600 2100 1400
A285-L* 3500 600 1050 1400 650 2350 1600
Table 11

* Preliminary

CONFIDENTIAL HZTL91004_EN Revision A April 2013

Minimum radial clearance around the filter silencer

The clearance (R) is required for the disassembly and assembly of the filter silencer.

Figure 4

Radial clearance R [mm]

A165-L A170-L A175-L A180-L A185-L A190-L

210 240 280 320 360 390
Table 12

A265-L* A270-L A275-L A280-L* A285-L*

240 280 320 360 390
Table 13

* Preliminary

CONFIDENTIAL HZTL91004_EN Revision A April 2013

Space required for assembly/disassembly of the speed sensor

The speed sensor (1) can be screwed into the bearing casing (2) at an angle from below on
either side.
Distance (S) adjacent to the bearing casing (2) must be maintained depending on the selected
position of the speed sensor (1). The minimum width (3) of this distance corresponds to the
flange width of the bearing casing.

Figure 5

Lateral distance S [mm]

A165-L A170-L A175-L A180-L A185-L A190-L

410 470 550 610 670 740
Table 14

A265-L* A270-L A275-L A280-L* A285-L*

410 470 550 610 670
Table 15

* Preliminary

CONFIDENTIAL HZTL91004_EN Revision A April 2013

4.4 Toolbox dimensions

Accessibility to tools and spare parts

The tools and spare parts supplied with the turbocharger must be located in the vicinity of the
turbocharger and must be accessible at all times.

Figure 6

Space required for toolbox

Product a [mm] b [mm] c [mm]

A165-L 550 500 800
A170-L 550 500 800
A175-L 750 600 800
A180-L 850 700 1200
A185-L 900 800 1200
A190-L 900 800 1200
Table 16

Product a [mm] b [mm] c [mm]

A265-L* 550 500 800
A270-L 590 590 750
A275-L* 750 600 800
A280-L* 850 700 1200
A285-L* 900 800 1200
Table 17

* Preliminary

CONFIDENTIAL HZTL91004_EN Revision A April 2013

Turbocharger installation

5 Turbocharger installation ......................................................................... 3

5.1 Installing the turbocharger.......................................................................... 3
5.1.1 Turbochargers for flexible cut-out............................................................... 3
5.1.2 Steps for fastening the turbocharger .......................................................... 4
5.1.3 Tightening the foot fixing screws ................................................................ 5
5.2 Admissible inclined positions ..................................................................... 8
5.3 Exhaust gas pipes and air lines.................................................................. 9
5.3.1 Mechanical decoupling of the turbocharger ................................................ 9
5.3.2 Fitting the pipes ......................................................................................... 10
5.3.3 Pressurised exhaust gas pipes before the turbocharger............................. 11
5.3.4 Exhaust gas pipes after the turbocharger ................................................... 12
5.3.5 Transition piece on the gas outlet casing ................................................... 13
5.3.6 Pressurised charge air ducts to the charge air cooler ................................. 14
5.3.7 Filter silencer casing .................................................................................. 15
5.3.8 Sealing air supply for flexible cut-out .......................................................... 16
5.3.9 Noise insulation bellow .............................................................................. 18
5.4 Installation examples ................................................................................. 20
5.5 Thermal expansion of the turbocharger ...................................................... 23
5.5.1 Thermal expansion on the gas inlet ........................................................... 24
5.5.2 Thermal expansion on the gas outlet ......................................................... 25
5.5.3 Thermal expansion on the air-outlet ........................................................... 26
5.6 Admissible vibrations on the turbocharger ................................................. 27
5.7 Draining at the gas outlet casing ................................................................ 30

CONFIDENTIAL HZTL91005_EN Revision A April 2013

5 Turbocharger installation

5.1 Installing the turbocharger

The bracket on the engine

The bracket to which the turbocharger is attached must be designed horizontally and with a
bend-resistant and torsionally rigid construction.
This prevents additional forces acting on the fixing screws or on the feet of the turbocharger.

The machined contact surface may have a maximum unevenness of 0.2 mm.

Foot parts on the turbocharger

The foot of the A...-L turbocharger consists of two parts:

 Compressor-end foot (CE), integrated in the bearing casing

 Turbine-end foot (TE), fitted on the gas outlet casing.

Casing and foot positions

The possible casing and foot positions of the turbochargers are shown in the Outline drawings
documentation.

5.1.1 Turbochargers for flexible cut-out

 On engines with three or four turbochargers, the turbochargers intended for flexible cut-out
must be installed in the centre of the engine.

CONFIDENTIAL HZTL91005_EN Revision A April 2013

5.1.2 Steps for fastening the turbocharger

Risk of tipping over

If the turbocharger is not sufficiently supported or not supported at all during
removal and installation, it can tip over and cause severe injury to personnel
WARNING
or accidents resulting in fatalities.
 Support the turbocharger at a suitable location.

Figure 1

 Remove the covers on the oil connections.

 Align turbocharger and place on engine bracket.
 Tighten the fixing screws (see section Tightening the foot fixing screws) while only slightly
loosening the lifting gear.
 Remove lifting gear from the suspension eyes of the bearing casing.

 Connect cable to speed sensor.

 Connect all gas, air and lubricating oil pipes.

CONFIDENTIAL HZTL91005_EN Revision A April 2013

5.1.3 Tightening the foot fixing screws

General information

Subject Related requirements

Material of fixing elements ISO property class ≥ 8.8
(for securing turbocharger on bracket)
Washers under the screw head or nut Use hardened washers,
thickness ≥ 15 % of the nominal thread diameter
Dimension a Height of the turbocharger foot
Dimension b Thread set deeper in bracket
Depth of thread c ≥ 1.5 x nominal thread diameter
With the 2 screws, Dimension a, including spacer sleeve D and foot F
in the centre of the turbine-end foot
Coefficient of friction 0.12 (lightly oiled)
Table 1

Compressor-end foot

Figure 2

 Tighten the foot fixing screws or nuts diagonally according to the selected tightening me-
thod.

CONFIDENTIAL HZTL91005_EN Revision A April 2013

Turbine-end foot

Figure 3

 Tighten the foot fixing screws or nuts according to the selected tightening method.

Torque-controlled tightening

Product Thread size Height a of foot Tightening torque

[mm] [Nm]
A165-L M22 86 560
A170-L M27 100 1000
A175-L M30 120 1400
A180-L M33 136 1900
A185-L M39 151 3200
A190-L M42 167 3900
Table 2

Torque-controlled tightening

Product Thread size Height a of foot Tightening torque

[mm] [Nm]
A270-L M27 100 1000
A275-L M30 120 1400
Table 3

CONFIDENTIAL HZTL91005_EN Revision A April 2013

Angle-controlled tightening

Product Thread size Height a of Pre-tightening Tightening Additional tightening angle

foot torque angle for for every 10 mm of additio-
[mm] [Nm] height a nal screw length b
[DEG] [DEG]
A165-L M22 86 120 30 3.7
A170-L M27 100 220 30 3.1
A175-L M30 120 300 30 2.6
A180-L M33 136 400 35 2.6
A185-L M39 151 600 35 2.4
A190-L M42 167 700 35 2.2
Table 4

Angle-controlled tightening

Product Thread size Height a of Pre-tightening Tightening Additional tightening angle

foot torque angle for for every 10 mm of additio-
[mm] [Nm] height a nal screw length b
[DEG] [DEG]
A270-L M27 100 220 30 3.1
A275-L M30 120 300 30 2.6
Table 5

Property classes of screws

Screws with a property class higher than 8.8 can also be used to install the
turbocharger.
NOTICE
Tightening torque and tightening angle remain identical to property class 8.8.

Pinning of turbocharger feet with positioning pins

If the turbocharger is pinned at its feet, one pin hole per foot must be used.

CONFIDENTIAL HZTL91005_EN Revision A April 2013

5.2 Admissible inclined positions

The overall admissible inclined position of the turbocharger results from the sum of the in-
clined positions of the engine, the turbocharger installation on the engine as well as the positi-
on of the ship in a swell.

Both of the inclined positions mentioned can occur at the same time.

Figure 4

Number Turbocharger axis Admissible inclined position, Admissible inclined position,

continuous temporary
1 about longitudinal ± 15° ± 22.5°
axis
2 about transverse axis ± 15° ± 22.5°
Table 6

Permitted inclined positions for the oil supply

The oil supply must be designed so that an ample supply of the turbocharger with lubricating
oil is assured at the inclined positions that occur.

CONFIDENTIAL HZTL91005_EN Revision A April 2013

5.3 Exhaust gas pipes and air lines

5.3.1 Mechanical decoupling of the turbocharger

Figure 5

The connections between the turbocharger and the exhaust gas pipes and air lines must be
decoupled from the vibration by bellows. The bellows are also required for compensation of
the thermal expansion of the pipes and the turbocharger. See also chapters:

 Thermal expansion of the turbocharger

 Admissible vibrations on the turbocharger

Vibration and thermal expansion

Vibration of the pipes and thermal expansion in the longitudinal and trans-
verse direction cause forces and torques on the turbocharger casing.
CAUTION
 Use steel bellows for mechanical decoupling.

Rubber bellows are only admissible as bellows on the air-inlet.

Flow losses with bellows

The flow losses remain low when using bellows with inner protection pipe.

CONFIDENTIAL HZTL91005_EN Revision A April 2013

Requirements of bellows and arrangement of pipes

 The bellows must ensure in all operating points that no vibrations as well as no forces and
torques of shifts resulting from thermal expansions are passed on to the turbocharger.
 The use of elbows/bends between the bellows and turbocharger casing is not permitted.
 A connecting piece may be installed in the gas outlet pipe between the casing flange and
the bellows (see chapter Exhaust gas pipes after the turbocharger).
 Pipes must be supported on the engine or in other suitable places.
 It is not allowed to support pipes on the turbocharger.

5.3.2 Fitting the pipes

 Attach and support all pipes to and from the turbocharger in such a way that free vibrations
are prevented.
 Route pipes in such a way that they do not impede the removal and installation of the filter
silencer, compressor casing and gas inlet casing.

Pretreatment of heat-resistant screws

 Coat the screw threads with high-temperature grease.

 Use heat-resistant screws for attaching pipes to the gas inlet flange and gas outlet flange of
the turbocharger.

CONFIDENTIAL HZTL91005_EN Revision A April 2013

5.3.3 Pressurised exhaust gas pipes before the turbocharger

General Avoid abrupt changes in cross sections and projecting edges.

Exhaust gas pipe (P) to the gas Passage area A2 ≥ 2 x A1 ;
inlet casing taper angle ≤ 20° ;
mill or round off transition pieces to prevent flow losses.
Wire grid in the exhaust gas Free through-flow surfaces of wire grid AGrid ≥ 3 x A1 .
collection pipe
Table 7

CONFIDENTIAL HZTL91005_EN Revision A April 2013

5.3.4 Exhaust gas pipes after the turbocharger

Figure 6

Reduction of gas speed Through the transition piece (TP) which acts as a diffuser;
it is fitted on the gas outlet casing
Pressure loss Calculated pressure loss of the complete exhaust gas system ≤ 30 mbar
Transition piece (TP) Area ratio A4 / A3 = 1.1 ... 1.6;
taper angle ≤ 40°,
for diameter D4, see following table.
The transition piece (TP) must be designed to be as short and as light as
possible.
For data on maximum admissible forces and weights on the flange of the
gas outlet casing, see section Stresses on the turbocharger casing.
Reference is made to the recommendations in the manual of the respective
enginebuilder for determining the dimensions of the transition piece (TP) and
for designing the exhaust gas system.
Table 8

Product A165-L A170-L A175-L A180-L A185-L A190-L

A270-L A275-L
Diameter D4 850 1000 1200 1300 1500 1600
gas outlet [mm]
Minimum diameter 750 850 1000 1100 1300 1400
D4 [mm]
Table 9

Transition piece to the gas outlet casing

It is essential for the transition piece to the gas outlet casing to be aligned
precisely in order to achieve minimum flow losses. The cams on the flange
NOTICE
of the gas outlet casing assist the correct alignment of the transition piece.
 Refer to the outline drawings for the required dimensions for the flange of
the transition piece.

CONFIDENTIAL HZTL91005_EN Revision A April 2013

5.3.5 Transition piece on the gas outlet casing

The transition piece on the gas outlet casing can be designed with parallel inlet and outlet
flanges or as an offset variant (as shown).
For dimensions, weights and forces, see the following table.

Product A165-L A170-L A175-L A180-L A185-L A190-L

A270-L A275-L
Maximum Ø D4 850 1000 1200 1300 1500 1600
[mm]
Maximum 700 800 950 1050 1200 1300
height H1 [mm]
Mass MG of transiti- 210 270 400 510 630 770
on piece
[kg]
FG [N] 2100 2700 4000 5100 6300 7700
F1 [N] 750 1000 1500 1900 2400 2900
F2 [N] 1800 2400 3500 4400 5500 6700
F3 [N] 1800 2400 3500 4400 5500 6700
Table 10

MG Maximum mass of transition piece (including half the mass of the bellows on the gas outlet)
FG Maximum weight force of the transition piece (FG = MG x g)
F1 Maximum radial force of the bellows
F2 Maximum axial force of the bellows
F3 Maximum transverse force of the bellows

CONFIDENTIAL HZTL91005_EN Revision A April 2013

5.3.6 Pressurised charge air ducts to the charge air cooler

Figure 7

Bellows (B) The scavenging air duct must be insulated to prevent the emission of noise. For
this reason, space for insulation around the air-outlet flange, the bellows, and the
scavenging air duct must be provided with an insulation thickness of at least 50
mm, see following table.
Diffuser (D) Taper angle 8° … 16°;
area ratio A6 : A5 = 2 : 1,
greater taper angles can lead to flow separation and hence to increased flow re-
sistance.
Avoid abrupt changes in cross section and narrowing of the pipes.
The scavenging air duct should be routed as straight as possible in the intermedia-
te casing (I) to the charge air cooler to minimise pressure losses.
Table 11

Product A165-L A170-L A175-L A180-L A185-L A190-L

Ø flange E [mm] 440 510 607 690 770 850
Ø insulation F [mm] 520 590 710 810 900 990
Table 12

Product A265-L* A270-L A275-L A280-L* A285-L*

Ø flange E [mm] 480 560 670 760 840
Ø insulation F [mm] 560 640 770 870 970
Table 13

* Preliminary

CONFIDENTIAL HZTL91005_EN Revision A April 2013

5.3.7 Filter silencer casing

Figure 8

The filter silencer casing (1), which is fitted around the filter silencer, must be decoupled from
the suction pipe (2) by bellows (3). The bellows can be designed as a non-metallic expansion
joint (plastic, rubber, leather).

CONFIDENTIAL HZTL91005_EN Revision A April 2013

5.3.8 Sealing air supply for flexible cut-out

Sealing air function

Turbochargers which are designed for "flexible cut-out" must be supplied with external sealing
air to ensure that no oil or gas can leak during cut-out operation. Sealing air must be supplied
to the turbocharger only when the engine is running. Therefore the sealing air is extracted
from the turbocharging system of the engine.

Sealing air requirements

 The sealing air must not contain any water, oil or dirt.
 The required sealing air pressure is determined by the design of the sealing air line.
 Sealing air temperature at the extraction point ≤ 150 °C.
 If the surface temperature of the sealing air line is > 80 °C, the line must be insulated or a
protection against contact must be fitted.

Choice of sealing air extraction point

The sealing air extraction point must be chosen so that the sealing air requirements are met in
all operating points of the engine. Preferably the sealing air is extracted at the outlet of the
auxiliary blower of another turbocharger. This is based on the assumption that the pressure at
the extraction point corresponds to the pressure in the scavenging air receiver.

Sealing air supply line from the extraction point to the turbocharger

The pressure at the extraction point P1 and the dimensioning of the supply line determine the
pressures that occur in the turbocharger. If the pipes are too long, the pressure in the tur-
bocharger is too low, and if the pipes are too short, the sealing air consumption is too high.
Therefore, depending on the pipe arrangement, an orifice is used at the turbocharger inlet.

Figure 9

CONFIDENTIAL HZTL91005_EN Revision A April 2013

Dimensioning

The following table lists the sealing air line arrangements Long, Medium and Short. The inside
pipe diameter corresponds to the connection diameter at the turbocharger.

Product A180-L A185-L A190-L

Version Long / Medium / Short Long / Medium / Short Long / Medium / Short
D [mm] 30 33 40
L [m] 6/4/2 6/4/2 6/4/2
Z 90° 6/4/2 6/4/2 6/4/2
ZK 2/1/1 2/1/1 2/1/1
B [mm] - / 20 / 19 - / 23 / 21 24 / 23 / 22
Table 14

B Orifice diameter D Inside pipe diameter

L Length of the sealing air line ZK Number of bellows
Z 90° Number of 90° elbows with a bending radius R = 2 x D

Required pressures and sealing air consumption during operation

The following pressures and sealing air volume flows result based on the above pipe versions
with the corresponding orifices. The sealing air consumption during operation depends on the
pressure P1 at the extraction point. The following volume flows apply during cut-out operation.

Product Pressure P1 Pressure P2 [mbar] Volume flow1

[mbar] Long2 Medium2 Short2 [m3/min]
100 20 60 70 1.5
500 120 300 370 4
A180-L 1000 280 620 750 6
1500 460 960 1140 8
2000 640 1300 1530 10
100 20 55 70 2
500 130 280 370 5
A185-L 1000 290 600 760 8
1500 470 920 1150 10
2000 660 1260 1540 13
100 60 75 85 2
500 320 380 420 6
A190-L 1000 650 770 850 9
1500 1000 1170 1290 11
2000 1350 1570 1720 14
1 Converted to ISO condition 2 Pipe version

Table 15

Cut-out operation
If the gas inlet flap is opened during cut-out operation or the air-outlet flap is
closed during normal operation, this causes very high turbocharger speeds.
CAUTION
These can result in damage with serious consequences or even a total loss
of the turbocharger.

CONFIDENTIAL HZTL91005_EN Revision A April 2013

5.3.9 Noise insulation bellow

The emission sound pressure level (A-weighted) is measured at a distance of 1 meter from
the turbocharger.

The highest value of the emission sound pressure level1) is reached in the area of the filter
silencer and is 105 dB(A) maximum over the entire speed range.

The following prerequisites must be fulfilled with regard to the turbocharger to observe this
limit value:

 Air-inlet system has been fitted

 All standard, noise-reducing measures2) have been fitted
 Bellows at the air-outlet has been properly acoustically insulated by the enginebuilder (see
Figure 10).

The enginebuilder is also responsible for insulating the charge air/scavenging air ducts and
the charge air cooler.

1) Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7:

A-weighted emission sound pressure level
2) The enginebuilder must provide acoustically equivalent measures in case of deviating insula-
tion versions

CONFIDENTIAL HZTL91005_EN Revision A April 2013

Suggestion for noise insulation, bellow

Figure 10

A Compressor casing D Insulating cushion

B Bellows E Insulation mat (at least 15 mm)
C Charge air duct / scavenging air duct F Sheet metal cover

CONFIDENTIAL HZTL91005_EN Revision A April 2013

5.4 Installation examples

Example 1: Gas inlet pipe

Correct Not admissible

The bellows are fitted directly on the gas inlet The exhaust gas pipe is connected directly to the
casing after the tapered exhaust gas pipe. gas inlet casing without bellows.
The large surface in the transition from the exhaust Consequence: High thermal load leads to damage.
gas collection pipe to the exhaust gas pipe pre- Cylindrical exhaust gas pipe to the turbocharger.
vents narrowing and reduces losses through uni- Consequences: High gas speeds, flow losses in
form flow. the transition from the exhaust gas collection pipe
to the exhaust gas pipe.

CONFIDENTIAL HZTL91005_EN Revision A April 2013

Example 2: Gas outlet pipe

Correct Not admissible

A short transition piece is fitted on the gas outlet The transition piece on the gas outlet casing is too
casing and the bellows are fitted onto the transition long and too heavy.
piece. It is also supported at the wrong position. This
The exhaust gas pipe must be supported on the leads to excessively large thermal loads on the
engine or on other suitable points. turbocharger.

CONFIDENTIAL HZTL91005_EN Revision A April 2013

Example 3: Air-outlet line

Correct Not admissible

The bellows are fitted on the air-outlet casing. The air-outlet casing is connected directly to the
The following air line to the charge air cooler is charge air cooler.
designed as a tapered diffuser. Consequence: High thermal loads.
Cylindrical pipe to the charge air cooler.
Consequence: High flow losses in the charge air
cooler.

CONFIDENTIAL HZTL91005_EN Revision A April 2013

5.5 Thermal expansion of the turbocharger

Stresses on the turbocharger casing

Forces and torques which act on the turbocharger casing can lead to serious
damage to machinery or property with grave consequences.
CAUTION
 Install bellows on the flanges of air-outlet, gas inlet and gas outlet casings.

Thermal expansions occur on the turbocharger, especially at the turbine end. The high tempe-
rature differences between standstill and operation lead to an expansion (relative displace-
ment) of the connecting flanges.

The values for thermal expansion listed below apply for conditions at full load.

The bellows used must be able to absorb the resulting expansions on the connecting flanges
in all operating points.

The original dimensions of the turbocharger appear in the separate Outline drawings docu-
mentation.

CONFIDENTIAL HZTL91005_EN Revision A April 2013

5.5.1 Thermal expansion on the gas inlet

The following values in the X, Y, Z directions apply for the construction of the bellows:

Gas inlet, position 0° Product X [mm] Y [mm] Z [mm]

A165-L 2.7 0.0 7.4
A170-L 3.2 0.0 8.5
A270-L
A175-L 3.8 0.0 10.3
A275-L
A180-L 4.3 0.0 11.6
A185-L 4.8 0.0 13.0
A190-L 5.3 0.0 14.3

Table 16

Gas inlet, position 270° Product X [mm] Y [mm] Z [mm]

A165-L 4.4 -3.0 4.4
A170-L 5.1 -3.4 5.1
A270-L
A175-L 6.1 -4.1 6.1
A275-L
A180-L 6.9 -4.6 6.9
A185-L 7.7 -5.2 7.7
A190-L 8.5 -5.7 8.5

Table 17

CONFIDENTIAL HZTL91005_EN Revision A April 2013

5.5.2 Thermal expansion on the gas outlet

The following values in the X, Y, Z directions apply for the construction of the bellows:

Gas outlet, position 0° Product X [mm] Y [mm] Z [mm]

A165-L -2.8 -0.1 4.5
A170-L -3.2 -0.2 5.2
A270-L
A175-L -3.9 -0.2 6.3
A275-L
A180-L -4.4 -0.2 7.1
A185-L -4.9 -0.3 7.9
A190-L -5.4 -0.3 8.8

Table 18

Gas outlet, position 45° Product X [mm] Y [mm] Z [mm]

A165-L -3.0 1.9 3.7
A170-L -3.4 2.2 4.3
A270-L
A175-L -4.1 2.6 5.2
A275-L
A180-L -4.6 2.9 5.9
A185-L -5.2 3.3 6.6
A190-L -5.7 3.6 7.2

Table 19

CONFIDENTIAL HZTL91005_EN Revision A April 2013

5.5.3 Thermal expansion on the air-outlet

The following values in the X, Y, Z directions apply for the construction of the bellows:

Air-outlet, position 165° Product X [mm] Y [mm] Z [mm]

A165-L 0.0 1.0 -0.1
A170-L 0.0 1.2 -0.2
A270-L
A175-L 0.0 1.4 -0.2
A275-L
A180-L 0.0 1.6 -0.2
A185-L 0.0 1.8 -0.3
A190-L 0.0 1.9 -0.3

Table 20

Air-outlet, position 195° Product X [mm] Y [mm] Z [mm]

A165-L 0.5 0.6 -0.4
A170-L 0.6 0.7 -0.5
A270-L
A175-L 0.7 0.9 -0.6
A275-L
A180-L 0.8 1.0 -0.7
A185-L 0.9 1.1 -0.8
A190-L 1.0 1.3 -0.8

Table 21

CONFIDENTIAL HZTL91005_EN Revision A April 2013

5.6 Admissible vibrations on the turbocharger

General

The measured vibrations are specified in the following quantities:

 Vibration displacement srms [mm]

 Vibration velocity vrms [mm/s]
 Vibration acceleration arms [m/s2]

The srms, vrms and arms variables indicate the effective values of the cumulative signal (RMS) in
the defined frequency range.

Low-frequency vibrations

Low-frequency vibrations are caused by the interactions of the characteristic frequencies of

the engine/bracket/turbocharger system. The vibrations are induced by rotating and oscillating
masses as well as gas forces in the engine.

These vibrations mainly stress the fastenings of the turbocharger on the engine, but also the
casing joints. The stresses are proportional to the accelerations that occur on the turbochar-
ger.
Shaking of the engine causes accelerations in all directions on the rotor of the turbocharger.
The resulting bearing stresses are, however, comparatively low.

The vibration velocity (v) and the vibration acceleration (a) are limited to ensure reliable opera-
tion of the turbocharger.

Measuring high-frequency vibrations on the turbocharger

The existing rotor unbalances generate rotating forces at the rotation frequency which are
partly transferred to the casings via the bearings.
The damping of the plain bearings as well as local vibration effects on the casings greatly af-
fect the amplitudes that can be measured from the outside.
Consequently, no statements regarding the unbalance status of the rotor or the status of the
bearings are possible as a result of a vibration measurement on the outside of the casing.

CONFIDENTIAL HZTL91005_EN Revision A April 2013

Characteristic frequencies of the turbocharger

The characteristic frequencies listed below apply for turbochargers which are fitted on an ab-
solutely rigid bracket.

Product A165-L A170-L A175-L A180-L A185-L A190-L

1st characteristic fre- 42 36 30 26 24 21
quency [Hz]
Table 22

Product A270-L A275-L

1st characteristic fre- 30 25
quency [Hz]
Table 23

In reality, the values for the characteristic frequencies are lower in the following cases:

 Experience shows that, with a good, rigid turbocharger bracket, they are about 20 to 30 %
lower.
 With a very elastic turbocharger bracket, they can be up to 60 % lower.

The order of the various characteristic frequencies can also vary depending on the design and
stiffness of the engine block and the turbocharger bracket.

The aim must be that the first characteristic frequency of the engine-bracket-turbocharger sys-
tem lies above the ignition frequency of the engine (high matching, bracket as rigid as possi-
ble).

This is not always possible in engines with a large number of cylinders. In such cases, the
characteristic frequencies of the system can be induced in the operating range of the engine
which leads to unacceptably high vibrations.

CONFIDENTIAL HZTL91005_EN Revision A April 2013

Measuring locations

Figure 11

Use measuring locations (CH) and (X) for vibration measurements during commissioning of
the engine or for monitoring purposes.

If the specified limit values are not complied with, additional measurements must be taken at
measuring locations (XS), (BH), (NH) and (SU) for a more accurate analysis.
The sensors used must be either screwed onto the casings or affixed using magnets.
A sensor that is suitable for high temperatures must be used for the measuring location (NH).

Limit values for vibrations at measuring point (CH)

The RMS values of the cumulative signal of the vibration velocity and/or the acceleration must
not be exceeded at any of the designated measuring points.

Product Frequency range for validi- Maximum admissible cumu- Maximum admissible cumu-
ty of limit values lative velocity RMS lative acceleration RMS
[Hz] [mm/s] [g]
A165-L 3 … 200 45 3.0
A170-L 3 … 200 45 3.0
A270-L
A175-L 3 … 200 45 3.0
A275-L
A180-L 3 … 100 50 2.5
A185-L 3 … 100 50 2.5
A190-L 3 … 100 55 2.0
Table 24

CONFIDENTIAL HZTL91005_EN Revision A April 2013

Limit values for vibration at measuring point (X)

Due to the distance of the filter silencer to the foot, higher vibration values are permitted at the
measuring point (X).

Product Frequency range for validi- Maximum admissible cumu- Maximum admissible cumu-
ty of limit values lative velocity RMS lative acceleration RMS
[Hz] [mm/s] [g]
A165-L 3 … 200 67.5 4.5
A170-L 3 … 200 67.5 4.5
A270-L
A175-L 3 … 200 67.5 4.5
A275-L
A180-L 3 … 100 75 3.75
A185-L 3 … 100 75 3.75
A190-L 3 … 100 82.5 3.0
Table 25

Additionally to be noted

 If the specified limit values are not adhered to, a frequency analysis for the entire tur-
bocharger, including bracket, is recommended for further assessment.
This procedure should always be carried out after prior coordination with ABB Turbo Sys-
tems.
 The frequency ranges correspond to the occurring low-frequency vibrations and excitati-
ons. These can be measured easily using commercially available vibrometers.
 In engines with constant speed, the highest vibration values (total effective values - RMS)
are usually measured at 100 % load.
 In engines with variable speed, the entire speed range must be passed through at the ma-
ximum load possible in order to determine the highest vibration values.
The highest vibration values occur at resonant positions at which the characteristic fre-
quencies of the engine/bracket/turbocharger system concur with the excitation frequencies
of the engine.

5.7 Draining at the gas outlet casing

There are connections on the gas outlet casing for draining the inside of the casing (ope-
ning (O) on the outline drawings).

Draining has the following purpose:

 If there is a boiler leak in the exhaust gas pipe or an ingress of water due to other causes,
the gas outlet casing can be drained.

Recommendation for the drain connection:

 The drain pipe must be fitted at the lowest connection point of the gas outlet casing.
 The drain pipe must be conducted downwards as close as possible after the connection
point.

CONFIDENTIAL HZTL91005_EN Revision A April 2013

Guiding the drain pipe

The drain pipe must not be guided above the height of the connection point on the turbochar-
ger.

Figure 12

1 Drain pipe 3 Drain

2 Drain cock 4 Air line from compressor casing
A Position 1 B Position 2

 On the drain pipe (1), set the drain cock (2) to position 1 (A).

If the drain pipe (1) is blocked:

 Set the drain cock (2) to position 2 (B) and clean the drain pipe (1) with air from the com-
pressor casing (4).

If cleaning with air is not sufficient, the drain pipe (1) must be cleaned mechanically.

CONFIDENTIAL HZTL91005_EN Revision A April 2013

Oil supply

6 Oil supply ............................................................................................... 3

6.1 Introduction ................................................................................................ 3
6.2 Requirements on the oil supply .................................................................. 4
6.3 Dimensioning of the lubricating system ...................................................... 7
6.4 Setting oil pressure with throttle valve (option) ........................................... 9
6.5 Oil quantity / Amount of heat dissipated / Blow-by...................................... 10
6.6 Admissible lubricating oils .......................................................................... 11
6.7 Oil filtering .................................................................................................. 13
6.8 Venting the lubricating system ................................................................... 14
6.9 Oil mist separator ....................................................................................... 15
6.10 Commissioning the lubricating system ....................................................... 18
6.11 Pre-lubrication, post-lubrication .................................................................. 20
6.12 Long-term lubrication in standby operation................................................. 20
6.13 Lubrication during flexible cut-out operation ............................................... 21
6.14 Lubrication at emergency stop ................................................................... 21

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6 Oil supply
6.1 Introduction
In all operating states, a functioning and carefully executed oil supply is an important prerequi-
site for trouble-free operation of the turbocharger.

This also includes the correct dimensioning and laying of the oil pipes.

The lubrication of the turbocharger is usually carried out with oil from the engine circula-
tion.
Alternatively, a separate lubricating system can be used for the turbocharger.

A separate lubricating system is not included in the ABB Turbo Systems scope of delivery.

Support through ABB Turbo Systems

ABB Turbo Systems can provide support in the construction of the system.

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6.2 Requirements on the oil supply

6.2.1 General conditions for installation

Air bubbles in oil pipes

The formation of large air bubbles in oil pipes can reduce or interrupt the oil
supply. The consequences can be serious damage to engine or property.
CAUTION
Oil pipes with elbows conducted upwards must be avoided.

The position and dimension of the connecting flanges for the oil inlet and oil outlet on the
turbocharger are shown in the Outline drawings documentation.
In branches and junctions of several pipes, the main pipe must at least have the total of
the cross sections of the individual pipes before or after the collecting point.
Install oil return flow pipes with an at least 5° greater incline than the maximum admissible
inclined position of the engine.
Only shut-off valves that can be secured against accidental operation are allowed to be
attached.

The lubricating system must be provided with a heating system if the required oil viscosity
cannot be guaranteed when cold.
This prevents any overload of the auxiliary bearing and, hence, damage to the turbo-
charger when starting the engine if the oil is too cold (< 30 °C, in combination with exces-
sively high oil pressures); see section "Commissioning the lubricating system".

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6.2.2 Oil supply from the engine circulation

Figure 1

In the case of the oil supply from the engine circulation, the oil inlet pipe after the pump
cooler filter system must be conducted via the shortest route to the turbocharger.
Blow-by air from the turbocharger is mainly discharged via the bearing casing and via a
venting pipe, see Venting the lubricating system section.

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6.2.3 Oil supply from separate lubricating system

Figure 2

The oil return flow pipe dissipates all of the blow-by air coming from the turbocharger.
This air is discharged via a venting pipe on the oil tank, see Venting the lubricating system
section.
A lubricating oil temperature of 80 °C at the inlet of the turbocharger is recommended to
improve efficiency.

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6.3 Dimensioning of the lubricating system

6.3.1 Minimum inside diameter of the piping

Product Number of D1 D2 D3 D5 D4, Metering orifice B [mm]

turbochargers [mm] [mm] [mm] [mm] D6 PbTC [bar]
per engine [mm] < 2.5 2 - 3.7 3.5 - 5 4.5 - 6
A165-L 1 32 32 60 50 65 No 9.7 7.8 6.7
A265-L 2 40 80 orifice

A170-L 1 32 32 65 65 10.8 8.5 7.8

A270-L 2 50 90
A175-L 1 32 32 65 65 12.5 10 --
A275-L 2 50 100
3 65 125
A180-L 1 40 40 80 80 13.7 11.1 --
A280-L 2 50 100
3 65 125
A185-L 1 40 40 80 80 14.9 12 --
A285-L* 2 65 125
3 65 150
4 80 150
A190-L 1 40 40 80 80 16.1 12.9 --
2 65 125
3 80 150
4 80 175
Table 1

* Preliminary

Pre-installed orifice
Serious damage to engine or property can result from insufficient oil supply.
The orifice supplied on the turbocharger always has the smallest diameter.
CAUTION
If necessary, drill out the diameter of the orifice or remove the orifice com-
pletely.

Dimensions of the pipe connections

The dimensions appear in the Outline drawings documentation.

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6.3.2 Oil tank capacity for separate lubricating system

V = [ (A x B) + V1 + V2 + V3 ] x C

V [dm3] Minimum oil tank capacity

A=4 [min] Flow time
B [dm3/min] Oil flow rate
(maximum value according to section Oil quantity, in [l/min])
V1 [dm3] Capacity for complete piping
V2 [dm3] Capacity for oil cooler and filter
V3 [dm3] Capacity for the remaining elements required in the system
C = 1.35 [-] Factor for additional 35% capacity for air

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6.4 Setting oil pressure with throttle valve (option)

Figure 3

The throttle valve (a) is integrated in the pressure adjusting unit (42295), depending on the
selected pressure adjusting unit version. The lubricating oil pressure is adjusted at the turbo-
charger inlet.

The oil pressure is throttled as required (poil, in > 2.5 bar). The adjustment is made either during
the test run of the engine or during commissioning of the system, see section Commissioning
the lubricating system.

The throttle valve (a) is adjusted as follows:

Loosen the two screws (b).

Turn the throttle (a) to adjust the oil pressure either according to the manometer (c) or with
the help of a manometer you have installed yourself (to do this, remove sealing plug (d)).
Secure the throttle valve (a) in the adjusted position by tightening the two screws (b).

Tightening torques [Nm]

Component A165-L A170-L A175-L A180-L A185-L A190-L

A265-L* A270-L A275-L A280-L A285-L* --
b M6
10
d G1/4"
40
Table 2

* Preliminary

If the manometer (c) needs to be replaced, fit it as follows:

Screw in the manometer and hand-tighten.

Tighten the manometer further until the scale faces the front and is readable.

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6.5 Oil quantity / Amount of heat dissipated / Blow-by

Product Number of turbo- Oil quantity 1) Amount of heat Blow-by

chargers per en- [l/min] dissipated
gine [kW]
nBmax 2) Oil mist + air Oil mist
[l/min] [g/h]
toil, in [°C] / poil, in [bar] toil, in [°C] pscav 3) p scav
[bar] [bar]
45 / 45 / 85 / 85 / 45 85 1.0 3.5 3.5
1.5 2.5 1.5 2.0
A165-L 1 78 96 89 100 56 45 150 360 41
A265-L 2 156 192 178 200 112 90 300 720 82
A170-L 1 89 110 101 114 72 58 190 480 55
A270-L 2 178 220 202 228 144 116 380 960 110
A175-L 1 105 130 120 135 100 80 280 700 79
A275-L 2 210 260 240 270 200 160 560 1400 158
3 315 390 360 405 300 240 840 2100 237
A180-L 1 127 157 145 163 124 99 360 890 101
A280-L 2 254 314 290 326 248 198 720 1780 202
3 381 471 435 489 372 297 1080 2670 303
A185-L 1 150 186 171 193 150 120 440 1110 126
A285-L* 2 300 372 342 386 300 240 880 2220 252
3 450 558 513 579 450 360 1320 3330 378
4 600 744 684 772 600 480 1760 4440 504
A190-L 1 174 216 199 224 178 142 540 1350 153
2 348 432 398 448 356 284 1080 2700 306
3 522 648 597 672 534 426 1620 4050 459
4 696 864 796 896 712 568 2160 5400 612
Table 3

* Preliminary

1) The quantity of oil must be increased by 20% if the oil pump is constructed with a separate
lubricating system.
2) At low turbocharger speeds, the amount of heat discharged decreases sharply.
3) pscav: Scavenging air pressure, relative

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6.6 Admissible lubricating oils

All lubricating oils suitable for the engine are admissible for the turbocharger. The same quali-
ty requirements also apply, in terms of the water content for example.

Depending on the specified oils, the permissible viscosity range at the oil inlet and the tem-
perature range is shown in the following chart and legend:

Figure 4

A Admissible viscosity range

t Oil temperature at turbocharger inlet [°C]
V Kinematic viscosity [mm2/s = cSt]

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Temperature/pressure chart of the lubricating oil during operation

Figure 5

The admissible pressure is limited to 2 bar at oil temperatures above 70°C.

We recommend operating the turbocharger in the lower range of the admissible oil pressure to
keep the energy consumption of the lubricating oil pump low.

For further information, see section "Commissioning the lubricating system".

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6.7 Oil filtering

Lubricating oil filtering

Heavily contaminated lubricating oil can cause excessive wear of bearing
parts.
CAUTION
The consequences can be serious damage to engine or property.
Observe the specifications for lubricating oil filtering.

Filtering of the lubricating oil with a mesh width of 0.050 mm is specified for A...-L turbo-
chargers.

Check that the oil filter is clean before commissioning.

If the lubricating system is separate, install a self-cleaning automatic filter in the oil inlet
pipe to the turbocharger.

Recommendation

The following products give good results:

Boll & Kirch automatic filter with integrated bypass

www.bollfilter.com
Moatti automatic filter from Alfa Laval
www.alfalaval.com

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6.8 Venting the lubricating system

Ventilation of the lubricating system

In closed rooms oil mist and oil vapour may form flammable air-mixtures.
WARNING Provide sufficient ventilation.

6.8.1 Requirements of the engine oil circulation

The venting pipe is connected to the bearing casing. The blow-by separating rate is ap-
proximately 80%.
The remainder of the blow-by is discharged through the oil drain pipe into the oil tank of
the engine and must be separated.
The venting pipe must have a constant gradient of at least 5° more than the maximum ad-
missible inclined position of the engine. This prevents accumulation of oil and oil mist in
the pipe.
It is recommend for an oil mist separator to be installed in the venting pipe before it is con-
ducted out into the atmosphere, see section "Oil mist separator".

6.8.2 Additional requirements with separate lubricating system

It is recommend to install an oil mist separator in the venting pipe before the pipe is con-
ducted from the oil tank out into the atmosphere, see Oil mist separator section.

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6.9 Oil mist separator

The oil mist separator must be mounted as far away as possible from the turbocharger.

Composition of the blow-by

The blow-by of the turbocharger consists of an assembly of air, oil mist and oil vapour. The
following concentrations can be expected:

Oil mist concentration: 500 … 700 ppm

Oil particle size: 0.1 … 10 µm
Oil vapour concentration: < 50 ppm

Requirements on the oil separator

Temperature resistance: 130 °C

Pressure resistance: ± 500 mbar
Pressure loss: < 5 mbar

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Passive oil mist separator with Rhodius filter

The Rhodius filter or oil mist separator is a maintenance-free, metallic filter. The oil separation
efficiency from the oil mist is approximately 80%.
The installation position, like the flow direction, is vertical. The venting pipe must rise constant-
ly before and after the oil mist separator.
Depending on the size, one single oil mist separator in the dimension shown can be used for
several turbochargers.

Product A165-L A170-L A175-L A180-L A185-L A190-L

A265-L A270-L A275-L A280-L A285-L* --
Number of turbo- 2 2 2 2 1 1
chargers per oil sepa-
rator
Table 4

* Preliminary

Figure 6

Item Specification

1 Rhodius filter RA-1074-4 wire mesh package Ø 210 mm x 150 mm;

further information: Rhodius GmbH, www.rhodius.com
2 Welded-on flange --
3 Pipe --
4 Safety ring --
5 Perforated sheet-metal Hole diameter 10 mm, hole spacing 12 mm, thickness 2 mm
Table 5

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Oil mist separator with high separation efficiencies

Active separator systems must be used for even better oil mist separation efficiencies.
Recognised suppliers of appropriate systems:

Manufacturer Principle

Alfa Laval www.alfalaval.com Centrifuge

Umwelttechnik 99 AG www.ut99.ch Centrifuge / electrostatic
Friedrichs Filtersysteme GmbH www.friedrichsfilter.de Micro-fibre filter and blower
Hilliard, Hilco Division www.hilliardcorp.com Micro-fibre filter and blower
Table 6

Manufacturers of oil mist separators

The products of the suppliers mentioned differ with regard to functional prin-
ciples, oil separation efficiencies, maintenance intervals, flow capacity rang-
NOTICE
es, pressure losses and dimensions.
Their mode of operation has not been tested by ABB Turbo Systems. Pre-
cise information regarding the separating rate and usability are to be ob-
tained directly from the manufacturer.

To be observed:

Electrostatic oil mist separators must not be used with gas engines due to the potentially ex-
plosive environment.

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6.10 Commissioning the lubricating system

Contaminated oil
Serious damage to engine or property can be caused by dirt and solid mate-
rial particles in the oil.
CAUTION
At initial commissioning and after all service work, the complete lubricating
system must be thoroughly flushed with warm oil.
Use special running-in filters when running in the engine and after all ser-
vice work on the lubricating system.

Lubricating oil pressure before turbocharger

Assuring lubricating oil pressure

Serious damage to engine or property can result from missing or insufficient
lubricating oil supply.
CAUTION
The lubricating oil pressure must be monitored during operation and the
necessary pressure assured at the oil inlet.

Status for operation Oil pressure before turbo-

charger
[bar]
Admissible, for normal operation, 0.8 … 2.5
with an oil temperature range at the inlet of 30 ... 70 °C
Admissible, for normal operation, 0.8 … 2.0
with an oil temperature range at the inlet of 70 ... 85 °C
Admissible, during engine warm-up 0.8 … 4.0
Temporarily admissible ( < 1 h ) alarm 0.6 … 0.8
emergency stop 0.0 … 0.6
Admissible, during pre-lubrication and post-lubrication (engine stopped) 0.2 … 0.6
Table 7: Lubricating oil pressure, oil inlet

Lubricating oil temperature at the inlet

Machine damage
If the oil temperature at the oil inlet exceeds the admissible range, this may
lead to engine damage.
CAUTION
Observe oil temperature at the oil inlet according to the following table.

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Status for operation Oil temperature at the inlet

Toil,inlet [°C]
Admissible 30 … 85
> 85
> 90
< 30
Table 8: Lubricating oil temperature at the inlet

Lubricating oil temperature at the outlet

The oil temperature at the outlet is mainly dependant on:

Lubricating oil temperature and pressure at the oil inlet

Engine load and turbocharger speed
Exhaust gas temperature

The maximum admissible oil temperature at the outlet is listed in the following table. The spec-
ified oil outlet temperature is to be considered as alarm value for the turbocharger operation
and must be monitored according to the current regulations.

Status for operation Oil temperature at the inlet Oil temperature at the outlet
Toil,inlet [°C] Toil,outlet [°C]
Admissible 45 110
Admissible 85 130
45 > 110
85 > 130
45 > 120
85 > 140
Table 9: Lubricating oil temperature at the outlet

If the turbocharger was operated for a longer period of time outside of the admissible range,
ABB Turbo Systems recommends to have the turbocharger inspected by an ABB Turbocharg-
ing Service Station.

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6.11 Pre-lubrication, post-lubrication

Pre-lubrication
Serious damage to engine or property can result if the turbocharger is not
supplied with oil from the first moment after starting the engine.
CAUTION
Activate the pre-lubrication device each time before starting the engine.

The pre-lubrication time is at least 5 minutes.

ABB Turbo Systems recommends integrating the pre-lubrication into the engine control.

The post-lubrication time is at least 10 minutes.

If the engine is operated for 5 to 10 minutes in idle mode before stopping, no additional post-
lubrication is required.

6.12 Long-term lubrication in standby operation

If the engine and turbocharger are in standby operation for more than 12 hours with activated
pre-lubrication pump, the oil pressure before the bearings (poil, in) can be reduced to 0.2 bar.

Recommendation: Keep the oil pressure as low as possible.

The maximum admissible oil pressure in the cold operating state (30 °C) is higher than in the
warm operating state (50 °C), see also table "Oil condition".

Oil condition for long-term standby operation Oil pressure before turbocharger (poil, in)
[bar]
Oil, 30 °C … 50 °C 0.2 … 0.6
Table 10

CONFIDENTIAL HZTL91022_EN Revision E November 2015

The Information contained in this document has to be kept strictly confidential. Any unauthorized use, reproduction, distribution or disclosure to third
parties is strictly forbidden. ABB reserves all rights regarding Intellectual Property Rights. © Copyright 2015 ABB. All rights reserved.
Enginebuilder Manual / A100-L, A200-L
6 Oil supply Page 21 / 21

6.13 Lubrication during flexible cut-out operation

During cut-out operation, the oil supply of the switched-off turbocharger must be active so that
the rotor is on a floating bearing. This ensures that no damage is caused to bearing and rotor
due to engine vibrations.

The same pressure and temperature regulations apply as for standard operation.

6.14 Lubrication at emergency stop

The turbocharger is equipped with a lubricating oil tank which is integrated in the bearing cas-
ing.

If an emergency stop of the engine causes an interruption to the lubricating oil supply, this
integrated lubrication supplies the bearing seats with oil until the rotor has stopped.

Emergency stop of the engine

If the engine and the associated turbocharger are operated after a sudden
interruption to the lubricating oil supply, this can lead to serious damage to
CAUTION
the engine or property with grave consequences.
The emergency stop of the engine must occur no later than 10 seconds
after failure of the oil supply.

CONFIDENTIAL HZTL91022_EN Revision E November 2015

The Information contained in this document has to be kept strictly confidential. Any unauthorized use, reproduction, distribution or disclosure to third
parties is strictly forbidden. ABB reserves all rights regarding Intellectual Property Rights. © Copyright 2015 ABB. All rights reserved.
Enginebuilder Manual / A100-L, A200-L
Table of contents Page 1 / 17

Speed measurement at the turbocharger

7 Speed measurement at the turbocharger ................................................. 3

7.1 Layout and overview .................................................................................. 3
7.2 Speed differences with several turbochargers per engine .......................... 4
7.3 Mode of operation ...................................................................................... 5
7.4 Cable guiding and connection .................................................................... 6
7.5 Technical data of the speed measurement system .................................... 9
7.6 Tachometer / F/I-converter......................................................................... 11

CONFIDENTIAL HZTL91007_EN Revision B August 2013

7 Speed measurement at the turbocharger

The speed of the turbocharger must be permanently monitored.

7.1 Layout and overview

Figure 1

86505 Speed sensor 86528 Tachometer

86506 O-ring 42047 Screw plug
86515 Cable connector 32109 Sealing disc with cam
86526 F/I converter *) Installation variant for speed sensor
or for second speed sensor

The following delivery variants and combinations of the accessories are available:

Version Speed sensor Cable connector F/I converter Tachometer

Variant 1 ✔ ✔ - -
Variant 2 ✔ ✔ ✔ -
Variant 3 ✔ ✔ - ✔
Table 1

CONFIDENTIAL HZTL91007_EN Revision B August 2013

7.2 Speed differences with several turbochargers per en-

gine
The speeds of all turbochargers on an engine vary only slightly from each other in standard
operation.

The difference between the highest and the lowest turbocharger speed must not be more than
3 %, relative to the speed limit nBmax.

If this admissible difference range is exceeded, the following steps must be performed:

 Reduce the engine performance immediately to the point at which the maximum turbochar-
ger speed does not exceed 70 % of nBmax.
 If the engine cannot be stopped, it can continue to be driven with this reduced engine per-
formance or turbocharger speed.
 If a turbocharger surges continuously, the engine performance must be reduced further.
 Measure the temperatures in the air lines and exhaust gas pipes from and to the tur-
bochargers and compare with normal values.

If the engine can be stopped temporarily:

 Inspect air lines, exhaust gas pipes and the turbochargers and remedy any malfunctions.
 In any case, contacting the nearest ABB Turbocharging Service Station is recommended.

CONFIDENTIAL HZTL91007_EN Revision B August 2013

7.3 Mode of operation

The sealing disc (32109) also turning on the shaft induces voltage pulses at the electromag-
netic speed sensor (86505).
The voltage limiting module limits the amplitudes of the pulses to a maximum value (< ± 15V)
and suppresses the signal noise (< ≈ 1.4V).

The pulse frequency of the speed signal is proportional to that of the rotor. The turbocharger
speed can be determined as follows:

nTL = f / l

nTL Turbocharger speed [rps]

f Frequency of the speed signal [Hz]
I Number of pulses per revolution [ - ]

Recommendations for signal strength

To obtain an output signal that is as strong as possible, ABB Turbo Systems recommend that
the down-circuit evaluation electronics (for example, a tachometer) should have a resistance
of > 10 kΩ and an adaptive trigger level of ~ 0.5 V.

Product Minimum measurable speed, Maximum frequency of the Number of

trigger level of 2.5 V speed signal f pulses I
[s-1] [Hz] [-]
A165-L, A265-L 27 2 × nMmax 2
A170-L, A270-L 23 2 × nMmax 2
A175-L, A275-L 19 2 × nMmax 2
A180-L, A280-L 17 2 × nMmax 2
A185-L, A285-L* 15 2 × nMmax 2
A190-L 14 2 × nMmax 2
Table 2

* Preliminary

CONFIDENTIAL HZTL91007_EN Revision B August 2013

7.4 Cable guiding and connection

Figure 2

1 Engine support
2 Speed sensor
3 Cable (2 m)
4 Voltage limiting module
5 Cable (12 m)
R Bending radius R ≥ 90 mm
A 64°
B 64°

 Secure cable (3) to the engine support (1) at the voltage limiting module (4) to prevent fati-
gue damage through vibrations.
 Cable (5) can be shortened to the required length.
The cable is a 3-wire cable (red/black/brown). The brown wire is not connected and can be
cut during shortening. The shield must be twisted.
 Connect the cable (5) according to the illustration (see section Connection schemes).

CONFIDENTIAL HZTL91007_EN Revision B August 2013

Cables close to heat sources and/or high voltage lines

High heat sources can lead to the destruction of the cable.
CAUTION High voltage lines can lead to signal interference.

 Do not exceed a maximum ambient temperature of + 125 °C.

 Do not lay cables parallel to high voltage lines or ignition cables.
 Leave sufficient space between cables and heat sources.

Destruction of the voltage limiter

An applied voltage can immediately destroy the voltage limiter (for example,
when the insulation resistance is measured).
CAUTION
 Observe the connection scheme.

CONFIDENTIAL HZTL91007_EN Revision B August 2013

Connection scheme

Figure 3

C Red (+)
A Black (-)
B Grey (grounding)
1 Speed sensor
2 Cable connector
3 Plug
4 Voltage limiting module
5 Cable
6 Terminals for open cable ends (A, B, C)
7 Evaluation electronics

Procedure for connecting

 Insert plug (3) of the cable connector (2) into the speed sensor (1).
 Connect open ends (A, B, C) of the cable (5) to the evaluation electronics (7).

Bringing together the plug connectors

Incorrectly bringing together the plug connector may bend the pins in the
plugs.
CAUTION

 Be sure to correctly bring together the plug connector.

 Assemble without the use of force.

CONFIDENTIAL HZTL91007_EN Revision B August 2013

7.5 Technical data of the speed measurement system

Signal aspect after voltage limiter

Figure 4

Signal amplitude: U(t) = f(nTL)

Signal aspect at open-collector output of the T401 / T411

Figure 5

Signal amplitude: U(t) ≠ f(nTL)

CONFIDENTIAL HZTL91007_EN Revision B August 2013

Resistance of the speed measurement system to climatic conditions

Figure 6

Range Component Working temperature, Relative humidity

permanent
1 Speed sensor ≤ 150 °C 95 %
2 Plug with cable, green ≤ 200 °C 95 %
3 Voltage limiting module ≤ 125 °C 95 %
4 Cable, black ≤ 125 °C 95 %
5 F/I-converter / tachometer ≤ 70 °C 75 %
Table 3

 Avoid condensation.

Protection class / electrical connection

Speed sensor and plug IP67

Wire cross section of the cables 0.21 mm2
Table 4

CONFIDENTIAL HZTL91007_EN Revision B August 2013

7.6 Tachometer / F/I-converter

7.6.1 Introduction

The T401 F/I-converter (frequency/current) or the T411 tachometer is available for displaying
and converting the turbocharger speed signal. Both devices are identical in terms of functiona-
lity. Unlike the T401, however, the T411 is also equipped with a display.

The parameters of the analogue output (4…20 mA) of both devices are set by ABB Turbo
Systems.

The following parameters (speed ranges) are recommended:

Product Speed range

[rpm]
0 … 15000 0 … 20000 0 … 25000 0 … 30000 0 … 40000
A165-L, A265-L -- -- -- ✔ --
A170-L, A270-L -- -- ✔ -- --
A175-L, A275-L -- ✔ -- -- --
A180-L, A280-L -- ✔ -- -- --
A185-L, A285-L* -- ✔ -- -- --
A190-L ✔ -- -- -- --
Table 5

* Preliminary

The corresponding speed range (0…X) is shown on the device label (see illustration).

Figure 7

The selection and parameterisation of the speed range does not affect the display (T411) and
the open-collector output (T401, T411).

Destruction of the device

Incorrect connection can immediately destroy the device.
CAUTION  Connect according to the connection scheme.

CONFIDENTIAL HZTL91007_EN Revision B August 2013

7.6.2 Signal outputs

Analogue output of tachometer, F/I-converter

Figure 8

The analogue output provides a 4-20 mA current signal proportional to the speed depending
on the speed range set in the parameters (see figure shown above).

CONFIDENTIAL HZTL91007_EN Revision B August 2013

Open-collector output of tachometer, F/I-converter

Figure 9

The open-collector output provides a square wave signal with constant amplitude. The output
must also be electrically supplied (power supply UL).
It offers the following application options:

 Amplification of the sensor signal to guarantee signal transmission over long signal lines.
 Reduction of the minimum measurable speed (due to the low adaptive trigger level of the
T401 or T411 of 250 mV).
 Use of tachometers without adjustable trigger level as well as tachometers which do not
have an input for inductive speed sensors.

7.6.3 Installation

T401 F/I-converter

The T401 F/I-converter must be installed in a switch cabinet (rails based on EN 50022-35 and
DIN 46277).

Figure 10

CONFIDENTIAL HZTL91007_EN Revision B August 2013

T411 tachometer

The T411 tachometer is installed using retainers (in accordance with DIN 43835 Form B), see
also installation instructions listed below.

Figure 11

86528 Tachometer 3 Cable plug

1 Front plate 4 Metal clips
2 Rear plate 5 Screws

Preparation for assembly

 Cut rectangular opening in the front plate (1),

dimensions: 90 x 43 mm (maximum: 91 x 44)
 Remove the cable plug (3) from the rear of the tachometer (86528) and connect with the
corresponding cables of the switch panel.
 Remove metal clips (4) which are fitted on both sides of the tachometer.

CONFIDENTIAL HZTL91007_EN Revision B August 2013

Installing the tachometer

Figure 12

86528 Tachometer 3 Cable plug

1 Front plate 4 Metal clips
2 Rear plate 5 Screws

 Insert the tachometer (86528) into the front plate (1).

 Connect the cable plug (3) to the rear of the tachometer.
 Fit the metal clips (4) sideways on the tachometer.
 Tighten both screws (5) of the metal clips until the tachometer is firmly fitted on the front
plate.

CONFIDENTIAL HZTL91007_EN Revision B August 2013

7.6.4 Connection schemes

T401 F/I-converter

2: Sensor connection C: Signal +

A: Signal -
B: Shielding

3: Power supply Supply F/I-converter with

10…30 VDC

4: Analogue output 4…20 mA current output

5: Open-collector output The voltage of the open-collector

output depends on the power supply
and, at a resistance of R = 10 kΩ, is
approx. 2 V less than the power
supply voltage.
Connect down-circuit evaluation
electronics accordingly:
 Connect the positive pole of the
evaluation electronics to the emit-
ter!
 Connect the negative pole of the
evaluation electronics to the collec-
tor!

Table 6

Destruction of the device

Incorrect connection can immediately destroy the device.
CAUTION  Connect according to the connection scheme.

Figure 13

 Connect the cable according to the labelling of the respective terminal level.

CONFIDENTIAL HZTL91007_EN Revision B August 2013

T411 tachometer

Figure 14

2: Sensor connection C: Signal +

A: Signal -
B: Shielding

3: Power supply Supply tachometer with 10…30 VDC

4: Analogue output 4-20 mA current output

5: Open-collector output The voltage of the open-collector output depends on the power
supply and, at a resistance of R = 10 kΩ, is approx. 2 V less
than the power supply voltage.
Connect down-circuit evaluation electronics accordingly:
 Connect the positive pole of the evaluation electronics to the
emitter!
 Connect the negative pole of the evaluation electronics to the
collector!
Table 7

CONFIDENTIAL HZTL91007_EN Revision B August 2013

Compressor and turbine cleaning

8 Compressor and turbine cleaning ............................................................ 3

8.1 Cleaning the compressor during operation ................................................. 3
8.2 Cleaning turbine blades and nozzle ring during operation .......................... 6
8.3 Suppliers of dry cleaning materials ............................................................ 9

CONFIDENTIAL HZTL91008_EN Revision A March 2013

8 Compressor and turbine cleaning

8.1 Cleaning the compressor during operation

Approval by enginebuilder

These instructions for wet cleaning only apply to cleaning with pure water and under the pre-
condition that the enginebuilder approves the process.

General

The contamination of the compressor stage (compressor wheel, wall insert and diffuser) de-
pends on the degree of purity of the taken-in air.

Deposits can form in the flow channels if salt, oil mist or dust are sucked in with the air.

Consequences of contamination:

 Impaired compressor efficiency

 Higher exhaust gas temperatures
 Increased fuel consumption
 Increased rotor unbalance

Periodic cleaning of the compressor during operation prevents or delays any great increase in
the contamination, but never replaces the regular service procedures where the turbocharger
is completely dismantled and the compressor is mechanically cleaned.

Cleaning interval

The interval between the cleaning cycles depends greatly on the operating conditions. Clean-
ing should normally take place about every 50 hours of operation.
If the specified cleaning intervals are incompatible with operation of the engine, contact ABB
Turbo Systems.

CONFIDENTIAL HZTL91008_EN Revision A March 2013

Cleaning method and operating state

The compressor is cleaned during operation using the wet cleaning method. It is carried out at
an engine load of 25 ... 85 %.
This cleaning method has been tested and approved by ABB Turbo Systems.

Principle of wet cleaning

To clean the compressor stage during operation, water is injected before the compressor
wheel.

The water does not act as a solvent. The coating is removed by the mechanical action of the
impacting droplets. The process is particularly suitable as long as the fouling is not too ad-
vanced.

Corrosion and deposits when cleaning

Salt water and cooling water treatment substances damage and adversely
affect turbocharger parts.
CAUTION
 Never use salt water, but only pure water for cleaning.

Cleaning several turbochargers

If several turbochargers are installed on an engine, it is recommended to clean one compres-

sor after the other.

Volume of water for cleaning the compressor

Uncontrolled volumes of water can cause great damage in the turbocharger
and especially in the engine.
CAUTION
 Do not guide water pipes to the filler openings.

CONFIDENTIAL HZTL91008_EN Revision A March 2013

Figure 1

81000 Filter silencer

81126 Lock
A Can
B Filler opening

The sequence of the manual compressor cleaning operations is described in the operation
manual.

CONFIDENTIAL HZTL91008_EN Revision A March 2013

8.2 Cleaning turbine blades and nozzle ring during opera-

tion
Combustion of heavy fuel oil in diesel engines causes contamination of the turbine blades and
nozzle rings of the turbochargers.
Contamination increases with time, which is why regular and properly carried out cleaning
operations are important to remove any deposits.

Contaminated turbine components lead to a decrease in turbocharger efficiency. Furthermore,

the exhaust gas temperature after the cylinders can rise and the charging pressure in the air
receiver can drop.
Moreover, contamination of the turbine leads to rotor unbalance. A very high level of contami-
nation can lead to intolerably high rotor unbalance.

Despite periodic cleaning during operation, experience shows that overhauls where the tur-
bine and nozzle ring (or VTG) are mechanically cleaned cannot be omitted.

Interval for dry cleaning

The interval between the cleaning cycles depends greatly on the operating conditions. Clean-
ing should normally take place about every 50 hours of operation.

Cleaning method

The turbine and the nozzle ring (or VTG) are cleaned during operation using the dry cleaning
method.
This cleaning method has been tested and approved by ABB Turbo Systems.

Principle of dry cleaning

During dry cleaning, the dirt coating is removed by the mechanical action of the impacting sol-
ids (granulate).

Operating state

The dry cleaning of the turbine-end components is carried out at an engine load of
25 ... 85 %.

Cleaning several turbochargers

If several turbochargers are installed on an engine, it is recommended to clean one turbine

after the other.

CONFIDENTIAL HZTL91008_EN Revision A March 2013

Dry cleaning device

Figure 2

11 Container for granulate material (51702) 16 Protection valve [closed] (51713)

12 Cover cap (51703) 17 Pressurised air valve [venting] (51704)
13 Pressurised air supply [4 ... 10 bar] 18 Plate
14 Piping 19 Cleaning instruction (51717)
15 On-Off valve [closed] (51705) 20 Gas inlet casing, insulated

Protecting the pressurised air system

 Protect the pressurised air system against overpressure (> 10 bar).
CAUTION

The operation of the dry cleaning device is described in the operation manual.

CONFIDENTIAL HZTL91008_EN Revision A March 2013

Material selection

The following materials are suitable for dry cleaning:

 Hard, granulated materials (such as natural core granulates)

 Softblast media
 Activated carbon particles

The average grain size of the cleaning granulate must be between 1.2 and 2.0 mm.

The specific weight of the cleaning granulate must not exceed 1.2 kg/dm3.

Amount of granulate per turbocharger

Product A165-L A170-L A175-L A180-L A185-L A190-L

Quantity 1.0 1.5 2.0 2.5 3.0 3.5
[dm3]
Table 1

Product A270-L A275-L

Quantity 1.5 2.0
[dm3]
Table 2

Storage of dry cleaning materials

The cleaning material must be stored in a dry and clean location to prevent
blockage of the pipes when cleaning.
NOTICE
Possible suppliers are listed in section Suppliers of dry cleaning materials.

CONFIDENTIAL HZTL91008_EN Revision A March 2013

8.3 Suppliers of dry cleaning materials

Manufacturer Country Address Contact numbers
ABB Australia Pty. Australia Dock 7W Bapaume Road Tel.: +61 2 9821 0940
Limited 2170 Moorebank- N.S.W. Fax: +61 2 9821 0941
Email: turbo@au.abb.com
Paul AUER GmbH Germany Bad Kreuznacherstr. 18 Tel.: +49 621 72 769 - 0
D-68309 Mannheim- Fax: +49 621 72 769 - 88
Kaefertal Email: vertrieb@auer-strahltechnik.de
BRIGANTINE Hong Kong 48 Wang Lok Street Tel.: +852 2473 7933
Service Ltd. Yuen Long Industrial Estate Fax: +852 2237 4731
N.T. Hong Kong Email:
gcabrgpropur@brigantinegroup.com
LEERING HEN- Nether- Barnsteenstraat 1 Tel.: +31 74 255 82 82
GELO B.V. lands NL-7554 TC Hengelo Fax: +31 74 242 23 73
The Netherlands Email: info@leering.nl
GUYSON United Snaygill Industrial Estate Tel.: +44 1756 799911
International Ltd Kingdom Keighley Road, Skipton, Fax: +44 1756 790213
North Yorkshire BD23 2QR Email: info@guyson.co.uk
United Kingdom
DASIC United Winchester Hill, Romsey, Tel.: +44 1794 512 419
International Ltd. Kingdom Hampshire SO51 7YD Fax: +44 1794 522 346
United Kingdom Email: info@dasicinter.com
PAN Singapore 24 Pioneer Sector 2 Tel.: +65 6861 6988
Abrasives (Pte) Jurong Fax: +65 6861 0919
Ltd. 628381 Singapore Email: pagroup@pan-abrasives.com
CARLANDER & Sweden Valtersang 9 Tel.: +46 303 630 75
Co. S-442 49 Kungalv Fax: +46 303 630 77
Sweden Email: lars@carlander.com
BOSUNG Engine- Korea 1189-1, Choryang-3 Dong, Tel.: +82 51 466 0881-5
ering Co., Ltd. Dong-Ku, Busan, 601-013 Fax: +82 51 466 0886-9
Email: master@bosung.com
POLITEK Ltd. Turkey Barajyolu Cad. No: 22/6 Tel.: +90 216 455 77 66
Y. Camlica Mahallesi Fax: +90 216 455 77 25
Yukari Dudullu Email: politekltd@politekltd.com
34779 Umraniye
Istanbul / Turkey
UNISERVICE S.A. Italy Via Al Santuario di N.S. Tel.: +39 010 711 395
della Guardia 58 / A Fax: +39 010 713 120
16162 Genova Email: info@uniservicemarine.com
Table 3

CONFIDENTIAL HZTL91008_EN Revision A March 2013

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