ABB Power2 Series Quick start guide
Turbocharger / A100-M radial
Original assembly instructions – English
This document is valid for the
Power2 series:
Power2 550-M
Purpose
The assembly instructions explain how the low-
and high-pressure stage of ABB Turbocharging
is fitted to the engine correctly and without any
health and safety risks.
Target group
The assembly instructions are intended for
engineers and mechanics responsible for fitting
the low- and high-pressure stage on the engine.
Power2 performance package
Two-stage turbocharging solution for highest
turbocharging efficiency
—
ASSEMBLY INSTRUCTIONS
Turbocharger / Power2 500-M
Original assembly instructions – English
Assembly Instructions / Power2 500-M
Table of contents
© Copyright 2020 ABB. All rights reserved. HZTL455311P0009_EN Rev.A July 2020
Assembly Instructions
1 Introduction............................................................................................................ 2
1.1 Purpose of the assembly instructions....................................................................... 2
1.2 Definition of target group ........................................................................................... 2
1.3 Symbols, definitions...................................................................................................... 2
1.4 Definition of warning, caution, note......................................................................... 4
1.5 Definition of mandatory signs ................................................................................... 4
2 Safety ...................................................................................................................... 5
2.1 Introduction .................................................................................................................... 5
2.2 Lifting of loads .............................................................................................................. 6
2.3 Occupational safety ...................................................................................................... 7
3 Weight and transportation of the low-pressure and the high-pressure
stages.................................................................................................................... 10
4 Installing the low-pressure stage ....................................................................... 11
4.1 Placing the low-pressure stage on the bracket and aligning ............................. 12
4.2 Steps for fastening the low-pressure stage .......................................................... 13
5 Installing the high-pressure stage..................................................................... 19
5.1 Inserting gaskets ......................................................................................................... 19
5.2 Placing the high-pressure stage on the bracket .................................................. 20
5.3 Steps for fastening the high-pressure stage......................................................... 22
5.4 Tightening the clamping nut .................................................................................... 24
5.5 Completion work, if required ................................................................................... 25
6 Storage of new low-pressure and high-pressure stages................................ 26
7 Further information............................................................................................. 28
Assembly Instructions / Power2 500-M
1 Introduction / 1.1 Purpose of the assembly instructions
© Copyright 2020 ABB. All rights reserved. HZTL455311P0009_EN Rev.A July 2020
1 Introduction
1.1 Purpose of the assembly instructions
The assembly instructions explain how the low- and high-pressure stage of ABB Turbochar-
ging is fitted to the engine correctly and without any health and safety risks. This element of
the documentation is supplied with the product, as is required for partly completed ma-
chinery in accordance with machinery directive 2006/42/EC.
The assembly instructions are a complement to and expansion of existing national regula-
tions for occupational safety, accident prevention and environmental protection.
1.2 Definition of target group
The assembly instructions are intended for engineers and mechanics responsible for fitting
the low- and high-pressure stage on the engine. Basic mechanical training is a prerequisite.
All persons who are involved in the transportation and installation of the low and high-pres-
sure stage have read and understood the assembly instructions.
1.3 Symbols, definitions
Symbols
The following symbols are used in this document:
uIndicates an action step.
1. Indicates a numbered action step.
¡Indicates a list.
➙Refers to a page number
Terms used
The following terms are used in this document:
¡Two-stage turbocharging (Power2)
¡Low-pressure stage (Power2 LP)
¡High-pressure stage (Power2 HP)
¡Low-pressure and high-pressure stage
The trademarks of outside companies are used in this document. These are marked with the
® symbol.
Page 2 / 29
Assembly Instructions / Power2 500-M
1 Introduction / 1.3 Symbols, definitions
© Copyright 2020 ABB. All rights reserved. HZTL455311P0009_EN Rev.A July 2020
Design variants
This document is valid for different design variants of low and high-pressure stages. There
may be sections and descriptions of components that are not relevant for a specific low or
high-pressure stage.
ABB Turbocharging Service Stations will be happy to provide information about questions
regarding a design variant (see "Contact Information" on our website www.abb.com/tur-
bocharging).
Accuracy of illustrations
The illustrations in this document are general in nature and intended for ease of understand-
ing. Differences in detail are therefore possible.
ABB Turbocharging
ABB Switzerland Ltd, Turbocharging is identified as ABB Turbocharging in this document.
Official service stations of ABB Turbocharging
Official service stations are identified in this document as ABB Turbocharging Service Sta-
tions. They are regularly audited and certified by ABB Turbocharging. See "Contact Informa-
tion" on our website at www.abb.com/turbocharging.
Definition of pictograms
The following pictograms can occur in this document. These point out actions that must be
taken in accordance with the meaning of the relevant pictogram.
Pictogram Meaning Pictogram Meaning
Tighten with specified torque Oil free, grease free and dry
Tighten over specified tightening
angle
Affix
Hand-tight, tighten without tools Measure
Oil Note
Apply screw locking paste (e.g.
Loctite)
Visually inspect
Apply high-temperature grease See document
Apply other paste in accordance
with specifications
Dispose of in an environmentally
compatible, professional way
and in compliance with locally
applicable regulations.
Table1: Definition of pictograms
Page 3 / 29
Assembly Instructions / Power2 500-M
1 Introduction / 1.4 Definition of warning, caution, note
© Copyright 2020 ABB. All rights reserved. HZTL455311P0009_EN Rev.A July 2020
1.4 Definition of warning, caution, note
WARNING
Definition of Warning
Non-compliance or inaccurate compliance with working or operating in-
structions indicated by this symbol and the word WARNING can lead to seri-
ous injuries to personnel and even to fatal accidents.
uWarning signs must always be observed.
CAUTION
Definition of Caution
Non-compliance or inaccurate compliance with working or operating in-
structions indicated by this symbol and the word CAUTION can lead to seri-
ous damage to engine or property with grave consequences.
uCaution signs must always be observed.
NOTICE
Note
The note provides advice which facilitates the work.
1.5 Definition of mandatory signs
To be worn at all times
Protective clothing Safety footwear to protect
against mechanical hazard and
risk of falling
Table2: Personal protective equipment to be worn at all times
To be worn specific to the respective task
Safety glasses Safety goggles
Safety gloves to protect
against
- Mechanical hazard
- Chemical hazard
- Thermal hazard
Respiratory mask to protect
against
- Dusts
- Gases
Safety helmet Ear protection
Table3: Personal protective equipment to be worn specific to the respective task
Page 4 / 29
Assembly Instructions / Power2 500-M
2 Safety / 2.1 Introduction
© Copyright 2020 ABB. All rights reserved. HZTL455311P0009_EN Rev.A July 2020
2 Safety
2.1 Introduction
The two-stage turbocharging system(Power2) manufactured by ABB Turbocharging is state
of the art and complies with the respective health and safety standards in effect at the time
the system was built. Thus Power2 is safe to operate. Nevertheless, there may be some re-
sidual risks during operation of the Power2 and work on Power2 components, such as low-
pressure stage and high-pressure stage, which:
¡Are caused by Power2 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 defining measures that regulate safe access to
and safe handling of the Power2.
All instructions contained in this chapter must be observed for safe and trouble-free opera-
tion of the Power2 and during all work on the Power2 components.
All further safety instructions contained and specifically identified in every chapter of this
document (see section Definition of safety instructions) must also be observed.
Information
Low-pressure and high-pressure stages from ABB Turbocharging comply with the machinery
directive 2006/42/EC and are partly completed machinery as defined by Article2g.
Responsibility of the operating company
In awareness of its responsibility, the operating company must ensure that only authorised
personnel work on the Power2, who:
¡Are versed in the general and locally applicable regulations for occupational safety and
accident prevention
¡Are equipped with the prescribed personal protective equipment
¡Have read and understood the Operation Manual
¡Have been instructed in the use of the Power2.
The safety-conscious work of the personnel and adherence to the Operation Manual must be
checked periodically.
Suitable working materials and personal protective equipment must be kept in a perfect
condition.
Only authorised personnel may remain in the vicinity of the Power2 when the engine is run-
ning.
Page 5 / 29
Assembly Instructions / Power2 500-M
2 Safety / 2.2 Lifting of loads
© Copyright 2020 ABB. All rights reserved. HZTL455311P0009_EN Rev.A July 2020
2.2 Lifting of loads
WARNING
Suspended loads
Loads that are not attached according to regulations can cause injury to
personnel or fatal accidents.
uLoads must always be fastened to properly functional lifting gear with a
sufficient load limit.
uPay attention to the correct attachment of loads on the crane hook.
uPeople must not stand beneath suspended loads.
Wear safety gloves to protect against mechanical hazards.
Wear safety helmet.
Fig.1: Attachment of loads on the crane hook
Fig.2: Attachment angle
If there are two or more suspension points, the attachment angle of 45° must not be ex-
ceeded. This prevents excessive loading due to diagonal pull.
uUse a suitable edge guard if there are sharp edges.
uThe assembly devices must be completely screwed in and must not unscrew during use.
uUse assembly devices only for the described applications.
Page 6 / 29
Assembly Instructions / Power2 500-M
2 Safety / 2.3 Occupational safety
© Copyright 2020 ABB. All rights reserved. HZTL455311P0009_EN Rev.A July 2020
2.3 Occupational safety
Occupational safety
WARNING
Injuries to persons
Severe injuries to personnel or fatal accidents can be caused by mechanical
influences as a consequence of hazardous and inadequate operational pro-
cedures or non-compliance with safety and health standards.
uWhen working on the Power2, always wear safety footwear and protect-
ive clothing to protect against mechanical hazards.
uKeep personal protective equipment in perfect condition.
uObey mandatory signs.
uObserve the general rules for occupational safety and prevention of acci-
dents.
uOnly perform operations that are described in this chapter.
uOnly perform operations for which you have received instruction or train-
ing.
Wear safety footwear to protect against mechanical hazard and risk of fall-
ing.
Wear protective clothing.
WARNING
Risk of falling
When work is performed on the low-pressure or high-pressure stage, there
is a risk of falling.
uDo not climb onto the low-pressure or high-pressure stage or onto at-
tached parts and do not use them as climbing aids.
uUse suitable climbing aids and working platforms for work above body
height.
uOnly perform work on the low-pressure or high-pressure stage when you are in a physic-
ally and psychologically stable condition.
uOnly work with suitable tools, equipment and appliances that function properly.
uKeep the workplace clean; clear away any loose objects and obstacles on the floor.
uKeep the floor, equipment and the low-pressure and high-pressure stage clean.
uHave oil binding agents ready and provide or keep oil pans at hand.
Welding work
uWear personal protective equipment (PPE) for welding operations.
Page 7 / 29
Assembly Instructions / Power2 500-M
2 Safety / 2.3 Occupational safety
© Copyright 2020 ABB. All rights reserved. HZTL455311P0009_EN Rev.A July 2020
uWhen performing welding work in the vicinity of the low-pressure stage, always cover the
filter silencer to prevent the filter mat from being damaged.
uKeep flammable objects and substances out of the vicinity of flying sparks.
uCover all connections on the low-pressure and high-pressure stage so that no foreign ob-
jects can enter the low-pressure or high-pressure stage.
Mechanical hazards when working on the low-pressure and high-pressure stage
WARNING
Physical hazards due to rotating parts
The rotor can rotate due to the stack draught alone. Contact with rotating
parts can cause severe injury.
uSecure rotor against turning.
WARNING
Mechanical hazard
Severe injuries to personnel or fatal accidents can be caused by mechanical
influences as a consequence of hazardous and inadequate operational pro-
cedures.
uObserve the general rules for occupational safety and prevention of acci-
dents.
uEnsure workplace safety.
uOnly perform operations that are described in this chapter.
uOnly perform operations for which you have previously received instruc-
tion or training.
Hazards due to operating materials and supplies
Operating materials and supplies can include: Oils, greases, coolants, cleaning agents and
solvents, acids or similar substances.
Page 8 / 29
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