HYUNDAI
INSTRUCTION BOOK VOLUME II Engine type H21/32 Hyundai Heavy Industries Co., Ltd. Engine & Machinery Division 1000 Bangeojinsunhwan-doro, Dong-Gu, Ulsan, Korea http://www.hhi.co.kr http://cs.hyundai-engine.com Warranty Service Engine CS Dep't
Parts Sales Global Service Dep't
TEL : (82) 52-202-7411 (Marine) (82) 52-202-7583 (Stationary) FAX : (82) 52-202-7581 E-mail :
[email protected]
TEL : (82) 52-202-7418
24/7 Hot Line: +1 212 845 9803
FAX : (82) 52-202-7582 E-mail :
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Table of contents 1
Preliminary remarks ....................................................................................
1.1
Purpose of the manual .................................................................................
1.2
Symbols, definitions, contact address ..........................................................
2
Safety .........................................................................................................
2.1
Introduction...................................................................................................
2.2
Definition of safety instructions.....................................................................
2.3
Warning plates on the turbocharger .............................................................
2.4
Safe operation and maintenance .................................................................
2.5
Hazards during operation and maintenance ................................................
2.6
Use of ABB turbochargers on gas engines ..................................................
2.7
Lifting of loads ..............................................................................................
3
Introduction .................................................................................................
3.1
Essential information ....................................................................................
3.2
Layout and function of the turbocharger.......................................................
3.3
Storage of new turbochargers ......................................................................
3.4
Intended use.................................................................................................
3.5
Prerequisites for operation ...........................................................................
3.6
Turbocharger rating plate .............................................................................
3.7
CE conformity...............................................................................................
4
Removal and installation .............................................................................
4.1
Transport ......................................................................................................
4.2
Turbocharger weights...................................................................................
4.3
Removing the turbocharger..........................................................................
4.4
Installing the turbocharger............................................................................
5
Commissioning ...........................................................................................
5.1
Oil supply......................................................................................................
5.2
Inspection procedures ..................................................................................
5.3
Commissioning after taking out of operation ................................................
6
Monitoring during operation ........................................................................
6.1
Oil pressure, oil temperature ........................................................................
6.2
Turbocharger speed .....................................................................................
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Operation and service ................................................................................
7.1
Noise emission .............................................................................................
7.2
Service procedures.......................................................................................
7.3
Expected replacement intervals....................................................................
7.4
Stopping the engine......................................................................................
8
Periodic maintenance.................................................................................
8.1
Foreword to maintenance .............................................................................
8.2
Cleaning the filter silencer ............................................................................
8.3
Cleaning the compressor during operation ...................................................
8.4
Cleaning the turbine during operation...........................................................
9
Troubleshooting .........................................................................................
9.1
Malfunctions when starting ...........................................................................
9.2
Malfunctions during operation.......................................................................
9.3
Surging of the turbocharger ..........................................................................
9.4
Malfunctions when stopping .........................................................................
9.5
Speed measurement system ........................................................................
10
Disassembly and assembly ........................................................................
10.1
Introduction ...................................................................................................
10.2
Weights of assemblies..................................................................................
10.3
Removing / Installing air-inlets ......................................................................
10.4
Removing / Installing compressor casing .....................................................
10.5
Removing the cartridge group ......................................................................
10.6
Installing the cartridge group ........................................................................
10.7
Radial clearances N and R ...........................................................................
10.8
Axial clearance A and radial flexibility B .......................................................
10.9
Table of tightening torques ...........................................................................
11
Taking out of operation at short notice .......................................................
11.1
Possible emergency repairs .........................................................................
11.2
Attaching a cover plate .................................................................................
11.3
Cover plate drawing......................................................................................
12
Mothballing the turbocharger......................................................................
12.1
Taking the engine out of operation for up to 12 months ...............................
12.2
Taking the engine out of operation for more than 12 months .......................
13
Disposal .....................................................................................................
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Reserve and spare parts.............................................................................
14.1
Ordering spare parts ....................................................................................
14.2
View of turbocharger with part numbers.......................................................
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Preliminary remarks
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1
Preliminary remarks
1.1
Purpose of the manual
Operation manual This operation manual will familiarise you with the turbocharger of ABB Turbo Systems and provides information on how to use it in compliance with its intended purpose. The operation manual explains what is important to know in order to operate the turbocharger safely, appropriately and profitably. The operation manual is a complement to and expansion of existing national regulations for occupational safety and accident prevention. Target group The operation manual is aimed at engineers, mechanics and service staff responsible for the proper operation of the engine and for the turbocharger connected to it. Availability of the operation manual An operation manual must be available where the turbocharger is used. All persons operating or working on the turbocharger must have read and fully understood the operation manual.
1.2
Symbols, definitions, contact address
Symbols The following symbols are used in the documents: Steps of a procedure
List, first level - List, second level
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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 Turbocharger service stations. 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 Customer service The Contact Information brochure includes a global overview of the official ABB Turbocharger service stations.
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Safety
2.1
Introduction
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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 and supplies or materials Are a consequence of insufficient compliance with safety instructions Are a consequence of insufficient or inappropriate performance of maintenance and inspection 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 manual (see section Definition of safety instructions) must also be observed.
2.2
Definition of safety instructions
The following symbols and nomenclature are used in this manual, referring to safety or indicating potential hazards:
Definition of Warning WARNING
Non-compliance or inaccurate compliance with working or operating instructions indicated by this symbol and the word WARNING can lead to serious injuries to personnel and even to fatal accidents. Warning signs must always be observed.
Definition of Caution CAUTION
Non-compliance or inaccurate compliance with working or operating instructions indicated by this symbol and the word CAUTION can lead to serious damage to engine or property with grave consequences. Caution signs must always be observed.
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2.3
Warning plates on the turbocharger 72080
Figure 1
81080
Figure 2 Table of warning plates Part number 72080 81080
Size [mm] 175 x 22 105 x 74
Product ≤ A145 ≥A150
Table 1 Turbochargers supplied to the enginebuilder without insulation must be fitted later with warning plates to be affixed to the insulation. This is the responsibility of the enginebuilder. Warning plates affixed to the turbocharger by ABB Turbo Systems must not be removed. Any warning plates that have become unreadable must be replaced. For additional information, please contact an ABB Turbocharger service station.
2.4
Safe operation and maintenance
The instructions specified in this section are for the safety of personnel. Together with the instructions in the Hazards during operation and maintenance section, they allow the user to safely use the turbocharger.
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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.
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.
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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/unauthorized 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.
Safety during cleaning It is possible that detergents or solvents are used for cleaning. In this case, the safety instructions 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.
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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.
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 WARNING
Contact with rotating parts can cause severe injury. The turbocharger must never be used without the air-inlet casing or filter silencer, respectively. With 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, noncompliance with safety and health standards, carelessness, or as a consequence of inadequate qualification.
Mechanical hazards WARNING
Severe injuries to personnel or fatal accidents can be caused by mechanical influences as a consequence of hazardous and inadequate operational procedure. 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 instruction or training.
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Noise hazards The turbocharger's 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 WARNING
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. 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]): y 240
180
120
60
05
30 15 85 88
Figure 3 x y
91
94
97
120 105 100
x
Noise level [dB(A)] Maximum duration of exposure [min] per working day
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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 WARNING
Touching hot surfaces or contact with hot operating fluids can cause severe burns. Do not touch hot surfaces, observe the warning plate on the turbocharger. 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 WARNING
Non-insulated turbochargers can cause serious injuries to personnel (burns). ABB Turbo Systems supplies the turbocharger with or without insulation in accordance with the purchase order received from the enginebuilder. If supply is without insulation, the enginebuilder is responsible for providing the turbocharger with proper insulation and for providing protection against contact with hot surfaces. Compliance with the indications and specifications given by the enginebuilder to protect against hot surfaces is compulsory.
Hazards due to operating materials and supplies Operating materials and supplies are substances required for the operation of the turbocharger or for the performance of maintenance work. Oils, greases, coolants, detergents and solvents, acids and similar substances can be classified as hazardous substances. Operating materials and supplies can be flammable and combustible.
Danger of poisoning or acid burns WARNING
Swallowing of or skin contact with toxic or caustic operating materials and supplies or breathing of any such vapours can be harmful to health. Do not breathe in these substances and avoid contact with the skin. Wear protective clothing and a breathing mask.
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Danger of fire or explosion WARNING
Flammable and combustible operating materials and supplies can catch fire or resulting vapours can lead to an explosion. Open flames are forbidden when carrying out cleaning work. Carry out cleaning in the open or provide sufficient ventilation.
Danger of environmental damage CAUTION
The emission of operating materials and supplies into the atmosphere or the contamination of ground or water systems as a result of improper disposal 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 compliance 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 regulations.
Hazards due to the handling of insulation materials
Danger from insulation materials WARNING
Dust or fibres from insulation materials can have adverse effects on the health or cause irritations. Unsuitable and combustible insulation materials 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.
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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 WARNING
Electrical components work with electrical voltages that can be a danger to humans. Any work on or with electrical components must only be performed by
specifically qualified electricians. National regulations must be observed.
2.6
Use of ABB turbochargers on gas engines
ABB turbochargers can tolerate a deflagration with a transient pressure increase of 12 bar. In deflagration tests on engines with flame barriers, a maximum of 11 bar was measured. This value is supported by the practical experience in operation gained by renowned gas engine manufacturers. ABB turbochargers have never been damaged in the past when deflagration events occurred.
ABB Turbo Systems recommends subjecting the turbocharger to a visual inspection after a deflagration event. As part of the inspection, the position of the turbine casing and the position of the compressor casing to the bearing casing must be checked, and the bearing casing must be examined to see if it has shifted in relation to the the bracket. A crack inspection of the casings and the bellows is also recommended. The nearest ABB Turbocharger service station should be instructed to carry out this inspection and assessment.
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Lifting of loads
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Figure 4
Suspended loads WARNING
Loads that are not attached according to regulations can cause physical injuries with grave consequences or fatal accidents. 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.
max. 45°
Figure 5 If there are two or more attachment points, the attachment angle of 45° must not be exceeded. 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.
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3
Introduction
3.1
Essential information
Design variants This document is valid for different design variants of turbochargers. There may be sections and descriptions of components that are not relevant for a specific turbocharger variant. The ABB Turbocharger service stations will be happy to provide information on questions regarding a design variant. Accuracy of illustrations The graphics and photographs presented in this document are general in nature and intended for ease of understanding. Differences in detail are therefore possible.
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Introduction
3.2
Layout and function of the turbocharger 1
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2
3
4
5
6
7
8
9 10
11 12 13
Figure 6 1 2 3 4 5 6 7
Filter silencer / air suction branch Compressor casing Diffuser Bearing casing Axial thrust bearing Radial plain bearing Turbine
© 2010 ABB Turbo Systems Ltd
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Gas outlet flange Nozzle ring Turbine casing Turbine-end bearing flange Compressor-end bearing flange Compressor wheel
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Mode of operation The turbocharger is a turbomachine and consists of the following main components: Turbine Compressor These components are installed on a common shaft and form the rotor (See Figure 6). The exhaust gases of the internal combustion engine flow through the turbine casing (10) and the nozzle ring (9) onto the turbine (7). The turbine (7) uses the energy contained in the exhaust gas to drive the rotor and, hence, the compressor wheel (13). The exhaust gases then reach the atmosphere through the exhaust gas pipe connected to the gas outlet flange (8). The compressor wheel (13) sucks fresh air through the air suction branch or the filter silencer (1). In the compressor wheel (13), the energy required for building up the pressure is transferred to the air. By flowing through the diffuser (3) and the compressor casing (2), the air is compressed further and is then directed to the engine cylinders. The rotor runs in two radial plain bearings (6) which are located in the bearing casing (4) between compressor and turbine. The axial thrust bearing (5) is located between the two radial plain bearings. 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 (4). Turbocharger version with compressor wheel cooling
1
Figure 7 Depending on the application of an A100 radial turbocharger, the turbocharger is equipped with compressor wheel cooling. With compressor wheel cooling, after the compressor air has cooled down by passing through the charge-air cooler on the engine side, it is supplied to the turbocharger for cooling the compressor wheel. Cooling of the compressor wheel is compulsory to ensure the reliability and replacement intervals for the relevant operating conditions. In the turbocharger version with compressor wheel cooling, the cooling air is supplied through a lateral connection in the bearing casing (1). In addition, the turbocharger version with compressor wheel cooling is shown by the turbocharger type (M61, M65 or M66) on the rating plate.
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3.3
Storage of new turbochargers
New turbochargers from ABB Turbo Systems can be stored for 6 months from the date of delivery without additional mothballing measures. Only dry rooms with 40-70% atmospheric humidity, in which no water condensation can form, are suitable as storage locations. The following mothballing measures are required after 6 months: Remove any insulation. Spray surfaces and all accessible spaces of the turbocharger with anticorrosive oil.
To prevent corrosion damage: Repeat mothballing measures every 6 months.
3.4
Intended use
Use on internal combustion engines ABB turbochargers are intended for turbocharging internal combustion engines. For use on gas engines, the enginebuilder must assure its end customers that, in compliance with the Machinery Directive 2006/42/EC, the turbocharger will be operated in an engine room that has the classification "not at risk of explosion". This is also in accordance with the position paper [2] relating to ATEX issued by EUROMOT [1]. For use on pre-mix gas engines with ignitable propellents in the gas control system, the enginebuilder must implement appropriate safety measures for explosion protection [3] (such as flame barriers in the inlet system, for example) to assure that the turbocharger will only be exposed to a transient pressure increase up to a maximum of 12 bar as the consequence of any deflagration. The turbocharger supplies the engine with the air volume and associated 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.
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[1] Euromot = The European Association of Internal Combustion Engine Manufacturers [2] Directive 94/9/EC concerning equipment and protective systems intended for use in potentially explosive atmospheres (ATEX) The Euromot Position as of November 2003, ATEX Euromot Position 191103 [3] Guidelines for proper safety design of inlet systems on gas engines, RWTÜV Essen, 1991
Approved operation WARNING
Any operation of the turbocharger outside of its operating limits can be hazardous to personnel. 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 modifications to the turbocharger.
3.5
Prerequisites for operation
Responsibility of the operating company In awareness of its responsibility, the operating company must ensure that only authorised personnel work on the turbocharger, who: Are versed in the general and locally applicable regulations for occupational safety and accident prevention Have read and understood the operation manual Have been instructed in the use of the turbocharger The safety-conscious work of the personnel and adherence to the operation manual must be checked periodically.
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Suitable working materials and personal protective equipment must be kept in a perfect condition. Only authorised personnel may remain in the vicinity of the turbocharger when the engine is running. Competence of personnel The turbocharger must only be operated and serviced by trained and authorised personnel. Modifications to the turbocharger Modifications to the turbocharger must be approved by ABB Turbo Systems. The turbocharger must be taken out of operation immediately by stopping the engine if the-
re is a malfunction or any abnormal operating behaviour.
The responsible body must be notified of the malfunction.
Original parts and safety Original parts and accessories are specially designed by ABB Turbo Systems for the ABB turbochargers.
Use original parts WARNING
Operation of the turbocharger with non-original parts can result in hazards to personnel and impair the safety of the turbocharger. Only use original parts from ABB Turbo Systems.
ABB Turbo Systems accepts no liability for any damage resulting from the use of non-original parts and associated accessories.
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3.6
Turbocharger rating plate
9
10
1
1
2
2
6 7
5
11
8
3
4
Figure 8 Operating limits 1 Turbocharger operating limits at engine overload (110 %). In test rig operation only, unless otherwise agreed with the enginebuilder. 2 Turbocharger operating limits during operation
Recommended checking / replacement intervals of turbocharger components 3 Checking 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 7 8 9 10 11
Customer part number Designation for special design Weight of turbocharger in kg Turbocharger type Serial number Year of construction of turbocharger
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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 unpredictable component failures. Locations of the rating plates
1
Figure 9 One rating plate (1) each is attached on the left and the right side of the turbocharger bearing casing.
3.7
CE conformity
Information ABB turbochargers comply with the Machinery Directive 2006/42/EC and are incomplete machines as defined by Article 2 g.
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4
Removal and installation
4.1
Transport
Suspension of complete turbocharger unit 1a
1b
2
Figure 10 1a 1b 2
Turbocharger with oil-cooled bearing casing Turbocharger with water-cooled bearing casing Complete turbocharger unit with gas outlet casing
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4.2
Turbocharger weights
Lifting gear with a sufficient load limit must be used for removing and installing the turbocharger. The following weight specification is the heaviest variant possible. This standard value may deviate from the data on the rating plate depending on the specification. Complete turbocharger Weights [kg] A130 190
A135 270
A140 460
A145 750
A150 --
A155 --
Table 2
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4.3
Removing the turbocharger
Disconnect all pipes according to the instructions of the enginebuilder.
Version with compressor wheel cooling: Loosen and remove the compressor wheel cooling connection. Close the compressor
wheel cooling opening with a screw plug.
If present: Unplug the plug to the speed sensor (86505) and secure the rolled-up cable (2 m) on the
turbocharger. This protects the plug from being crushed. e
f
42190 c a
b 86505
d
5 2 4
3
Figure 11 a c e
Oil-cooled bearing casing Position of expansion sleeves A130 to A145 Clamping nut
b d f
Water-cooled bearing casing Bracket A150 to A155 Standard nut
Treat the stud (2) and nut (1) with penetrating oil on the thread and let it work in.
Safeguard against wrong fitting (only for water-cooled bearing casings) NOTICE
Depending on the bracket version (4), two positioning pins (5) can be used for positioning and safeguard against wrong fitting of the turbocharger. This ensures that the turbocharger can always be removed and installed vertically from/onto the bracket.
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Gas-outlet casing (51100) The gas-outlet casing (51100) can remain fitted in the exhaust gas pipe if the locking nuts remain accessible. Otherwise the complete turbocharger unit including gas-outlet casing must be removed.
NOTICE
Treat the thread of the screw fitting between the turbine casing and gas-outlet casing with
penetrating oil and let it work in. Loosen nuts.
Remove turbocharger (see following section).
4.3.1
Fastening of the turbocharger
Depending on the type and version, the turbocharger can be fastened in different ways. The appropriate procedure must be chosen to undo the connection. Oil-cooled bearing casing (a) Attach lifting gear to the suspension eye. Loosen and remove nuts.
Water-cooled bearing casing (b) Loosen and remove water connections. Close the openings of the water connections with
screw plugs.
Attach lifting gear to the suspension eye. Loosen and remove nuts.
Freezing of the cooling water in the bearing casing CAUTION
Serious damage to property can be the consequence if the cooling water freezes in the pipes and in the bearing casing. For transport and storage of the turbocharger, drain the cooling water in the bearing casing via one of the two bottom openings of the water connections.
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Loosening the clamping nut
1/4
Figure 12
Incorrect procedure can make loosening impossible CAUTION
Never relieve individual pressure screws completely. If this procedure is not complied with, the pressure screws can get compressed, thus making it impossible to loosen them. Relieve pressure screws only step by step. Loosen the pressure screws in a circular order.
Break loose all pressure screws of the clamping nut in a circular order. In circular order, loosen each of the pressure screws by about ¼ revolution. Repeat the previous step until the pressure screws are relieved of pressure. Loosen clamping nut by hand.
Hydraulic loosening (round special nut) If the turbocharger was fitted by the enginebuilder with a hydraulic tool, removal is also only possible with a hydraulic tool (see instructions of the enginebuilder). Remove the turbocharger. Cover the oil connections (3) on the engine side to protect against dirt.
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4.4
Installing the turbocharger
4.4.1
Placing the turbocharger on bracket A130...A145
A150...A155 2 3
5
5
2
1
3
1 4
Figure 13 1 Bracket 2 Oil supply 3 Oil drain
4 Slot for gasket 5 O-rings
Inserting the gaskets CAUTION
Damaged or improperly inserted gaskets lead to oil leaks. Always use new gaskets and insert them carefully into the slot.
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Inserting studs
A130...A145
A150...A155 1
1
2
Ød
L
Ød
L
2
Figure 14
1 Nut 2 Stud Lightly oil the thread of the stud (2). Screw the studs into the bracket with the aid of locknuts (1). Remove nuts (1) again. Product
A130 A135 A140 A145 A150 A155
Stud diameter [mm]
Material DIN / ISO 898 (Part 1)
Thread length [mm]
Ø 16 / M16 Ø 20 / M20 Ø 24 / M24 Ø 30 / M30 ---
10.9 / 12.9 10.9 / 12.9 10.9 / 12.9 10.9 / 12.9 ---
≥ 30 ≥ 30 ≥ 70 ≥ 80 ---
Length (L) of the stud Oil-cooled [mm] 250 270 350÷360 415÷425 ---
Water-cooled [mm] 250 325 410÷420 -- -- - -- -
Table 3
Fixing material scope of delivery The studs and nuts for fastening the turbocharger on the bracket are not included in the ABB Turbo Systems scope of delivery. These parts depend on the version of the engine-side bracket.
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Place and align the turbocharger e
f
42190 c a
b 86505
d
5 2 3
4
Figure 15 a c e
Oil-cooled bearing casing Position of expansion sleeves Clamping nut
b d f
Water-cooled bearing casing Bracket A150 to A155 Standard nut
Place and align the turbocharger. Remove the covers of the oil and water connections. Visually inspect the gaskets (3) of the oil supply pipe and oil drain pipe. Clean the contact surfaces of the expansion sleeves (42190) in the bearing casing. Clean the expansion sleeves. Attach the lifting gear to the suspension lug / eye. Place the turbocharger on the bracket (4). If present, observe the positioning pins (5) or
centring sleeve (6) in the bracket.
Align the turbocharger and insert the expansion sleeves in the correct position (pay atten-
tion to notch) (illustration above, c)
Safeguard against wrong fitting (only for water-cooled bearing casings) NOTICE
Depending on the bracket version (4), two positioning pins (5) can be used for positioning and safeguard against wrong fitting of the turbocharger. This ensures that the turbocharger can always be removed and installed vertically from/onto the bracket.
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Gas-outlet casing (51100) The gas-outlet casing (51100) may still be fitted in the exhaust gas pipe if the locking nuts remain accessible for removing the turbocharger.
NOTICE
4.4.2
Steps for fastening the turbocharger
Securing the bearing casing Fit the nuts and tighten according to one of the following variants.
The procedure for securing using a clamping nut is described separately at the end. O = Oil-cooled bearing casing
W = Water-cooled bearing casing Hydraulic tightening (standard)
Product A130 A135 A140 A145
O x x x x
B x x x --
Fixing screws [mm] M16 M20 M24 M30
Hydraulic pre-tensioning forces [kN] 110 175 250 400
Table 4 Torque-controlled tightening Product A130 A135 A140 A145 A150 A155
O x x x x ---
B x x x ----
Fixing screws [mm] M16 M20 M24 M30 ---
Tightening torques [Nm] 280 560 960 1900 ---
Table 5 Angle-controlled tightening Product
O
B
Fixing screws [mm]
A140 A140 A145
x -x
-x --
M24 M24 M30
Initial tightening torques [Nm] 450 540 575
Tightening angle [°] 90 90 120
Table 6 Remove lifting gear. Connect cable to speed sensor (86515). Connect all gas, air and oil pipes.
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Version with water-cooled bearing casing: Remove the screw plugs on the water connections and fit the water pipes according to the
enginebuilder's specifications.
Version with compressor wheel cooling: 6
Figure 16 Remove the screw plug on the connection for the compressor wheel cooling (6) and fit the cooling air line. Connect cable to speed sensor (86515). Connect all gas, air and oil pipes.
4.4.2.1
Tightening the clamping nut 4 3
2 1
~ 1 mm
Figure 17 Clean the thread of the bolt (1) and the contact surface. Coat the bolt thread with grease. Position the thrust washer (2) in place.
Pressure screws (4) must not protrude from the clamping nut (3) in the direction of the thrust washer (2) NOTICE
In order to correctly fit the clamping nuts, the pressure screws must not protrude in the direction of the thrust washer.
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Tighten the clamping nut by hand and then unscrew it again by ¼ of a revolution.
The distance between the thrust washer and the clamping nut is now about 1 mm. 20°
100% Nm
100% Nm 50% Nm 50% Nm 100% Nm
Figure 18
Hand-tighten the pressure screws diagonally. Tighten two opposite pressure screws with 50 % of the tightening torque specified in the
table.
Tighten two other opposite pressure screws with 100 % of the tightening torque specified in
the table.
Tighten all pressure screws in a circular order to 100 % of the tightening torque specified in
the table.
Repeat until all pressure screws are evenly tightened (less than 20° of remaining distance). Torque-controlled tightening Product A140 A145
Fixing screw [mm] M24 M30
Tightening torques [Nm] 36 43
Table 7
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Operation Manual / A130-M...A155-M 5
Commissioning
5
Commissioning
5.1
Oil supply
5.1.1
Introduction
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In all operating states, a functioning and carefully executed oil supply is an important prerequisite for trouble-free operation of the turbocharger. The lubrication of the turbocharger is usually carried out with oil from the engine oil circulation. The directives of the enginebuilder on the selection of the lubricating oil and the oil change
intervals must be followed.
5.1.2
Pre-lubrication and post-lubrication
Pre-lubrication Pre-lubrication must be carried out as follows: Switch on the oil pump. Build up oil pressure (See Table 8). Do not exceed a pre-lubrication time of 2 minutes. Start the engine. Let the oil pump run until the pump driven by the engine generates sufficient pressure.
Post-lubrication Run the engine for 5 to 10 minutes at idling speed before stopping it. Observe the oil pressure specified for engine idling (See Table 8).
Post-lubrication is not required and not recommended for water-cooled bearing casings. For oil-cooled bearing casings, post-lubrication is mandatory for 20 minutes if the turbine inlet temperature (tTE) exceeds the following values when the engine is stopped: – 550 °C with insulated casing – 600 °C with non-insulated casing At temperatures below the specified values, post-lubrication for 10 minutes is recommended. Observe the oil pressure specified for post-lubrication (See Table 8).
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Oil filtering
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Lubricating oil filtering with a filter mesh width of ≤ 0.034 mm is sufficient for this turbocharger.
5.1.4
Oil pressure
Comply precisely with the oil pressure before the turbocharger for trouble-free operation. The admissible values are listed in the chapter "Monitoring during operation".
5.1.5
Oil orifice for oil-cooled bearing casing
With an oil inlet pressure of more than 3 bar (when engine under load) before the turbocharger, the oil-cooled bearing casings are equipped as standard with an orifice at the oil inlet. When disassembling the turbocharger, a fitted oil orifice must not be removed.
5.2
Inspection procedures
5.2.1
Introduction
The inspection procedures include preventative visual controls, monitoring and measuring work which assure the operability of the turbocharger. They help in detecting deviations before and during commissioning and as a result to avoid machine damage.
5.2.2
Checks before commissioning
Air filter mat (if present) Check for damage and contamination.
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Lubricating system Check that the oil filter is clean before commissioning.
Contaminated oil CAUTION
Serious damage to engine or property can be caused by dirt and solid material particles in the oil. For the initial commissioning and after all service procedures, the com-
plete lubricating system must be flushed thoroughly with warm oil. Use running-in filters when running in the engine and after all service procedures on the lubricating system. Check the oil pressure in the oil supply pipes.
Air/water cooling Version with compressor wheel cooling: Check whether the compressor wheel cooling is fitted on the bearing casing.
Failure of compressor wheel cooling CAUTION
Any prolonged failure of the compressor wheel cooling will negatively affect the lifetime of the compressor wheel. Ensure the supply of cooling air.
Version with water-cooled bearing casing Check whether the water pipes are fitted on the bearing casing.
Failure of bearing casing cooling CAUTION
Any prolonged failure of the water cooling will negatively affect the lifetime of the turbocharger. Ensure the supply of the water pipes.
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5.2.3
Checks after commissioning (engine in idle mode)
Lubricating system Check the oil pressure in the oil supply pipes. Check oil inlet temperature.
The admissible values are listed in the chapter "Monitoring during operation". Gas, air, water and oil pipes After starting the engine, check all gas, air, water and oil pipes for leaks.
5.2.4
Checks when starting up the engine
Measure speed, oil pressure and charging pressure at various engine performances. Measure the exhaust gas temperature before and after the turbine. Measure the air temperature before and after the compressor.
The measured values must be compared with the values of the acceptance protocol; different operating conditions must be taken into account here.
Escape of oily fluids NOTICE
Lubricants and pastes used for the assembly of the turbocharger can liquefy or vaporise and escape as oily fluids during the initial hours of operation. Continual escape of an oily fluid indicates a possible leak. If there is a leak, contact an ABB Turbocharger service station.
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5.3
Commissioning after taking out of operation
If present Remove cover plates (blind flanges) on the compressor casing, on the gas-inlet as well as
on the gas-outlet.
Remove the screw plugs on the water connections and fit the water pipe.
Version with compressor wheel cooling: Remove the screw plug on the cooling air connection and fit the cooling air line.
General Check the exhaust gas pipe before and after the turbine for combustion residues or water
residues and clean it. Remove any foreign objects that may be present.
Check and clean filter silencer or air supply line, and remove any foreign objects that may
be present.
Put engine-side oil circulation to the turbocharger into operation. Prepare the turbocharger for operation according to section "Checks before commission-
ing".
Start the engine and put the turbocharger into operation.
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Monitoring during operation
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6
Monitoring during operation
6.1
Oil pressure, oil temperature
Lubricating oil pressure, oil inlet Status for operation
Normal operation Engine start: Cold oil, admissible for max. 15 minutes Engine idling Pre-lubrication and post-lubrication (engine stopped) Warning signal: (nTurbocharger ≥ 0.5 x nBmax) Alarm signal: Stop the engine after 1 minute at the latest.
Oil pressure before turbocharger [bar] 2.0…4.5 < 8.0 0.5…2.5 0.5…1.0 < 1.25 < 0.6
Table 8 Assuring lubricating oil pressure Serious damage to engine or property can result from missing or insufficient lubricating oil supply. The lubricating oil pressure for the turbocharger must be monitored during operation and the necessary pressure assured at the oil inlet.
CAUTION
1 2 3
T
1 2 3 M T
Turbocharger contact surface Oil inlet Oil outlet Oil pressure measuring point Oil temperature measuring point
M
Monitoring of the lubricating oil pressure NOTICE
For monitoring the lubricating oil pressure, ABB Turbo Systems recommends installing an "M" manometer immediately before the turbocharger. If the pressure is controlled electronically, the corresponding signals are to be triggered at the warning and alarm values.
Lubricating oil temperature, oil inlet The temperature before the turbocharger and the temperature increase can also be measured. The maximum permitted oil temperature at the oil inlet is 105 °C, the maximum permitted oil heating is 50 K.
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6.2
Turbocharger speed
6.2.1
Introduction
A speed measuring system enables the constant monitoring of the turbocharger speed.
6.2.2
Layout and overview 86528 32109
*)
86526 42189 42188 1 86515 86505
Figure 19 86505 86515 86526 86528 32109
6.2.3
Speed sensor Cable connector F/I converter Tachometer Sealing disc with cam
42188 42189 1 *)
Screw plug Gasket Plug with integrated voltage limiter Installation variant for speed sensor
Speed differences with several turbochargers per engine
The speeds of all turbochargers on an engine vary only slightly from each other in standard operation. The admissible difference of the maximum and minimum turbocharger speed must not be more than 5 %, relative to the highest speed. 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 turbo-
charger speed does not exceed the value 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 the turbocharger surges continuously, the engine performance must be reduced further.
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Monitoring during operation
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Measure the temperatures in the air lines and gas lines from and to the turbochargers and
compare with normal values.
If the engine can be stopped temporarily: Inspect air lines, gas lines and the turbochargers and remedy any malfunctions. In any case, contacting the nearest ABB Turbocharger service station is recommended.
6.2.4
Replacing the speed sensor
Hot cable connector and hot speed sensor WARNING
Danger of burns. The cable connector and the speed sensor can reach temperatures of more than 100 °C during operation. When disassembling the cable connector and speed sensor, wear leather gloves.
Reduce the engine performance to idling and then stop the engine. Observe post-
lubrication time (see section "Stopping the engine").
Switch off the lubricating oil supply to the turbocharger. Disconnect the cable connector from the speed sensor. Screw out defective speed sensor.
Screw in new speed sensor to the stop. Observe tightening torque [(See Table 33)chapter Disassembly and assembly].
Sealing of the speed sensor NOTICE
The speed sensor is designed with a sealing lip and an additional O-ring and does not need an additional gasket for assembly.
Connect the cable connector with the speed sensor. Switch on lubricating oil supply to the turbocharger.
6.2.5
Malfunction of the speed measuring system
The possible reasons for failure of the speed measuring system are described in chapter Troubleshooting(See Table 27).
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7
Operation and service
7.1
Noise emission Danger due to noise
WARNING
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. When the engine is running, always wear hearing protection. Always wear hearing protection if the noise level exceeds 85 dB(A).
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 on the turbocharger must be fulfilled 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 20). He is also responsible for insulating the charge air/scavenging air ducts and the charge air cooler.
1) 2)
Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7: A-weighted emission sound pressure level The enginebuilder must provide acoustically equivalent measures in case of deviating insulation versions
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Suggestion for noise insulation, bellow C D
E
B F D
E
D
A
Figure 20 A B C
Compressor casing Bellows Charge-air duct / scavenging air duct
7.2
D E F
Insulating cushions Insulating mat Sheet metal cover
Service procedures
Service procedures during operation include visual controls, monitoring, measuring and inspection, as well as function checks. This enables changes to the turbocharger to be detected and remedied. This assures full operability of the turbocharger.
Service intervals CAUTION
Service procedures on the turbocharger that are omitted or performed too late can cause excessive fouling and operating failures. Carry out the service procedures at the specified time intervals.
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7.2.1
Service work on turbocharger every 25 to 50 hours
Visual control for air, exhaust gas, water and oil leaks Recording of operating data as well as entries in the engine logbook In case of deviations, determine the cause.
Unknown operational changes CAUTION
7.2.2
Damage including failure can be the consequence. Unknown causes must be clarified by an ABB Turbocharger service station.
Service work on turbocharger at 100 hours after commissioning
Clean or replace oil filter when engine is stopped.
7.2.3
Service procedures according to instructions of enginebuilder
Clean or replace oil filter when engine is stopped.
7.2.4
Service work acc. to specifications on the rating plate
(Usually after 8,000 – 12,000 operating hours) The rotor and bearing parts must be checked and assessed by an ABB Turbocharger service station. Remove the turbocharger from the engine and dismantle according to chapter Disassembly
and assembly. Measure clearances.
Clean nozzle ring, turbine casing and compressor casing and check for cracks and ero-
sion/corrosion.
7.2.5
Entries in the engine logbook
The monitoring of the engine system enables conclusions to be drawn on the behaviour of the turbocharger. The following operating data and measured values must be entered regularly in the engine logbook of the enginebuilder: Rating and speed of the engine © 2010 ABB Turbo Systems Ltd
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Air intake temperature Pressure of the charge air Pressure loss in the charge-air cooler Lubricating oil pressure and lubricating oil temperature If present: Speed of the turbocharger Air temperature after the compressor and after the charge-air cooler Exhaust gas temperature before and after the turbine Pressure loss in the filter silencer.
7.3
Expected replacement intervals
Rotating components The recommended replacement intervals for the compressor and turbine wheels are specified based on the safety concept for rotating parts and dependent on the operating conditions. These intervals are shown on the rating plate of the turbocharger. Non-rotating components Depending on the system-specific operating conditions, a differentiation must be made between the intervals to be expected for: replacing the bearing parts and replacing the non-rotating components exposed to hot gas.
A decisive role is played by diverse influencing parameters which, in extreme cases, can drastically reduce the replacement interval of these parts. During the prescribed periodic service procedures, the individual parts are examined for wear and replaced if necessary.
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Operation and service
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Expected replacement intervals [h] Turbine casing Nozzle ring Gas outlet flange Heat shield Rotor components Bearing parts Other casings
Table 9 GAS MDO HFO
GAS / MDO HFO 25'000…50’000 25'000…50’000 25'000…50’000 25'000 25'000…50’000 25’000 25'000…50’000 25’000 See rating plate data 12'000…24’000 12'000…24’000 50’000 50’000
= Gas = Marine Diesel Oil = Heavy Fuel Oil
The specified values are guideline values and not guaranteed values (see following section "Influencing parameters"). Influencing parameters The specified values are guideline values and are not guaranteed. The actual values can deviate considerably from the guideline values, for example, due to the following influences: Fuel quality Load profile (thermal cycling, also number of starts/stops, emergency shutdowns) Gas inlet temperature Frequency and execution of turbine and compressor cleaning Turbocharger specification.
For bearing parts Lubricating oil quality (oil filtering, oil condition, oil monitoring) Load profile (speed, pressure conditions, temperature) Imbalance of the rotor (degree of contamination)
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7.4
Stopping the engine Stopping the engine
CAUTION
In the turbocharger, the heat from the lubricating oil that continues to circulate must be dissipated. Let the engine continue to run at idling speed for 5 to 10 minutes before stopping it.
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Periodic maintenance
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8
Periodic maintenance
8.1
Foreword to maintenance
Maintenance work includes regular visual controls and cleaning operations which should ensure the trouble-free functioning of the turbocharger. The exterior condition and the degree of contamination of the maintenance points are determined here. The maintenance points described include: Filter silencer Compressor Turbine and nozzle ring.
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Periodic maintenance
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8.2
Cleaning the filter silencer
81271 81270 81136 81137
81265
81266
81010 81135
Figure 21 81010 81135 81136 81137
O-ring Filter silencer body Absorption segment Cover sheet-metal
81265 81266 81270 81271
Filter ring Cover grid Tension band Lock
Disassembly and assembly NOTICE
The disassembly and assembly of the filter silencer is described in chapter Disassembly and assembly.
Remove filter ring (81265), if present. Clean filter ring (81265) as required or every 500 hours of operation and replace after the
fifth cleaning process at the latest. Contamination of the filter ring depends on the degree of purity of the sucked-in air.
Cleaning the filter ring Rinse the filter ring (81265) with water and mild detergent or, in the case of heavy contami-
nation, soak and carefully push through. Rinse in cold water. Avoid high mechanical loads (water jet).
Let the filter ring dry completely before assembling.
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Periodic maintenance
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Clean the absorption segments (See Figure 21) Remove the tension bands (81270). Remove the cover grid (81266). Pull out and bend up the cover sheet-metal (81137), and remove the absorption segments
(81136).
Clean the absorption segments (81136).
When cleaning, note that the absorption segments (81136) must only be cleaned lightly with pressurized air, with a soft brush or a moist cleaning cloth.
Have any heavily contaminated absorption segments replaced by an ABB Turbocharger
service station.
Fitting the filter silencer (See Figure 21) Insert the absorption segments (81136) into the cover sheet-metals (81137). Bend the cover sheet-metals (81137) into the original shape and insert into the slotted gui-
des in the filter silencer body (81135).
Fit the cover grid (81266). Fit the tension bands (81270) and tighten them at the locks (81271). Any tension bands that have become damaged must be replaced. Fit the filter ring (81265), if present.
8.3
Cleaning the compressor during operation
Introduction The instructions for wet cleaning only apply to cleaning with pure water and under the precondition that the enginebuilder approves the process. The contamination of the compressor stage (compressor wheel and diffuser) depends on the degree of purity of the sucked-in air. Deposits of dirt can form in the flow channels if the following substances are sucked in with the air: Oil mist or salt spray Solid combustion residues Dust
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The contamination of the compressor stage can have a negative influence on the compressor efficiency and on the charging pressure. On the engine side, this causes higher exhaust gas temperatures and increased fuel consumption. The contamination of the compressor can also increase the unbalance of the rotor. Periodic cleaning of the compressor during operation never replaces the service procedures where the turbocharger is completely dismantled and the compressor is mechanically cleaned. Cleaning interval The time period between the periodical cleaning cycles depends greatly on the operating conditions. Cleaning should normally be every 24 to 72 hours of operation. If the specified cleaning intervals are incompatible with operation of the engine, please contact ABB Turbo Systems. Cleaning method The compressor is cleaned during operation using the wet cleaning method. This cleaning method is 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 advanced.
Corrosion and deposits when cleaning CAUTION
Salt water and cooling water treatment substances damage and adversely affect turbocharger parts. Only use pure water for cleaning.
Volume of water CAUTION
Uncontrolled volumes of water can damage the turbocharger and the engine. Never connect injection tube to a water pipe or a larger metering container other than that specified by ABB Turbo Systems.
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V-engines On V-engines with several turbochargers per engine, parallel cleaning of both turbochargers is recommended. This cleaning process is faster and reduces the risk of surging of the turbocharger. Sequential charging With sequential charging, it is important to make sure that all compressors are cleaned, especially after operating periods in the lower range of performance.
8.3.1
Prerequisites
To carry out the cleaning operation checked and recommended by ABB Turbo Systems, the engine load must be 50 % to 85 %.
8.3.2
Wet cleaning of the compressor with external water pressure vessel
Turbochargers can be equipped with an external water pressure vessel (4) for wet cleaning of the compressor.
6 5
1
2
1 2 3 4 5 6
Compressor casing Pressurized air inlet pipe Valve activator External water pressure vessel Screw plug Water pipe to filter silencer or air suction branch
4 3
Pressurized air from the compressor casing (1) of the turbocharger passes through the pipe (2) into the water pressure vessel (4). As a result, the water is pressed in the pipe (6) and guided to the filter silencer or air suction branch.
8.3.3
Procedure for wet-cleaning the compressor
Operation of the water pressure vessel Remove screw plug (5). Fill container with 0.4 dm3 pure water.
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Screw in screw plug (5) again. Push valve activator (3) against the spring and hold for 10 to 15 seconds until the whole
volume of water is injected.
Repetitions of wet cleaning of the compressor Before repeating the wet cleaning or after the last cleaning, observe a minimum drying time of 5 minutes with the engine running. The success of the cleaning can be recognised based on the charging pressure or the exhaust gas temperature. If the cleaning is still unsuccessful after three processes and the engine values are unsatisfactory, it is recommended to have the turbocharger checked and cleaned by an ABB Turbocharger service station. Cleaning parameters for each compressor Engine load 50…85 %
Filling amount of water pressure vessel [dm3] 0.4
Water injection period [s] 10
Table 10
8.4
Cleaning the turbine during operation
Introduction The combustion of fuels such as marine diesel oil (MDO) and heavy fuel oil (HFO) in diesel engines causes contamination of the turbine components of the turbocharger. Poor quality fuel in conjunction with a high exhaust gas temperature can lead to very hard deposits on the nozzle ring and particularly on the gas outlet flange. Consequences of contamination: Poor efficiency of turbine Elevated exhaust gas temperatures Higher charging and ignition pressures with increasing turbocharger speed Lower engine performance Experience in operation shows that, with periodic cleaning during operation, the interval between overhauls can be extended. The wet cleaning of a turbine described in the following can be used for 4-stroke applications with heavy deposits (such as MDO and HFO applications, for example). In general, turbine cleaning is not required for the other applications. Periodic cleaning of the turbine during operation never replaces the service work where the turbocharger is completely dismantled and mechanically cleaned.
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Very heavily contaminated turbines can no longer be cleaned in this way. In this case, the contaminated components must be cleaned by an ABB Turbocharger service station. Cleaning interval The time period between the periodical cleaning cycles depends greatly on the operating conditions. Cleaning should normally be every 50 to 200 hours of operation. If the specified cleaning intervals are incompatible with operation of the engine, please contact ABB Turbo Systems. Cleaning method The turbine components are cleaned during operation using the wet cleaning method. This cleaning method is tested and approved by ABB Turbo Systems. The precondition for wet cleaning is that the enginebuilder approves the process and these regulations are observed. Principle of wet cleaning To clean the turbine stage during operation, water is injected before the nozzle ring. Based on an injection phase of 10 minutes, this cleaning procedure uses the principle of water solubility of dirt deposits.
8.4.1
Prerequisites
Corrosion and deposits when cleaning CAUTION
Salt water and cooling water treatment substances damage and adversely affect turbocharger parts. Only use pure water for cleaning.
Recommended operating state for wet cleaning of turbine Characteristic/component Engine load (guideline value) *) Turbine inlet temperature TTE before water injection (guideline value) Stabilisation phase after TTE has been reached Water supply Differential pressure: Water to exhaust gas at the inlet
Conditions 20 … 40 % 350° to 380 ℃ 10 minutes guaranteed ≥ 1.5 bar
Table 11
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*) Compared to the exhaust gas temperature after the cylinder, the temperature at the turbine inlet is higher. This must be taken into account when setting the operating point before cleaning. If necessary, the engine performance must be reduced to meet these conditions. The cleaning cycle can be started when the above conditions are fulfilled.
8.4.2
Procedure for wet-cleaning the turbine
Open the stop valve. Adjust required water volume flow VW according to the table with a flowmeter and inject for
10 minutes.
Inadmissible thermal stress and flooding of the turbine CAUTION
Smaller amounts of water can lead to an inadequate cleaning result. Larger amounts of water lead to inadmissible thermal stress on the turbine components and can cause flooding of the turbine. It is imperative that the turbine cleaning parameters be observed.
Close the stop valve. Then wait for 10 minutes for stabilisation.
8.4.3
Cleaning parameters for wet cleaning
Cleaning parameters Product
A130 A135 A140 A145 A150 A155
Temperature before turbine (guideline value) before cleaning [°C] 350…380 350…380 350…380 350…380 ---
Maximum temperature before turbine during cleaning [°C]
Water volume flow VW [dm3/min]
Injection time [min]
450 450 450 450 ---
4.0 5.5 8.5 12.0 ---
10 10 10 10 ---
Table 12
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Maximum temperature at turbine inlet during cleaning CAUTION
During cleaning, the temperature at the turbine inlet will rise and may strain the material significantly. The temperature at the turbine inlet can be up to 100 °C higher than the exhaust gas temperature after the cylinder. This must be taken into account when setting the operating point before cleaning. Make sure the maximum temperature at the turbine inlet is not exceeded during cleaning.
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9
Troubleshooting
9.1
Malfunctions when starting
Delayed start-up Possible causes Turbocharger Turbocharger contaminated Bearing damaged Rotor rubbing Foreign object in the turbocharger
Remedy Clean Contact ABB Turbocharger service station
Table 13 Vibrations Possible causes Engine Vibrations from engine Turbocharger Rotor unbalance Turbine or compressor damaged Bearing damaged
Remedy Contact enginebuilder Contact ABB Turbocharger service station
Table 14 Rubbing of rotating parts Normal behaviour, not a malfunction Turbocharger A minimal and uniform wear at the circumference of the rotor components, caused by slight local rubbing against adjacent components is permitted. This causes the compressor or turbine blades to be somewhat shortened. To prevent significant loss of efficiency, specific tolerances must be fulfilled. If there is any doubt about the extent of the rubbing, contact an ABB Turbocharger service station. Have a dimensional check carried out by an ABB Turbocharger service station.
Table 15
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9.2
Malfunctions during operation
Lubricating oil pressure too low Possible causes Engine Oil filter heavily contaminated Oil pump in lubricating system defective Manometer displays incorrectly Turbocharger Axial clearance of the rotor excessive
Remedy Clean Check/replace Replace manometer Contact ABB Turbocharger service station
Table 16 Drop in speed Possible causes Engine Defect on the connected cylinders in pulse charging Turbocharger Heavy contamination of the turbine Damaged rotor components or bearing Pipes Defects, such as leaks, in the exhaust gas pipes or charge air ducts
Remedy Contact enginebuilder Clean Contact ABB Turbocharger service station Repair
Table 17 Increase in speed Possible causes Turbocharger Heavy fouling of the turbine (on 4-stroke application)
Remedy Contact ABB Turbocharger service station
Table 18
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Exhaust gas temperature too high Engine performance and engine speed unchanged Possible causes Engine Malfunction in the injection system Turbocharger Insufficient air, such as filter silencer blocked by dirt, for example Compressor/turbine contaminated Exhaust gas back pressure too high Charge air cooler
Turbine damaged or eroded Cooler contaminated Cooling water volume too low Inlet temperature of cooling water too high Insufficient ventilation
Remedy Repair or contact manufacturer Clean Clean or repair boiler or exhaust gas silencer Contact ABB Turbocharger service station Clean Fill Check/clean cooling system Improve ventilation
Table 19 Charge air pressure too low Engine performance and engine speed unchanged, suction condition normal Possible causes Engine Air receiver not sealed Gas pipe between engine and turbine not sealed Injection mistimed Valve controller misadjusted Turbocharger Manometer display not correct Supply pipe to manometer not sealed Filter silencer contaminated, therefore pressure drop too high Compressor/turbine contaminated Compressor/turbine damaged Exhaust gas back pressure too high
Remedy Repair Set correctly Replace manometer Repair leak Clean Contact ABB Turbocharger service station Clean or repair boiler or exhaust gas silencer
Table 20
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Charge-air pressure too high Engine performance and engine speed unchanged, suction condition normal Possible causes Engine Malfunction in the injection system Injection mistimed Engine performance higher than expected Turbocharger Manometer display not correct
Remedy Repair or contact manufacturer Set correctly Check engine performance Replace manometer
Table 21 Contamination of the compressor Reduced compressor performance/efficiency, hence engine performance losses Possible causes Turbocharger Heavy contamination of the compressor components due to the feeding in of ventilation gases Increased vibrations, compressor blade damage due to the feeding in of ventilation gases
Remedy Clean compressor Optimize oil separation Correct the feed of ventilation gases according to instructions of enginebuilder
Table 22
Reduced fatigue strength of the compressor wheel, compressor blade failure Possible causes Turbocharger Material of the compressor wheel corroded due to the feeding in of ventilation gases containing corrosive components Material of the compressor wheel corroded due to intake air containing exhaust gases or salt
Remedy Correct the feed of ventilation gases according to instructions of enginebuilder Prevent exhaust gas leakages in the engine space Clean compressor
Table 23
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9.3
Surging of the turbocharger
Surging of the turbocharger Possible causes Engine Protective grating in front of the turbocharger contaminated or damaged Turbocharger Filter silencer or diffuser contaminated Heavy dirt deposits in the turbine or in the nozzle ring Charge air coo- Cooler contaminated ler Charge air duct blocked
Remedy Clean/Replace Clean Clean
Table 24
Continuous or periodic surging CAUTION
Possible damage to components such as compressor wheel, turbine blades, bearing and filter silencer. Have the cause clarified and remedied immediately by an ABB Turbo-
charger service station. Have parts assessed for damage and, if necessary, replaced by an ABB Turbocharger service station.
Sporadic surge blows Surging of the turbocharger can occur during certain operating states such as when reducing the engine performance quickly when manoeuvring. At the same time, the flow direction in the compressor is momentarily reversed. Such sporadic surge blows do not impair the safe operation of the turbocharger. A surge blow is accompanied by a loud bang and escape of hot air from the filter silencer.
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9.4
Malfunctions when stopping
Runout noises Possible causes Turbocharger Turbocharger contaminated Bearing damaged Rotor rubbing Foreign object in the turbocharger
Remedy Clean Contact ABB Turbocharger service station
Table 25 Runout time too short Possible causes Turbocharger Turbocharger contaminated Bearing damaged Rotor rubbing Foreign object in the turbocharger
Remedy Clean Contact ABB Turbocharger service station
Table 26
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9.5
Speed measurement system
Possible causes No signal or poor signal amplitude present
Measured speed too high
Measured speed too low Other causes of malfunction
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Remedy Assembly fault The screw plug for the sensor is fitted with an additional gasket (copper ring). This gasket must be removed when assembling the speed sensor. If this has been inadvertently fitted, the distance of the sensor tip to the sealing disc giving the signal is increased. This reduces the voltage amplitude of the speed signal which can lead to problems with the evaluation electronics. This problem will be remedied by removing the gasket. Sensor defective Contact ABB Turbocharger service station Fouling of the sensor As the sensor tip is magnetic, it can attract material partitip cles. This reduces the distance to the signal-emitting sealing disc which can lead to amplification of the noise component and, hence, to false triggering. Dismantle the sensor, clean the sensor tip and refit the sensor with the specified tightening torque. -Contact ABB Turbocharger service station --
If none of the measures described above remedy the malfunction, it is recommended to have the speed measurement system checked by an ABB Turbocharger service station.
Table 27
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10
Disassembly and assembly
10.1
Introduction
The precondition for the work described in the following is a turbocharger removed from the engine (see chapter Removal and installation).
Further operations CAUTION
Further operations that are not described here must only be carried out by trained staff of an ABB Turbocharger service station. Only perform operations that are described in this chapter.
Marking casing position for assembly NOTICE
ABB Turbo Systems recommends marking casing positions prior to disassembly.
Identification of the assembly devices Not all assembly devices are marked with a part number. Identification is guaranteed by the tool list. This list is enclosed in the toolbox.
Servicing the assembly devices Assembly devices must be checked for damage before and after use. WARNING
Visual inspection for corrosion, cracks, deformation and wear. Damaged assembly devices must no longer be used and must be re-
placed.
Customer spare part kit Before starting operations, make sure the required customer spare part kits are available. See chapter Reserve and spare parts.
Oil orifice When disassembling the turbocharger, a fitted oil orifice must not be removed.
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Tightening torques for components of the turbocharger The specified tightening torques of the screw fittings must be observed (see chapter Disassembly and assembly, section Table of tightening torques). Tightening torques for assembly devices from ABB Turbo Systems Unless described otherwise, the screws and nuts of the assembly devices must be tightened so they rest firmly against the surface. Definition of terms Attachment point Defined loading point on a component or an assembly (blind hole thread, eyelet, lug). Assembly device Devices that are fitted on the turbocharger in order to obtain an attachment point. Assembly devices are specially constructed and designed for the defined use, they are not trading goods. Use assembly devices only for the described applications. Lifting gear Equipment for the lifting and transporting of loads (ropes, chain hoist, crane). Lifting gear is not supplied by ABB Turbo Systems AG.
Swivel lifting eyes to be used Two swivel lifting eyes are required for the safe lifting of loads, which are not supplied by ABB Turbo Systems. Swivel lifting eye
Turbocharger type A130 A135 A140 A145 A150 A155
180°
360°
Thread M M10 M10 M12 M12 ---
Length L 17 mm 17 mm 21 mm 21 mm ---
Minimum load Number limit of 100 kg 2 150 kg 2 250 kg 2 300 kg 2 -----
L M
Table 28
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10.2
Weights of assemblies
The specified weights of the individual parts or assemblies are rounded-up standard values. 7 6 5 4 3 2 12
1 11
10 9
8
Figure 22
Designation 1 2 3 4 5 6 7 8 9 10
Filter silencer Radial air suction branch Axial air suction branch Compressor casing Wall insert Diffuser Cartridge group Nozzle ring Burst ring Turbine casing * 1 inlet Turbine casing * 2 inlets 11 Gas outlet flange 12 Gas outlet casing
A130 [kg] 19 6 4 24 6 3 40 2 2 45 40 7 30
A135 [kg] 30 8 5 40 8 4 60 2 3 65 60 13 35
A140 [kg] 40 13 6 60 15 7 110 4 5 120 120 20 65
A145 [kg]
A150 [kg]
A155 [kg]
65 21 9 95 24 11 180 6 12 190 180 23 120
--------------
--------------
Table 29 * Including burst protection
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10.3
Removing / Installing air-inlets A130...A145
A150...A155
82000
82010 72020
51002
82010 82000 81010 81000
Figure 23 A130 to A145 Loosen V-clamp (72020) and remove filter silencer (81000) with O-ring (81010) or air suc-
tion branch (82000) with O-ring (82010).
A150 to A155 Undo the fastening strip connection (51002) and remove filter silencer (81000) with O-ring
(81010) or air suction branch (82000) with O-ring (82010).
Installing air-inlets A130 to A145 Fit the filter silencer (81000) or air suction branch (82000) with the V-clamp (72020).
A150 to A155 Fit the filter silencer (81000) or air suction branch (82000) with the fastening strip connec-
tion (51002).
Observe tightening torque (See Table 33).
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10.4
Removing / Installing compressor casing
72000 a
77005 90042 77000
79000 79040 79041 72012
72011
Figure 24 Loosen screws (72011) and remove with the fastening strips (72012). Attach swivel lifting eyes (a) to the compressor casing and lifting gear. Remove the compressor casing (72000) together with the wall insert (77000).
Loosening the compressor casing with press-off tool NOTICE
If the compressor casing cannot be loosened, it can be pressed off against the turbine casing with the press-off tool (90042).
Axial force of the press-off tool CAUTION
A high axial force can be generated with the press-off tool. If this tool is handled improperly (pressing off with too much force on one side), this may result in damage to the rotor. Use the tool on both sides alternatingly and make sure not to press off too hard on either side.
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Disassembly of wall insert A145 to A155 a 90258 77000
77005
Figure 25 A145 Attach the lifting beam (90258) to the wall insert (77000). Attach swivel lifting eye (a) to the lifting beam. Remove wall insert (77000) using lifting gear.
A150 to A155 Attach the swivel lifting eye M8 to the wall insert (77000). Remove the wall insert (77000).
Installing the compressor casing To be observed: Install the compressor casing in reverse order accordingly (See Figure 24)
Always replace O-rings (see section Reserve and spare parts). Thoroughly clean the fastening strips (72012) before assembly. Observe tightening torques (See Table 33).
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10.5
Removing the cartridge group a
51007 51003 51002 51006
90042
Figure 26 a Oil-cooled bearing casing Treat the threads of the studs (51006) with penetrating oil and leave it on. Loosen nuts (51007) and remove Verbusripp washers (51003) together with the fastening
strips (51002).
Attach the lifting gear to the frame and loop around the bearing casing as shown.
Looping around the cartridge group CAUTION
The loop can slip off and lead to serious injuries to persons or even to fatal accidents. Make sure that the surface for the loop on the cartridge group and the rope are free from oil.
Remove the cartridge group. After the nozzle ring has been removed, the cartridge group
can be placed on the service support (90012). Axial force of the press-off tool
CAUTION
A high axial force can be generated with the press-off tool. If this tool is handled improperly (pressing off with too much force on one side), this may result in damage to the rotor. Use the tool on both sides alternatingly and make sure not to press off too hard on either side.
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Removing the nozzle ring 90012
56001
90070 56005 51002 51000
Figure 27 Place the fastening strips (51002) under the nozzle ring. Pull out the nozzle ring (56001) with the two extraction devices (90070) and the service
support base (90012).
Remove the labyrinth sealing ring (56005).
a
90012
Figure 28 Place the cartridge group on the service support (90012). Measure axial clearance A and radial flexibility B (See Table 32).
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10.6
Installing the cartridge group
Nozzle ring compression For the nozzle ring (56001) to be fixed during operation, it must be clamped between the heat shield (42400) and the turbine casing (51000). Measure dimensions A, B and S on cleaned surfaces. Calculate compression (PD).
51000 PD = A + B - S
42400
A
42001 56001
B S
Figure 29 42001 Bearing casing 42400 Heat shield PD [mm]
A130 -0.15 ... 0.15
51000 Turbine casing 56001 Nozzle ring A135 -0.16 ... 0.16
A140 -0.16 ... 0.16
A145 -0.16 ... 0.16
A150 --
A155 --
Table 30
If the calculated value (PD) lies outside the specified range, contact an ABB Turbocharger
service station.
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Installing the nozzle ring 56001
56005
A
1
51000
Figure 30 Fit the labyrinth sealing ring (56005) and, for type A130 to A145, secure it with adhesive
tape (1). At the same time, ensure correct winding of the labyrinth sealing ring (see detail A).
Align the cams on the nozzle ring to the recesses of the turbine casing (51000). Insert the nozzle ring (56001) into the turbine casing up to the stop. Do not remove the ad-
hesive tape (1).
Installing the cartridge group a
a
51007 51003 51002 51006
90012
Figure 31 Attach the lifting gear to the suspension lug / eye of the cartridge group. For an oil-cooled
cartridge group, see detail a.
Lift the cartridge group out of the service support (90012). Additionally, loop the lifting gear around the cartridge group as shown.
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Looping around the cartridge group The loop can slip off and lead to serious injuries to persons or even to fatal accidents. Make sure that the surface for the loop on the cartridge group and the rope are free from oil.
CAUTION
Fasten fastening strips (51002) together with nuts (51007) and Verbusripp washers
(51003).
Observe tightening torque (See Table 33).
R2
Radial clearances N and R
N1
10.7
N
R1
N2
R
Figure 32 N and R These are theoretical values for the radial clearance between the compressor wheel and the wall insert or between the turbine wheel and the gas-outlet flange. The minimum and maximum values result from the manufacturing tolerances of the compressor and turbine wheel or the wall insert and the gas-outlet flange. N1, R1, N2, R2 The clearances in the bearings and casing centrings are not distributed evenly because of the rotor weight.
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Feeler gauge N1/N2 or R1/R2, respectively, are always measured at the same time using two feeler gauges. The feeler gauges must be inserted without clearance between wall insert/compressor wheel or gas outlet flange/turbine wheel.
Measurement of N and R
R1 + R2 =R 2
N1 + N2 =N 2
Figure 33 The measured average values must lie within the admissible values of radial clearance N and R. Radial clearances N and R [mm] N R
A130 0.26 ... 0.60 0.45 ... 0.70
A135 0.34 ... 0.70 0.51 ... 0.85
A140 0.45 ... 0.90 0.64 ... 1.00
A145 0.56 ... 0.95 0.76 ... 1.20
A150 ---
A155 ---
Table 31 Clearances outside the tolerance CAUTION
Serious damage to engines or property can be caused by unauthorised clearance values and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Turbocharger service station.
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10.8
Axial clearance A and radial flexibility B B
A
Figure 34 After the removal and the installation of the cartridge group axial clearance A and radial
flexibility B must be measured and recorded.
For correct measurement of axial clearance A the turbine must be lifted slightly.
Axial clearance and radial flexibility [mm] A B
A130 0.08 ... 0.16 0.47 ... 1.00
A135 0.10 ... 0.18 0.58 ... 1.16
A140 0.12 ... 0.21 0.70 ... 1.37
A145 0.15 ... 0.25 0.88 ... 1.56
A150 ---
A155 ---
Table 32 Clearances outside the tolerance CAUTION
Serious damage to engines or property can be caused by unauthorised clearance values and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Turbocharger service station.
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Disassembly and assembly
10.9
Table of tightening torques 02
04
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08
09
15
16
11
Figure 35
The following tightening torques must be observed for the designated screw fittings: Tightening torques [Nm] Item 02
Part number 72020
04
79041
08
51007
09
51008
11
72011
15
86505
16
51101 / 51103 / 51104 / 61201
A130 M12 60 M6 8 M8 25 M8 20 M8 35 M12x1.5 15 M10 38
A135 M12 60 M6 8 M10 45 M10 38 M10 70 M12x1.5 15 M10 38
A140 M12 60 M6 8 M12 75 M12 65 M12 105 M12x1.5 15 M12 65
A145 M12 60 M6 8 M12 75 M12 65 M12 105 M12x1.5 15 M12 65
A150 --
A155 --
--
--
--
--
--
--
--
--
--
--
--
--
Table 33
© 2010 ABB Turbo Systems Ltd
HZTL2413_EN
Version 6.0
October 2010
Operation Manual / A130-M...A155-M 11
Taking out of operation at short notice
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11
Taking out of operation at short notice
11.1
Possible emergency repairs Danger of fire and explosion due to lubricating oil leaks
WARNING
Leaking hot oil can ignite. This can cause severe injuries to personnel or accidents resulting in fatalities. Seal any oil leaks immediately.
Directives for taking out of operation CAUTION
Serious damage to machinery or property can be caused by disregarding the directives for blanking off the turbocharger on the engine. Follow the directives of the enginebuilder.
If the engine has to be brought back into operation again as quickly as possible in the case of turbocharger damage, a cover plate must be attached for the emergency repair. Remove the turbocharger (see chapter Removal and installation).
Gas-outlet casing removed Fit the turbine casing with the gas-outlet casing into the gas pipe again. Attach the cover plate (see following section).
Gas-outlet casing not removed Fit the turbine casing into the gas pipe again and on the gas-outlet casing. Attach the cover plate (see following section).
© 2010 ABB Turbo Systems Ltd
HZTL2413_EN
Version 6.0
October 2010
Operation Manual / A130-M...A155-M 11
Taking out of operation at short notice
11.2
Attaching a cover plate
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51000 51006 A 51002 51003 51007
Figure 36 Make sure that the oil connections in the bracket are equipped with gaskets. Close the opening in the turbine casing (51000) with the cover plate (A). Thoroughly clean the fastening strips (51002) before assembly. Coat the threads of the
studs (51006) with ceramic paste.
Fasten the cover plate (A) with fastening strips (51002), Verbusripp washers (51003) and
nuts (51007) on the turbine casing (51000) and screw it onto the bracket.
© 2010 ABB Turbo Systems Ltd
HZTL2413_EN
Version 6.0
October 2010
Operation Manual / A130-M...A155-M 11
Taking out of operation at short notice
11.3
Cover plate drawing
Page 87 / 95
The cover is not included in the ABB Turbo Systems scope of delivery and must be manufactured by the operating company according to the following drawing. Material: General structural steel, in compliance with DIN EN 10025-2. B4 B5
R1
30
B3
R1
Ø D1
15
°
M
B2
B7 B1
Ø D2 B6
Figure 37 Product A130 A135 A140 A145
B1 ± 0.5 65.7 79.6 98.2 116.8
B2
B3
60 80 102 120
130 155 190 226
B4 ± 0.2 11.7 14.2 17.2 20.5
B5
B6
B7
1.4 1.6 2.0 2.4
150 180 220 260
35.7 39.6 48.2 56.8
ØD1 ± 0.2 227.7 271.7 332.5 395.9
ØD2
R1
M
17 21 25 31
≤ 105 ≤ 125 ≤ 153 ≤ 182
M8 M8 M10 M10
Table 34
Dimensions in [mm]
© 2010 ABB Turbo Systems Ltd
HZTL2413_EN
Version 6.0
October 2010
Operation Manual / A130-M...A155-M 12
Mothballing the turbocharger
Page 89 / 95
12
Mothballing the turbocharger
12.1
Taking the engine out of operation for up to 12 months
State of the engine lubricating oil The turbocharger normally remains attached to the engine. The measures to be taken for mothballing of the turbocharger depend on the state of the lubricating oil: If the acid number (TAN) is less than 2 mg KOH/g, no measures need to be taken. If the engine lubricating oil is replaced with a preservative oil and circulated with the prelubrication pump before the engine is taken out of operation, no measures need to be taken either. Residues of old engine oil are flushed away in this way and the bearing parts are largely protected against corrosion. Preparations for mothballing If the acid number (TAN) is greater than 2 mg KOH/g, the following mothballing preparations are necessary after taking the engine out of operation: Dismantle the turbocharger. The rotor and bearing parts must be dismantled and subsequently refitted by an ABB Tur-
bocharger service station.
Clean all parts. Coat plain surfaces of steel and cast parts with anticorrosive oil. Fit turbocharger completely.
Rotation of the rotor in the stack draught If the rotor turns as a result of the stack draught: Fit a blind flange between the outlet flange of the compressor casing and the charge-air
duct.
© 2010 ABB Turbo Systems Ltd
HZTL2413_EN
Version 6.0
October 2010
Operation Manual / A130-M...A155-M 12
Mothballing the turbocharger
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12.2
Taking the engine out of operation for more than 12 months
If the engine is taken out of operation, the following variants are possible with regard to the turbocharger: Turbocharger remains attached to the engine. The casings of the turbocharger remain attached to the engine, the rotor and bearing parts are dismantled by an ABB Turbocharger service station and stored separately. The turbocharger is completely removed, either as a whole unit or in single parts.
For the measures always necessary for preparing the turbocharger parts for mothballing, see section Taking the engine out of operation for up to 12 months in Preparations for mothballing.
If the turbocharger remains attached to the engine, see section Taking the engine out of operation for up to 12 months in Rotation of the rotor in the stack draught.
If the complete turbocharger is removed, or the turbocharger is fitted again from the single parts: Seal all openings of the turbocharger with paraffin paper and wooden lids.
Only dry rooms with 40-70 % atmospheric humidity, in which no water condensation can form, are suitable for mothballing. State of the mothballed turbocharger Check the turbocharger parts annually for corrosion If there are signs of rust: Thoroughly clean parts and renew corrosion protection.
© 2010 ABB Turbo Systems Ltd
HZTL2413_EN
Version 6.0
October 2010
Operation Manual / A130-M...A155-M 13
Disposal
13
Disposal
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Disposal must be environmentally compatible, competent and in compliance with locally applicable regulations. The turbocharger consists largely of metal (cast iron materials, steel, nickel-steel alloys, aluminium and bearing brass). Further components are: Non-metallic materials (filter components of felt and polyethylene), lubricants (engine oil), electronic parts (speed sensor and associated components) and thermal insulation. Dispose of metals as scrap metal for recycling. Dispose of non-metallic materials as waste. Dispose of residues of lubricants as waste oil. Dispose of electronic components as electronic waste.
Handling of damaged thermal insulation WARNING
Damaged thermal insulation can lead to dust exposure. The glass fibres can cause mechanical irritation of the eyes, skin and respiratory tracts.
Avoid the formation of dust Vacuum up dust with a suitable vacuum cleaner Wear respirator mask for particles (P1 or P2 mask) Wear work gloves made of leather Wear tightly fitting protective goggles.
Dispose of thermal insulation as hazardous waste.
© 2010 ABB Turbo Systems Ltd
HZTL2413_EN
Version 6.0
October 2010
Operation Manual / A130-M...A155-M 14
Reserve and spare parts
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14
Reserve and spare parts
14.1
Ordering spare parts
Please quote the following data when making queries and ordering spare parts: Turbocharger type Serial number (HT……) Designation and part number
Spare parts can be ordered from an ABB Turbocharger service station. If different model variants are not taken into account in this document, contact an ABB Tur-
bocharger service station or an ABB agency.
Required customer spare part set (97070) For the operations described in the operation manual, the customer spare part set (97070) is required. These parts are only available in the complete set. Part number 42012 61002 * 77005 79041 81010/ 82010
Designation O-ring Gasket O-ring Counter-sunk screw O-ring
Quantity 1 1 1 2 1
Table 35 * This gasket can only be installed when a gas outlet casing from ABB Turbo Systems is used.
Spare part storage CAUTION
All spare parts that were ordered together with the turbocharger must be kept intact and ready for use. Carefully clean any rusted parts and grease them.
Dispose of replaced parts and parts that are not reusable in a professional and environmen-
tally compatible manner.
© 2010 ABB Turbo Systems Ltd
HZTL2413_EN
Version 6.0
October 2010
Operation Manual / A130-M...A155-M 14
Reserve and spare parts
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14.2
View of turbocharger with part numbers 42201*
82000 82010
72011
79041 79040 79000 77000 72000
42012 10900
72012
77005
72050 (A150...A155)
61205
72020
81010
61200
(A130...A145)
61001 61002
81000
57002 57003* 51000 51500 57210 51002 56005 56001 51105*
86526* 86505* 86515*
86528*
Figure 38
© 2010 ABB Turbo Systems Ltd
HZTL2413_EN
Version 6.0
October 2010
Operation Manual / A130-M...A155-M 14
Reserve and spare parts
Part number 10900 42008 42012 (in the customer spare part set) 42201* 51000 51002 51105* 61200 61205 57002 61001 61002 (in the customer spare part set) 57003* 56001 51500 57210 72000 72011 72012 72020 72050 77000 77005 (in the customer spare part set) 79000 79041 (in the customer spare part set) 81000 81010 (in the customer spare part set) 82000 82010 (in the customer spare part set) 86505* 86515* 86526* 86528*
Page 95 / 95
Designation Cartridge group Socket screw O-ring Clamping nut Turbine casing Fastening strip Metal C-ring Burst protection Protective grid Gas outlet flange Gas outlet casing Gasket Metal C-ring Nozzle ring Burst protection Burst ring Compressor casing Hexagon-head screw Fastening strip V-clamp (A130 to A145) Fastening strip (A150 to A155) Wall insert O-ring Diffuser Counter-sunk screw Filter silencer O-ring Air suction branch O-ring Speed sensor Cable connector F/I converter Tachometer
Table 36 * Depending on the specification of the turbocharger
© 2010 ABB Turbo Systems Ltd
HZTL2413_EN
Version 6.0
October 2010
Product Manual 26580 (Revision A) Original Instructions
UG-25+ Actuator
Installation and Operation Manual
DEFINITIONS
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. DANGER—Indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING—Indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION—Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE—Indicates a hazard that could result in property damage only (including damage to the control). IMPORTANT—Designates an operating tip or maintenance suggestion.
The engine, turbine, or other type of prime mover should be equipped with an overspeed shutdown device to protect against runaway or damage to the prime mover with possible personal injury, loss of life, or property damage. The overspeed shutdown device must be totally independent of the prime mover control system. An overtemperature or overpressure shutdown device may also be needed for safety, as appropriate.
Read this entire manual and all other publications pertaining to the work to be performed before installing, operating, or servicing this equipment. Practice all plant and safety instructions and precautions. Failure to follow instructions can cause personal injury and/or property damage.
This publication may have been revised or updated since this copy was produced. To verify that you have the latest revision, be sure to check the publications page on the Woodward website: www.woodward.com/searchpublications.aspx The current revision and distribution restriction of all publications are shown in manual 26311. The latest version of most publications is available on the publications page. If your publication is not there, please contact your customer service representative to get the latest copy.
Any unauthorized modifications to or use of this equipment outside its specified mechanical, electrical, or other operating limits may cause personal injury and/or property damage, including damage to the equipment. Any such unauthorized modifications: (i) constitute "misuse" and/or "negligence" within the meaning of the product warranty thereby excluding warranty coverage for any resulting damage, and (ii) invalidate product certifications or listings.
To prevent damage to a control system that uses an alternator or battery-charging device, make sure the charging device is turned off before disconnecting the battery from the system.
To prevent damage to electronic components caused by improper handling, read and observe the precautions in Woodward manual 82715, Guide for Handling and Protection of Electronic Controls, Printed Circuit Boards, and Modules.
Revisions—Text changes are indicated by a black line alongside the text.
Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly undertaken.
© Woodward 2011 All Rights Reserved
Manual 26580
UG-25+ Actuator Installation and Operation
Contents REGULATORY COMPLIANCE ........................................................................III ELECTROSTATIC DISCHARGE AWARENESS ................................................. IV CHAPTER 1. GENERAL INFORMATION ........................................................... 1 How to Use This Manual ........................................................................................1 General Description ................................................................................................1 Operational Features ..............................................................................................1 Inputs / Outputs ......................................................................................................1 Available Drive Shafts ............................................................................................1 Available Terminal Shafts .......................................................................................2 UG Governor Similarities ........................................................................................2 Hydraulic Pump ......................................................................................................2 References .............................................................................................................2 Serviceability ..........................................................................................................3
CHAPTER 2. MECHANICAL INSTALLATION .................................................... 7 Introduction .............................................................................................................7 Initial Operation ......................................................................................................7 Unpacking ...............................................................................................................8 Drive Shaft Rotation .............................................................................................10 Mounting Location ................................................................................................11 Drive Connection ..................................................................................................11 Control Linkage ....................................................................................................12 Oil Supply .............................................................................................................13 Heat Exchanger ....................................................................................................16 Recommended Service ........................................................................................16
CHAPTER 3. ELECTRICAL INSTALLATION .................................................... 17 Introduction ...........................................................................................................17 Unit Grounding .....................................................................................................17 Shielded Wiring ....................................................................................................18 Electrical Connections ..........................................................................................18 Customer I/O Terminal Position Assignment .......................................................27 Detailed Description of UG-25+ Actuator Electrical I/O ........................................28 High Potential Testing ..........................................................................................30 Insulation Resistance Testing ..............................................................................31
CHAPTER 4. DESCRIPTION OF OPERATION ................................................. 32 General .................................................................................................................32 Principal of Operation ...........................................................................................33 Fault Detection and Annunciation ........................................................................35 Shutdown Details..................................................................................................35
CHAPTER 5. TROUBLESHOOTING ............................................................... 37 Introduction ...........................................................................................................37 General System Troubleshooting Guide ..............................................................37 Engine/Generator Troubleshooting ......................................................................39
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Contents CHAPTER 6. SERVICE OPTIONS ..................................................................41 Product Service Options .......................................................................................41 Woodward Factory Servicing Options ..................................................................42 Returning Equipment for Repair ...........................................................................42 Replacement Parts ...............................................................................................43 Engineering Services ............................................................................................43 How to Contact Woodward ...................................................................................44 Technical Assistance ............................................................................................44 APPENDIX A. ACRONYMS / ABBREVIATIONS ...............................................45 APPENDIX B. UG-25+ ACTUATOR SPECIFICATIONS .....................................46 I/O Specifications ..................................................................................................48 REVISION HISTORY ....................................................................................49
Illustrations and Tables Figure 1-1a. UG-25+ Actuator Outline Drawing ......................................................4 Figure 1-1b. UG-25+ Actuator Outline Drawing ......................................................5 Figure 1-2. UG-25+ Drive Shaft Configurations ......................................................6 Figure 2-1. UG-25+ Actuator Overview ...................................................................9 Figure 2-2. Terminal Shaft Travel .........................................................................12 Figure 2-3. Linear Linkage....................................................................................13 Figure 2-4. Non-linear Linkage .............................................................................13 Figure 2-5. Oil Chart .............................................................................................14 Figure 2-6. Viscosity Comparisons .......................................................................15 Figure 3-1. Access Cover Instruction Label .........................................................19 Figure 3-2. UG-25+ Actuator Application Wiring ...................................................22 Figure 3-3a. Connector Wiring .............................................................................23 Figure 3-3b. Connector Wiring .............................................................................24 Figure 3-3c. Connector Wiring..............................................................................25 Figure 3-3d. UG-25+ Actuator Terminals ..............................................................26 Figure 3-4. Internal Block Diagram .......................................................................28 Figure 3-5. Correct and Incorrect Wiring to Power Supply ...................................29 Figure 3-6. Relay Driver Output............................................................................29 Figure 4-1. UG-25+ Actuator Front Panel .............................................................32 Figure 4-2. UG-25+ Actuator Functional Overview ...............................................34
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Regulatory Compliance European Compliance for CE Marking: These listings are limited only to those units bearing the CE Marking. EMC Directive:
Declared to 2004/108/EC COUNCIL DIRECTIVE of 15 Dec 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility and all applicable amendments.
Other European Compliance: Machinery Directive:
Compliant as a component with 98/37/EC COUNCIL DIRECTIVE of 23 July 1998 on the approximation of the laws of the Member States relating to machinery.
Pressure Equipment Directive:
Compliant as “SEP” per Article 3.3 to Pressure Equipment Directive 97/23/EC of 29 May 1997 on the approximation of the laws of the Member States relating to machinery.
Marine Compliance (APPROVALS PENDING): Special Conditions for Safe Use: Wiring must be in accordance with North American Class I, Division 2 wiring methods as applicable, and in accordance with the authority having jurisdiction. Field wiring must be suitable for at least 105 °C. EXPLOSION HAZARD—Do not connect or disconnect while circuit is live unless area is known to be non-hazardous.
RISQUE D’EXPLOSION—Ne pas raccorder ni débrancher tant que l’installation est sous tension, sauf en cas l’ambiance est décidément non dangereuse.
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Electrostatic Discharge Awareness All electronic equipment is static-sensitive, some components more than others. To protect these components from static damage, you must take special precautions to minimize or eliminate electrostatic discharges. Follow these precautions when working with or near the control. 1.
Before doing maintenance on the electronic control, discharge the static electricity on your body to ground by touching and holding a grounded metal object (pipes, cabinets, equipment, etc.).
2.
Avoid the build-up of static electricity on your body by not wearing clothing made of synthetic materials. Wear cotton or cotton-blend materials as much as possible because these do not store static electric charges as much as synthetics.
3.
Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam cups, cup holders, cigarette packages, cellophane wrappers, vinyl books or folders, plastic bottles, and plastic ash trays) away from the control, the modules, and the work area as much as possible.
4.
Do not remove the printed circuit board (PCB) from the control cabinet unless absolutely necessary. If you must remove the PCB from the control cabinet, follow these precautions:
Do not touch any part of the PCB except the edges.
Do not touch the electrical conductors, the connectors, or the components with conductive devices or with your hands.
When replacing a PCB, keep the new PCB in the plastic antistatic protective bag it comes in until you are ready to install it. Immediately after removing the old PCB from the control cabinet, place it in the antistatic protective bag. To prevent damage to electronic components caused by improper handling, read and observe the precautions in Woodward manual 82715, Guide for Handling and Protection of Electronic Controls, Printed Circuit Boards, and Modules.
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Manual 26580
UG-25+ Actuator Installation and Operation
Chapter 1. General Information How to Use This Manual The following summarizes how to install a UG-25+ actuator into a new or existing system: Unpack and inspect the hardware. Mount and wire the hardware following the procedures and recommendations in Chapters 2–3. Specifications and Troubleshooting information are provided in the Appendixes.
General Description The Woodward UG-25+ actuator is a microprocessor controlled mechanical hydraulic actuator used in conjunction with an external governor for controlling diesel, gas, or dual fuel engines, or steam turbines. The UG-25+ actuator provides a fast-acting and high-work-output actuator, without the need for any auxiliary devices such as a start booster or oil cooler. The UG-25+ actuator uses an internal, self-contained oil system operating at 1034 kPa (150 psi) internal pressure with an internal oil pump driven from the actuator's drive shaft. Oil pressure is maintained by a relief valve system with a drain to an internal oil sump.
Operational Features The UG-25+ actuator terminal shaft assumes a position which is directly proportional to the (4 to 20) mA analog input signal.
Inputs / Outputs The following inputs and outputs are available: Input Power (single or dual) Unit Healthy Status discrete output Analog (4 to 20) mA input controlling terminal shaft position
Available Drive Shafts The following drive shafts are available: Standard— 0.625–36 serrated drive shaft 0.625 keyed drive shaft with 0.625-18 thread Available (for special applications at additional cost)— Extended 0.625 keyed drive shaft
Woodward
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UG-25+ Actuator Installation and Operation
Manual 26580
Available Terminal Shafts The following output terminal drive shafts are available: Standard— 0.625–36 serrated terminal shaft (25 ft-lb version only) 0.750-48 serrated terminal shaft (31 ft-lb version only) Available (for special applications at additional cost)— 0.562 / 0.625 D-shaped terminal shaft
UG Governor Similarities The base is designed to fit any engine drive designed for a UG8 governor. The terminal shaft location relative to the mounting base is similar to a UG8 governor.
Hydraulic Pump The UG-25+ actuator is equipped with a Gerotor fixed displacement pump (similar to the 3161 governor type) with a relief valve. The pump/relief valve uses oil from its self-contained sump to provide 1035 kPa (150 psi) internal operating pressure. Two displacements are offered to cover the speed range up to 1700 grpm. The large displacement pump (22.22 mm / 0.875 inch thick) is intended to be used with actuator drive speeds from 350 to 1200 rpm. Running the large displacement pump continuously above 1200 grpm will result in excessive oil temperatures. The small displacement pump (15.88 mm / 0.625 inch thick) is designed to be used with drive speeds between 500 and 1700 rpm maximum continuous operation. The direction of rotation is selected by pump housing alignment. The pump operates in the selected direction only. The drive uses a maximum of 335 W (0.45 hp).
References The following publications provide additional information about installation, operation, and storage of Woodward products. All are available on the Woodward website (www.woodward.com). Publication 25071 Oils for Hydraulic Controls 25075 Commercial Preservation Packaging for Storage of MechanicalHydraulic Controls 50516 Governor Linkage for Butterfly Control Valve 03386 UG-25+ Actuator Product Specification 36684 Booster Servomotor Contact your nearest Woodward Distributor or Authorized Independent Service Facility about repairs.
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Serviceability The UG-25+ actuator has no field-replaceable parts. The UG-25+ actuator is not equipped with an overspeed trip function. The engine, turbine, or other type of prime mover should be equipped with an overspeed shutdown device to protect against runaway or damage to the prime mover with possible personal injury, loss of life, or property damage. The overspeed shutdown device must be totally independent of the prime mover control system. An overtemperature or overpressure shutdown device may also be needed for safety, as appropriate.
Woodward
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UG-25+ Actuator Installation and Operation
Manual 26580
Figure 1-1a. UG-25+ Actuator Outline Drawing
4
Woodward
Manual 26580
UG-25+ Actuator Installation and Operation
Figure 1-1b. UG-25+ Actuator Outline Drawing
Woodward
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UG-25+ Actuator Installation and Operation
Manual 26580
Figure 1-2. UG-25+ Drive Shaft Configurations
6
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Manual 26580
UG-25+ Actuator Installation and Operation
Chapter 2. Mechanical Installation Introduction This chapter describes receiving, storage, and installation requirements for the UG-25+ actuator. Due to typical noise levels in turbine or engine environments, hearing protection should be worn when working on or around the UG-25+ actuator.
The surface of this product can become hot enough or cold enough to be a hazard. Use protective gear for product handling in these circumstances. Temperature ratings are included in the specification section of this manual.
Use of an independent device for positive shutdown, such as a fuel shut-off valve, is highly recommended. Failure to comply with this recommendation can cause personal injury and/or property damage.
Use of an external spring to return to minimum fuel is highly recommended. Failure to comply with this recommendation can cause personal injury and/or property damage.
Use of a predicted minimum fuel shutdown procedure is highly recommended. Failure to comply with this recommendation can cause personal injury and/or property damage. Use care while handling and installing the UG-25+ actuator. Be particularly careful to avoid striking the drive shaft, terminal shaft, or the electrical connector. Abuse can damage seals, internal parts, and factory adjustments. Do not set the actuator on its drive shaft.
Initial Operation Before initial operation of the engine equipped with a UG-25+ actuator, read all of Chapters 2 and 3, Installation Procedures and Electrical Installation. Make sure that all installation steps have been correctly accomplished and all linkages are secured and properly attached. Carefully review the direction of rotation for the actuator oil pump.
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Follow this procedure when putting a new or repaired UG-25 actuator into service. 1.
Check that the actuator is full of the proper type and grade of clean oil (refer to the Oil Supply section in this manual).
2.
Properly adjust the linkage (refer to the Control Linkage section in this manual). To prevent possible serious injury or loss of life, or damage to the engine, be sure to allow sufficient overtravel at each end of the terminal shaft so the actuator can shut down the engine, and also give maximum fuel when required. Misadjusted linkage could prevent the actuator from shutting down the engine.
3.
Adjust the external control system to give a low Position Command signal to the UG-25+ actuator to achieve a low speed setting to give low engine speed at initial start-up. Be prepared to make an emergency shutdown when starting the engine, turbine, or other type of prime mover, to protect against runaway or overspeed with possible personal injury, loss of life, or property damage.
4.
Follow the engine manufacturer's instructions, and start the engine.
5.
Adjust the selected speed setting of the control system to bring the engine to rated speed.
6.
Obtain system stability by adjusting the control system's dynamics. (If less than the recommended actuator output stroke is used, it may cause for less than optimum engine stability or response.)
All operating adjustments of the UG-25+ actuator are made during factory calibration. Additional adjustment should not be needed.
Unpacking Be careful when unpacking the unit. Check the unit for signs of damage, such as bent or dented panels, scratches, and loose or broken parts. Notify the shipper and Woodward if damage is found.
Receiving After factory testing and calibration, the UG-25+ actuator is drained of oil. This leaves a light film of oil on internal parts to prevent rust. External parts are painted or coated with a spray lubricant/rust inhibitor. No internal cleaning or flushing is necessary before installation and operation. The little oil left in the actuator is clean, multi-viscosity engine oil, which will not contaminate the oil selected to operate the actuator.
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Manual 26580
UG-25+ Actuator Installation and Operation
Fill the actuator with 2.1 liters (2.2 quarts) of oil selected to match the expected operating conditions. (If the actuator is a direct replacement for a UG governor, you may use the same grade and weight of oil that was being used in the governor.) Use only new, clean oil in the actuator. Do not allow dirt or contamination to enter the actuator while filling with operating oil. Do not use oil drained from the UG governor.
L-Series Electrical Connection L-Series Controller
Oil Fill Plug/Breather Wiring Access Panel
Oil Level Gauge
Front Panel
Terminal Shaft
Case Oil Drain Plug
Base
Drive Shaft
Figure 2-1. UG-25+ Actuator Overview Woodward
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Storage The UG-25+ actuator may be stored for short periods of time (less than a year) as received from the factory. For long-term storage (more than a year), storage in an environment with large temperature changes, humid or corrosive atmosphere, etc., or if the actuator is installed on the engine for storage, fill the actuator with oil and follow preservation packaging instructions in Woodward manual 25075, Commercial Preservation Packaging for Storage of Mechanical-Hydraulic Controls.
Drive Shaft Rotation The actuator drive-shaft rotation is one direction only. Rotation, as viewed from the top of the actuator, must be the same as that of the engine drive when looking down on the mounting pad. If the actuator oil pump is rotated in the wrong direction, no oil pressure will be generated in the actuator. Be sure engine mounting-pad drive and actuator-drive rotation are the same. Incorrect drive rotation will cause the actuator to become inoperative, and may cause actuator damage.
Use the following procedure to change the direction of rotation: 1. Remove the four pump-housing screws located on the bottom of the UG-25+ actuator. 2. Index the pump plate 180 degrees to align the arrow corresponding to the direction of rotation selected with the reference notch in the base. 3. Replace the four screws, and torque the screws to 10.2 N·m (90 lb-in). 4. Make sure that the actuator drive shaft rotates freely.
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Mounting Location Locate the UG-25+ actuator at a distance from sources of extreme radiant heat, such as exhaust manifolds, turbochargers, or live steam lines. The ambient operating temperature range of the control is (0 to 55) °C / (32 to 131) °F (maximum allowable actuator case temperature is 100 °C / 212 °F max). In spark-ignited applications, make sure the UG-25+ actuator is located away from the ignition coil, and that harness wires are not routed next to the spark plug wires. As shown in the specifications, the UG-25+ actuator has been designed for and validated to a given accelerated life vibration test level at the mounting surface of the actuator. The user should be aware that in any application, bracket design could significantly change the vibration levels at the actuator base. Therefore, every effort should be made to ensure the bracket is as stiff as possible so that engine vibrations are not unduly amplified, creating an even more severe environment at the actuator.
Attitude The UG-25+ actuator can be installed in a vertical or near vertical position without affecting its calibration. Do not install more than 45 degrees from vertical. See the outline drawing for installation instructions and dimensions.
Mounting Dimension When using the O-ring supplied with the actuator to seal between the UG-25+ actuator and actuator mounting pad on the engine, the mounting hole should have dimensions of (82.7 to 83.2) mm / (3.255 to 3.275) inches in order to provide the correct amount of squeeze on the o-ring. The mounting hole must be concentric with the drive in order to avoid side-loading the UG-25+ actuator drive shaft.
Drive Connection Make sure the UG-25+ actuator drive shaft turns freely before installing the actuator. The drive gear or coupling must slip freely into the actuator drive of the engine. In case of a keyed drive shaft, torque the nut that secures the drive gear to (34 to 41) Nm / (25 to 30) lb-ft maximum. Do not apply external force. The drive must be free of binding, side load, or excess end-play. Improper alignment or fit between the parts can result in excessive wear or actuator-drive seizure. + Mount the UG-25 actuator squarely on the mounting pad. Torque the mounting bolts evenly. There can be no movement or rocking of the actuator on the engine-mounting pad.
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Control Linkage The terminal shaft has a travel of 42 degrees. Use 2/3 of the total rotation between no load and full load. The additional “overtravel” should be split and used at both ends to provide maximum fuel when required and to assure shutdown at minimum-fuel actuator position (see Figure 2-2). To prevent possible serious injury or loss of life, or damage to the engine, be sure to allow sufficient overtravel at each end of the terminal shaft so the actuator can shut down the engine, and also give maximum fuel when required. Misadjusted linkage could prevent the actuator from shutting down the engine. Many control problems are related to the linkage between the actuator and the engine. Use only high-quality rod-ends for the linkage which will last under the nearly constant motion associated with precise speed control. The linkage must be stiff, not subject to engine-caused vibration. The linkage must be as light as possible and still maintain the attributes of stiffness. Linkage which is too heavy can damage the actuator as well as make it difficult to achieve steady control. Installed linkages must operate smoothly, be free of binding, and free of lost motion due to worn parts. If there is a collapsible member in the linkage, be sure it does not yield each time the actuator moves the linkage rapidly.
Figure 2-2. Terminal Shaft Travel
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Use a linear linkage for most diesel applications. Most gas-fueled engines will require a non-linear linkage. See Figures 2-3 and 2-4 for information on the arrangements of linear and nonlinear connections. Linear linkage moves the fuel setting shaft in direct proportion to the movement of the actuator terminal shaft.
Figure 2-3. Linear Linkage
Figure 2-4. Non-linear Linkage
A non-linear fuel arrangement lets the actuator move the fuel setting more at maximum settings than it does at minimum settings. Woodward application note 50516, Governor Linkage for Butterfly Throttle Valves, provides more information about non-linear linkage. Design the linkage so the power output of the engine is proportional to the position of the actuator terminal shaft. Follow the engine manufacturer's instructions on linkage selection, installation, and adjustment. In almost all cases, the linkage designed for a UG-8 governor + will work with the UG-25 actuator, with the exception that the standard terminal shaft size (for the 25 ft-lb version) is 0.625-36 serrated versus the UG-8 standard size of 0.50-36 serrated. The terminal shaft size for the 31 ft-lb version is 0.750-48 serrated. In the case of a direct exchange, make sure that the engine fuel linkage is in good condition and the installation of the terminal lever on the actuator is in the same position as it was on the old governor.
Oil Supply See Woodward manual 25071, Oils for Hydraulic Controls, for more details on oil supply. Use the information given in Figures 2-5 and 2-6 as a guide in the selection of a suitable oil. Oil grade selection is based on the operating temperature range of the actuator. Also use this information to aid in recognizing and correcting common problems associated with oil used in the actuator. Many operation and maintenance problems associated with UG-25+ actuators are directly related to the selection and condition of the oil in the actuator. Use care in the selection and make sure that the oil in the actuator is not contaminated. The oil in the UG-25+ actuator is both a lubricating and hydraulic oil. It must have a viscosity index that allows it to perform over the operating temperature range and it must have the proper blending of additives that cause it to remain stable and predictable over this temperature range.
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Figure 2-5. Oil Chart The UG-25+ actuator is designed to give stable operation with most oils, if the fluid viscosity at the operating temperature is within a 50 SUS to 3000 SUS (Saybolt Universal Seconds) range (see Figure 2-6). Poor actuator response or instability can be an indication that the oil is too thick or too thin. Actuator oil must be compatible with seal material, that is, nitrile, polyacrylic, and fluorocarbon. Many automotive and gas engine oils, industrial lubricating oils, and other oils of mineral or synthetic origin meet these requirements. Fill the UG-25+ actuator with about 2.1 liters (2.2 quarts) of oil, to a level visible in the oil sight glass. After the engine is started and the actuator is at operating temperature, add oil if necessary. Oil must be visible in the glass under all operating conditions.
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Excessive component wear or seizure in the actuator indicates the possibility of: 1.
Insufficient lubrication caused by: an oil that flows slowly when it is cold, especially during start-up; no oil in the actuator.
2.
Contaminated oil caused by: dirty oil containers; an actuator exposed to heating and cooling cycles, which created condensation of water in the oil.
3.
Oil not suitable for the operating conditions caused by: changes in ambient temperature; an improper oil level which creates foamy, aerated oil.
Operating an actuator continuously beyond the high limit temperature of the oil will result in oil oxidation. This is identified by varnish or sludge deposits on the actuator parts. To reduce oil oxidation, lower the actuator operating temperature with a heat exchanger or other means, or change to an oil more oxidationresistant at the operating temperature. To prevent possible serious injury or loss of life, or damage to the engine, resulting from engine overspeed or a runaway engine, be sure to use only oil that falls within the 50 SUS to 3000 SUS range. Using oils outside this range could cause the actuator to be unable to prevent a runaway engine.
Figure 2-6. Viscosity Comparisons
Oil Maintenance Replace the actuator oil if it is contaminated, and change it if it is suspected of contributing to instability. Drain the oil while it is still hot. Flush the actuator with a clean solvent having some lubricating quality (fuel oil or kerosene) before refilling with new oil. If drain time is insufficient for the solvent to completely drain or evaporate, flush the actuator with the same oil it is being refilled with to avoid dilution and possible contamination of the new oil. Woodward
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Oil that has been carefully selected to match the operating conditions and is compatible with actuator components should give long service between oil changes. Check oil conditions regularly and change oil if any deterioration or contamination is suspected. Regularly scheduled oil changes will extend the life of the actuator and improve actuator operation. Properly selected oil should permit annual oil changes, but more frequent changes are recommended. Too long an interval between oil changes can result in sticking of components and plugged oil passages. Do not remove covers or connect/disconnect electrical connectors unless power has been switched off or the area is known to be nonhazardous.
Ne pas enlever les couvercles, ni raccorder / débrancher les prises électriques, sans vous en assurez auparavant que le système a bien été mis hors tension; ou que vous vous situez bien dans une zone non explosive.
Heat Exchanger A heat exchanger for the UG-25+ actuator is not available from Woodward.
Recommended Service Carefully consider the choice of actuator oil with your oil supplier. Monitor the condition of the oil, especially the build-up of deposits, to ensure that the oil remains within the operating conditions defined by the oil supplier. See manual 25071 for more information on oil and oil maintenance. To change oil, remove the drain plug and drain out the old oil. Flush the UG-25+ actuator by filling it with fuel oil, and with the prime mover running at low speed, cycle the actuator. Let the actuator hunt for a minute or two, then stop the engine and drain the UG-25+ actuator. Flush the actuator once again. Refill the UG-25+ actuator with oil (see Chapter 2, Oil Supply). Restart the engine and reset the control system's stability. Woodward recommends the UG-25+ actuator be overhauled after 20 000 hours of normal operation to inspect for wear and to replace seals, bearings, etc. Units may need to be re-manufactured/overhauled before that time if there is oil leakage, parts become loose, or if the unit experiences severe operating conditions of heat or vibration.
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Chapter 3. Electrical Installation Introduction This chapter provides instructions for making the proper electrical connections to the UG-25+ actuator. Detailed wiring diagrams and recommended wiring practices are given to make the electrical installation as straightforward as possible. The only input that is absolutely required is a power connection and a position command signal; all others are optional features. All wiring and accessories (wire ferrules, cable gland nuts, etc) are provided by the customer, but are shown in this chapter for ease of assembly. The UG-25+ actuator has an operating voltage range of (18 to 32) V (dc). This input is protected against reverse input polarity, and consumes approximately 27 W maximum power at a peak current of 1.5 A (18 V) at 25 °C. Maximum power at the UG-25+ actuator is only realized if an internal fault occurs. Nominal operating current will be less than 500 mA at 24 V (dc) nominal. The control system should be protected with a 6 A fuse in the voltage supply lines. The application should be configured to apply power to the UG-25+ actuator when the engine is first cranked, or slightly before.
Unit Grounding The UG-25+ actuator housing must be electrically bonded to earth ground through the mechanical mounting interface in order to ensure proper EMC and Safety compliance. Do this using a 1" wide braided grounding strap with as short a length as possible. The ground strap can be tied to the ground post on the front of the actuator, directly below the user interface panel. Assure the ground strap is in contact with bare (unpainted) metal.
Tie Ground Strap Here
Due to the hazardous location listings associated with this product, proper wire type and wiring practices are critical to operation. Do not connect any cable grounds to “instrument ground”, “control ground”, or any non-earth ground system. Make all required electrical connections based on the wiring diagrams (Figures 3-2 and 3-3). Woodward
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Shielded Wiring The use of cable with individually shielded-twisted pairs is required where indicated by the control-wiring diagram (Figure 3-2). Cable shields must be terminated as indicated in the control-wiring diagram using the installation notes described below. DO NOT attempt to directly ground the shield at both ends or an undesired ground loop condition may occur. It is best to terminate the shield at the UG-25+ actuator, leaving the other end of the shield unterminated or electrically floating.
Installation Notes
Wires exposed beyond the shield should be as short as possible, not exceeding 50 mm (2 inches). The shield termination wire (or drain wire) should be kept as short as possible, not exceeding 50 mm (2 inches), and where possible the diameter should be maximized. Installations with severe electromagnetic interference (EMI) may require additional shielding precautions. Contact Woodward for more information.
Failure to provide shielding can produce abnormal conditions which are difficult to diagnose. Proper shielding at the time of installation is required to assure satisfactory operation of the product. EXPLOSION HAZARD—Do not connect or disconnect while circuit is live unless area is known to be non-hazardous.
External independent safety devices are always recommended by Woodward. Fuse the Power Input +(Terminal 19) with a 6 A fuse.
This UG-25+ actuator does NOT provide for power-loss annunciation. Woodward recommends that the device that is powered by this UG-25+ actuator have an independent power-loss annunciation.
Electrical Connections Prior to installation, refer to the wiring diagrams and the representative I/O interfaces schematic in this chapter. Also, review the hardware I/O specifications in Appendix B. Use 1.3 mm² (16 AWG) stranded copper wire with insulation that meets temperature requirements in the harness design. A wiring harness stress relief within 400 mm (16 inches) of the UG-25+ actuator is recommended. Contain the harness with wire loom or sheath to make it into a single bundle or a cable with an overall jacket containing the signal wires. Use grommets when passing the harness through metal panels.
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Recommended Signal Wire Specifications 1.3 mm² (16 AWG), Minimum Insulation O.D. 1.96 mm (0.077 inch), –65 °C to +200 °C, 1000 V (rms), 19/29 Stranded Conductor, Teflon Insulation (TFE). All field communications and commands enter the UG-25+ actuator through a threaded port in the top of the UG-25+ actuator User Interface panel assembly. These signal wires should be contained in a cable with an overall jacket or bundled together with an overall sheath. To maintain the IP-56 ingress protection rating, the field cable must be installed through a cable gland nut, which is threaded into the cable entry port in the top of the User Interface panel. Several suggested gland nut sizes are listed in table below, depending on the overall diameter of the field cabling used in the installation. Remove the wiring access cover plate located on the front of the User Interface panel by removing the six M4 x 0.7, 10 mm long locking screws (Woodward part number 1031-1806) to access all customer field connection terminal blocks. Securely replace the wiring cover plate after completing the wiring connections to ensure the integrity of electromagnetic noise interference capabilities of the + UG-25 actuator. The UG-25+ actuator will not meet ingress protection requirements unless the cover is in place. See Figure 3-1 for warning label found on the inside of the cover.
Figure 3-1. Access Cover Instruction Label
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Slide the cable gland over the end of the cable with the cable gland threads toward the cable end. Select the appropriate cable gland from the chart below, depending upon the cable size. Woodward Part Number 1325-4007
Heyco Part Number 4572
9.5 to 12.5
0.750-14 (3/4" NPT)
1325-4008
4573
12.5 to 16
0.750-14 (3/4" NPT)
1325-4009
4574
16 to 20.5
0.750-14 (3/4" NPT)
Cable Diameter in mm
Mounting Hole Size
Remove approximately 100 mm (4 inches) of the overall cable jacket to provide a sufficient service loop inside the User Interface panel to land the individual signal wires on the proper internal terminal. Strip approximately 10 mm (0.4 inch) of insulation from each individual signal wire and crimp on a wire ferrule, Woodward part number 1606-667 (Phoenix part number 3200043) for 16 AWG wire, to the end of each signal wire. Use the proper crimp tool, “CRIMPFOX 6H” Woodward part number 8996-2197 (Phoenix part number 12 12 046) to crimp the ferrules onto the signal wires with a hexagonal crimp. The wire should extend to the end of the ferrule, but not beyond it. If the wire extends beyond the end of the ferrule, cut the excess wire off with wire cutters. The ferrule assures the signal wire does not slip out of the terminal block in high vibration environments. Tinning (soldering) the ends is not an acceptable option since the spring terminals will not grip the wires as well. Remove the threaded plug from the customer wiring port located on the top of the User Interface panel. Insert the ferrules and wires through the threaded port far enough to hook up the wiring. Use the small terminal release tool (Woodward part number ST-15011, WAGO part number 236-332), located inside the wiring + cavity of the UG-25 actuator, to assist in the insertion of the ferrule on the end of each signal wire into its associated terminal location. The terminal release tool is the best way to release the spring-loaded connection clamp located in the wiring terminal block, but a thin, flat-bladed screw driver can also be used if the terminal release tool is not available. To provide better access to the terminal blocks, install wires going into Terminals 8 through 1 first, followed by the wires going into Terminals 16 through 9 next, and then wires going to Terminals 22 through 17 next. After installing the wires, apply thread sealant (Woodward part number 2001-4002, Loctite 572 or equivalent) to the NPT threads and screw the cable gland into the customer wiring port in the top of the UG-25+ actuator User Interface panel assembly. Make sure that the cable’s overall jacket extends slightly past the cable gland so that the rubber seal completely and tightly grips the cable jacket.
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Tighten the NPT thread to 10 Nm (88 lb-in). Then tighten the cable gland top dome nut securely against the rubber gland as shown below. Incorrect Installation
Do not over-tighten the top dome nut. Over-tightening the top dome nut causes the rubber gland to “bulge” out the top of the dome nut, as shown above, and compromises the IP-56 ingress protection seal. Replace the wiring access cover plate and the six M4 screws holding it to the User Interface panel. Torque all six screws to (3.4 ± 0.2) Nm / (30 ± 2) lb-in. When routing cables, allow a sufficient service loop when routing the cable around corners. Two customer cable clamp mounting holes are located on the top, front corners of the User Interface panel and accept M5 x 0.8, 10 mm long screws, Woodward part number 1029-972.
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Figure 3-2. UG-25+ Actuator Application Wiring 22
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Figure 3-3a. Connector Wiring
Due to the hazardous location listings associated with this product, proper wire type and wiring practices are critical to operation. Do not connect any cable grounds to “instrument ground”, “control ground”, or any non-earth ground system. Make all required electrical connections based on the wiring diagrams (Figures 3-2 and 3-3).
The Hi-Pot jumper must be installed for normal operation, and must be removed only during a Hi-Pot test.
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Figure 3-3b. Connector Wiring
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Figure 3-3c. Connector Wiring Woodward
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Figure 3-3d. UG-25+ Actuator Terminals
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Customer I/O Terminal Position Assignment Terminal Position 1 (TB2-1) 2 (TB2-2)
3 (TB2-3)
Description No Connection Optional Power Out – (Return for 18 V to 32 V (dc) supply input) Analog Ground
4 (TB2-4)
Chassis Ground
5 (TB2-5)
Optional Power Out + (Supply Power, 18 V to 32 V (dc), 1.5 A max.)
6 (TB2-6) 7 (TB2-7) 8 (TB2-8) 9 (TB3-1) 10 (TB3-2) 11 (TB3-3)
No Connection No Connection No Connection No Connection No Connection External Status Output
12 (TB3-4)
Shield
13 (TB3-5)
Position Command +
14 (TB3-6)
Position Command –
15 (TB3-7) 16 (TB3-8) 17 (TB4-1) 18 (TB4-2) 19 (TB4-3)
No Connection No Connection Hi-Pot Test Jumper Hi-Pot Test Jumper Power Input +
20 (TB4-4)
Power Input –
21 (TB4-5)
Power Input –
22 (TB4-6)
Power Input +
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Comment Return for Supply Power. Do not connect Analog Ground to this terminal. Do not connect Analog Ground to Input Power (–) This terminal connects to Chassis ground through the circuit board, and then to + the UG-25 actuator metal housing. This is an output only! Do not connect external power to this power output. This output voltage follows the Power Input(+) minus a protection diode drop.
This provides for a remote “Unit Healthy” status. See + UG-25 actuator Application Wiring Figure 3-2. This terminal is a conditioned shield tie point. (capacitively coupled to Chassis Ground) This is the positive input of the (4 to 20) mA circuitry from the actuator's Position Command signal. This is the negative input of the (4 to 20) mA circuitry from the actuator's Position Command signal.
Supply Power, (18 to 32) V (dc), 1.5 A max. Return for (18 to 32) V (dc) Supply Input. Return for (18 to 32) V (dc) Supply Input. Supply Power, (18 to 32) V (dc), 1.5 A max.
Type N/A Output
N/A N/A
Output
N/A N/A N/A N/A N/A Output, open drain, lowside switch.
N/A
Input
Input
N/A N/A Input Input Input Input Input Input
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Detailed Description of UG-25+ Actuator Electrical I/O
Figure 3-4. Internal Block Diagram
Power Supply Input 1 (18 V to 32 V Power Input (+) at Terminal 19, Power Input (–) at Terminal 21) Power Supply Input 2 (18 V to 32 V Power Input (+) at Terminal 22, Power Input (–) at Terminal 20) The two power-supply inputs are high-signal selected using diodes, so the input with the higher voltage will conduct, and other will remain in "standby" mode until the first supply's voltage drops below the "standby" supply's voltage. Both can remain connected, and there will be no electrical current flow from one power source to the other. + The UG-25 actuator will handle a voltage range of 18 V to 32 V (dc), with an absolute maximum of 60 V.
The power supply terminals are reverse polarity protected, and in the case that a reverse polarity condition exists, the UG-25+ actuator will not power-up. Woodward recommends using a 6 A fuse on the power supply line feeding Terminals 19 and 22 of the UG-25+ actuator. The input power must be fused. Failure to fuse the UG-25+ actuator could, under exceptional circumstances, lead to personal injury, damage to the control valve, and/or explosion. If circuit ground and chassis ground are shorted together at the UG-25+ actuator, there is an increased risk of EMI susceptibility.
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Figure 3-5. Correct and Incorrect Wiring to Power Supply
Woodward recommends using a standard 6 A fuse on the (18 to 32) V (dc) input as show in Figure 3-2. Do NOT use a slow-blow-type fuse in this application. Relay Driver Output (Status/Unit Healthy) A discrete output is provided to serve as a status indicator, mimicking the front panel Unit Healthy LED. This switchable discrete output is a closure to ground capable of sinking 500 mA maximum with an output voltage rise of less than 1.5 V, and it is available to power external relays for devices such as alarms or fuel shutoff solenoids. The circuit is protected internally against over-current and inductive spikes, so external clamping is not necessary.
Figure 3-6. Relay Driver Output
Analog Position Command This input accepts a 4 mA to 20 mA current input that comes from an external electronic control system's speed setpoint. The user must provide an external means to clamp the position command input at 3 mA and 21 mA. An analog position command input below 3 mA or above 21 mA is out of the normal 4 mA to 20 mA input range and may cause the analog position command function to become disabled even though the Analog indication LED remains on.
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To avoid EMI interference between the wire bundle and the interface panel, route the wires out of the connectors away from the panel controls. Do not allow the interface wiring to drape in front of the panel controls.
MAGNETIC FIELDS—During installation, avoid placing the interface panel in close proximity with any source of strong magnetic field (permanent magnet motor, magnetized tools, etc.). Strong magnetic fields can inject error into the adjustments available on the front of the interface panel.
High Potential Testing Occasionally, marine certification requires that a high potential (HI-POT) test of the engine or prime mover be performed after the UG-25+ actuator is installed. The UG-25+ actuator is designed to accommodate this testing. Before performing any HI-POT testing, remove the small HI-POT jumper, Woodward part number 2008-1443, located between Terminals 17 and 18, which are found under the wiring access cover plate on the front of the User Interface panel. The HI-POT test voltage is +755 V (dc). Repeat the test with the polarity reversed at –755 V (dc). Apply the HI-POT voltage between all customer input and output terminals (located under the wiring access cover plate on the front of the User Interface panel) connected together and chassis ground (located on the front of the + UG-25 actuator), except that Terminal 4 (chassis ground) and Terminal 12 (shield) must remain un-connected and not electrically tied to the other terminals during this test. The HI-POT test voltage ramp-up time is 5 seconds, and dwell is 60 seconds, or as specified by the certification authority. Use the ground terminal located on the outside of the User Interface panel as the chassis ground tie point for the HI-POT test. Using Terminal 4 as the chassis ground tie point during the test does not properly check the internal chassis to circuit board connection. Do not perform “AC” Hi-Pot testing on this assembly.
Securely replace the jumper between Terminals 17 and 18 after completing the HI-POT test to ensure that the electrical power surge protection on the electrical circuit board is maintained during normal operation. Install the jumper between Terminals 17 and 18 for normal operation. The UG-25+ actuator may be damaged by power surges if this jumper is not properly installed.
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Insulation Resistance Testing Occasionally, marine certification requires that an insulation resistance test of the engine or prime mover be performed after the UG-25+ actuator is installed. The UG-25+ actuator is designed to accommodate this testing. Before performing any insulation resistance testing, remove the small HI-POT jumper, Woodward part number 2008-1443, located between Terminals 17 and 18, which is found under the wiring access cover plate on the front of the User Interface panel. Connect the plus (+) probe of a multi-meter to each terminal block location in turn and the minus (–) probe to chassis ground. Do not use test equipment that is powered from a power source that exceeds 64 V (dc) to perform the insulation resistance testing. It may damage the actuator electronics. The resistance measured between each terminal block location (Terminals 1 through 3, 5 through 11, 13 through 16, and 19 through 22) and chassis ground must be greater than 830 k. Use the ground terminal located on the outside of the User Interface panel as the chassis ground tie point for the insulation resistance test. Using Terminal 4 as the chassis ground tie point during the test does not properly check the internal chassis to circuit board connection. Securely replace the jumper between Terminals 17 and 18 after completing the insulation resistance test to ensure that the electrical power surge protection on the electrical circuit board is maintained during normal operation. Install the jumper between Terminals 17 and 18 for normal operation. The UG-25+ actuator may be damaged by power surges if this jumper is not properly installed.
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Chapter 4. Description of Operation General The UG-25+ actuator receives a 4 mA to 20 mA Position Command signal from an external electronic control. This mA position command is converted into a direct proportional output position for the actuator's terminal shaft. This conversion is such that a 4 mA position command directs the terminal shaft to go to minimum position, a 20 mA position command directs the terminal shaft to go to maximum position, and a 12 mA position command directs the terminal shaft to go to mid position. The actuator terminal shaft provides a maximum rotational travel of 42 degrees for controlling diesel, gas, or dual fuel engines, or steam turbines. + The UG-25 actuator front panel provides a convenient operating interface for the user, and includes:
UNIT HEALTHY LED—This LED illuminates when there is electrical power supplied to the UG-25+ actuator and the L-Series electronic controller internal to the UG-25+ actuator is working properly. This LED turns off off if supply power is removed or there is a fault in the L-Series electronics.
Figure 4-1. UG-25+ Actuator Front Panel
The control has a switching power supply with excellent spike, ripple, and EMI (electromagnetic interference) rejection. Discrete inputs are capable of rejecting EMI and variable resistance in switch or relay contacts. Analog inputs are differential type with extra filtering for common-mode noise rejection.
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The control provides one discrete output, which provides a Unit Healthy indication. The UG-25+ actuator should not be used as the primary means of shutting down the engine.
Principal of Operation The UG-25+ actuator consists of the following 3 main components: L-Series Controller Assumes a rotary output position directly proportional to the (4 to 20) mA input current from an external control. Hydraulic Amplifier Amplifies the work output of L-Series control. User Interface Provides local Unit Healthy status. Also provides electrical connector for power and customer inputs. The hydraulic amplifier operation is depicted in Figure 4-2, which illustrates the working relationship of the various parts. The main elements of the hydraulic amplifier are listed below: Oil Pump The oil pump is a Gerotor-type pump element, driven by the actuator drive-shaft to provide oil pressure for the actuator. The pump is fed oil from the self-contained sump. Relief Valve Set to maintain an internal operating pressure set at 1034 kPa (150 psi). Rotary to Linear Conversion Mechanism This mechanism converts the rotary output position of the L-Series controller into linear motion required to operate the pilot valve of the amplifier. Return Spring The conversion mechanism incorporates a return spring which is used to move the pilot valve to the minimum fuel position upon loss of function of the L-Series controller. Pilot Valve Plunger The 3-way pilot valve directs oil flow to the control side of the differential area of the power piston or towards the actuator drain. Power Piston, Terminal Shaft Lever, and Terminal Shaft The terminal shaft lever converts the linear motion of the differential-type power piston into a rotary motion of the terminal shaft, which in turn moves the fuel linkage. The terminal-shaft position is fed back to the pilot valve to provide the proportional control.
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Figure 4-2. UG-25+ Actuator Functional Overview
Increase in Position Command Signal An increase in the externally supplied Position Command signal causes the L-Series controller output shaft to rotate CCW when viewed from the top on the UG-25+ actuator. This, in turn, causes the pilot valve to lift allowing control oil pressure to act on the underside of the power piston. This oil pressure underneath the power piston opposes the pump outlet oil pressure acting on the topside and causes the piston to rise, since the piston bottom has twice the area of the topside.
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Manual 26580
As the power piston rises, the power piston rod moves with it and rotates the terminal shaft, converting the output motion back to rotary. One end of the floating lever is directly connected to the power piston rod and this end rises correspondingly. When the desired terminal shaft position is reached, the floating lever provides a mechanical feedback/restoring signal between the power piston rod and the pilot valve. During this condition, the pilot valve will be at its “null” position. Therefore, the L-Series control and the hydraulic amplifier are proportional devices with their positions a direct function of the externally supplied Position Command signal.
Decrease in Position Command Signal A decrease in the externally supplied Position Command signal causes the L-Series controller output shaft to rotate CW. This, in turn, causes the pilot valve to lower allowing the control oil pressure acting on the underside of the power piston to flow to drain. The pump outlet oil pressure acting on the topside of the power piston will cause the piston to lower. As the power piston lowers, the power piston rod moves with it and rotates the terminal shaft towards the minimum fuel direction. The floating lever then lowers its end coupled to the power piston rod and provides its position feedback/restoring feedback to the power piston and pilot valve.
Loss of Position Command Upon loss of the Position Command signal, the actuator terminal shaft goes to minimum fuel, thus offering a safety feature. With loss of power supply voltage, the L-Series controller loses torque and the force of the loading or return spring causes the center adjustment to lower. The pilot valve follows, keeping the control port uncovered. Trapped oil under the power piston escapes to drain, and the servo power piston moves down until it reaches minimum fuel position.
Fault Detection and Annunciation The UG-25+ actuator provides complete shutdown fault monitoring. A detected shutdown condition forces the actuator to go to the minimum fuel (0 %) position. When the shutdown condition no longer exists, the UG-25+ actuator is returned to a non-shutdown state. Faults are globally set as non-latching. When the condition no longer exists, the fault is automatically cleared without any reset.
Shutdown Details Shutdown—Voltage Sense Fail Indicates an out-of-range signal on the input power. Could indicate input power out of range or a fault in the supply voltage sense circuitry. This shutdown causes the Unit Healthy LED to turn off and the External Status output (Terminal 11) to open-circuit, turning off any External Status device that is connected. Failure levels: >33 V and 150 °C and 125 °C Persistence: 650 ms Hysteresis: 5 °C ( 100 MW at 100 V d.c. SEN 361503 IEC 68-2-6 IEC 68-2-34, IEC 68-2-36 IEC 68-2-27 IEC 68-2-32 IP 65 - IEC 529
Mechanical specification Pressure connection Electrical connection
Wetted parts, material
versions without flange connection Pressure connection Plug versions with flange connection Plug gasket O-ring for flange
Housing material Weight
G 1/4, ISO 228/1 or flange DIN 43650 plug AISI 316L, W.no 1.4404 AISI 316L ETG 88 Zn 10F W.no. 1.0388 Sn5 NBR Anodized AIMgSiPb 0.4 kg
Electrical connection 2-wire, 4 - 20 mA
1. Supply + 2. Supply 3. Function test Connected to MBS transmitter enclosure
2
DKACT.PD.P20.Q2.02
ã Danfoss 02-2001
Data sheet
Pressure transmitters MBS 5100 and MBS 5150
MBS 5150 with integrated pulse snubber
MBS 5150 has an integrated pulse snubber for protection of the sensor element against extreme pressure peaks and pulsations. Such conditions may be caused by pumps or fast operating valves in both high and low pressure plants. The integrated pulse snubber is designed as an 0.3 mm orifice mounted in the pressure connection. The medium should not contain particles which may clog up in the orifice. The viscosity has only little effect on the response time. Even at viscosities up to 100 Cst. the response time will not exceed 4 msec.
Mechanical connection Thread
Flange
Adjustment Span –5 ... + 5 % FS
Zero Pressure range
Adjustment
0-1 to 0-10 bar
–5 ... +20 % FS
0-16 to 0-40 bar
–5 ... +10 % FS
0-60 to 0-600 bar –5 ... +2.5 % FS
DKACT.PD.P20.Q2.02
ã Danfoss 02-2001
3
Data sheet
Pressure transmitters MBS 5100 and MBS 5150
Ordering of standard MBS 5100 and MBS 5150 Relative pressure version, G 1¤4 with flange connection, DIN 43650 Pg 11 plug, 4 - 20 mA output Pressure range bar 0 to 1 0 to 2,5 0 to 4 0 to 6 0 to 10 0 to 16 0 to 25 0 to 40 0 to 60 0 to 100 1) 2)
Max. operating pressure bar2) 2 8 8 20 20 50 50 80 200 200
Min.burst pressure bar1) 50 50 50 50 50 100 100 800 800 800
MBS 5150
Type no.
Code no.
Type no.
Code no.
MBS 5100-1011-1DB04 MBS 5100-1411-1DB04 MBS 5100-1611-1DB04 MBS 5100-1811-1DB04 MBS 5100-2011-1DB04 MBS 5100-2211-1DB04 MBS 5100-2411-1DB04 MBS 5100-2611-1DB04 MBS 5100-2811-1DB04 MBS 5100-3011-1DB04
060N1032 060N1033 060N1034 060N1035 060N1036 060N1037 060N1038 060N1039 060N1040 060N1041
MBS 5150-1011-1DB04 MBS 5150-1411-1DB04 MBS 5150-1611-1DB04 MBS 5150-1811-1DB04 MBS 5150-2011-1DB04 MBS 5150-2211-1DB04 MBS 5150-2411-1DB04 MBS 5150-2611-1DB04 MBS 5150-2811-1DB04 MBS 5150-3011-1DB04
060N1081 060N1083 060N1084 060N1063 060N1064 060N1065 060N1085 060N1066 060N1086 060N1087
200 bar for abs. pressure versions FS £ 300 bar min. 2 x FS; FS > 300 bar min. 1,5 x FS
Ordering of customized types
Type no: MBS 5100Type no: MBS 5150-
xx x x- x xxxx xx x x- x xxxx
Measuring range
10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 xx
Pressure reference
PRESSURE SWITCH TYPE
Specification form
Order specification DSC
Contact person
Order No.
Order date
Code No.
Type No.
0 6 1 B
M B C 5
Approvals No approvals ............................................. Ship-approvals .......................................... Other ** .....................................................
MBC5000 and MBC5100 Customer Quantity
Delivery week
0 0
-
-
1 0 1 2 1 4 2 2 2 4 3 2 3 4 3 6 4 2 X X
Type Low pressure below (-1 - 10 bar) ............................................... High pressure below (-1 - 30 bar) ............................................... Low pressure diaphragm (1 - 20 bar) ......................................... High pressure diaphragm (5 - 100 bar) ...................................... Other ** .......................................................................................
* **
C A 0 5 C A 0 7 C B 0 2 C B 0 4 C C 0 4 D A 0 5 D A 0 7 D B 0 2 D B 0 4 D C 0 4 X X X X
0 1 X
Measuring range -1 - 1 bar ..................................................................... -1 - 4 bar ..................................................................... -1 - 10 bar ..................................................................... 1-6 bar ..................................................................... 1 - 10 bar ..................................................................... 5 - 20 bar ..................................................................... 5 - 30 bar ..................................................................... 5 - 40 bar ..................................................................... 10 - 100 bar ..................................................................... Other ** ...........................................................................
0 1 2 X 1 2 3 4 1 X X
Pressure connection M10 x 1 female * M12 x 1,5 female * G1/8 female * G1/4 female NPT 1/4 female * M10 x 1 female with flange * M12 x 1,5 female with flange * G1/8 female with flange connection * G1/4 female with flange connection NPT 1/4 female with flange connection *
Other **
Electrical connection No plug (DIN 43650 A) Standard plug (DIN 43650 A), PG11 GL approved plug (DIN 43650 A), PG13,5 Other **
Microswitch 0,1A, 250V (AC11); 12W, 125V (DC11) Other **
On request Please state below
Application
Medium
Medium temperature
991L1100 udg. 12.94
Comments / special requirements
0 - 1 bar 0 - 1.6 bar 0 - 2.5 bar 0 - 4 bar 0 - 6 bar 0 - 10 bar 0 - 16 bar 0 - 25 bar 0 - 40 bar 0 - 60 bar 0 - 100 bar 0 - 160 bar 0 - 250 bar 0 - 400 bar 0 - 600 bar Others Relative Absolute
CA05 CA07 CB02 CB04 CC04 DA05 DA07 DB02 DB04 DC04
0 1 2 3 1 2
1
An order form has been worked out to facilitate specification of special MBS block transmitters.
M 10 ´ 1 female Pressure M 12 ´ 1.5 female connection G 1/8 female G 1/4 female NPT 1/4 female M 10 ´ 1 female with flange M 12 ´ 1.5 female with flange G 1/8 female with flange connection G 1/4 female with flange connection NPT 1/4 female with flange connection
No plug (DIN 43650 A) Pg 11 plug (DIN 43650 A) Pg 13.5 plug (DIN 43650 A) Pg 9 plug (DIN 43650 A) 4-20 mA
Electrical connection
Output signal
The order form with code no. 991L1099 can be ordered from Danfoss.
For DN use only OB-nr.
Dato
Bekræftet uge
Prod. spec. udsendt dato
NSP
AG-S sign.
ISO 9001 quality approval ISO 9001
4
MBS 5100
Danfoss A/S is certificated in accordance with international standard ISO 9001. This means that Danfoss fulfils the international standard in respect of product development, design, production and sale.
DKACT.PD.P20.Q2.02
ã Danfoss A/S AC-TMP 02-2001
INSTRUCTION MANUAL FOR THERMOCOUPLE
HERIANA CO., LTD #688-1,JURE1-DONG, SASANG-KU, BUSAN, KOREA TEL : 82-51-313-6690~1 FAX : 82-51-313-6693 E-mail :
[email protected] http://www.heriana.co.kr
-CONTENTS LIST1.General
2.Constitution
3.Installation and wiring
4.Type of thermocouple
5.Presumption cause about the trouble state
1.General Thermocouple is manufactured by connecting both ends of two dissimilar metal wires, and when temperature difference occurs on the contacts on these two ends, terminal electro motive force occurs in this closed-circuit and electric current floes on this circuit. The size and the polarity of this electric motive force are determined by the temperature on both ends and the combination of the two metal wires and are not affected by the thickness or the length of the metal wire. As the electro motive force can be pre-reading according to the temperature can be measured. Thermocouple not only requires selection of appropriate wires according to the temperature measurement range, situation of the measuring places and the required accuracy but also requires the maintaining of sure performance even when it is used for a long period of time.
2. Constitution * Thermocouple wire : The wire ends are welding to create the temperature checking contacts * Protecting tune : This protecting tube protects the thermocouple wire and insulators from surrounding conditions to which components and terminal read are connected. As the conditions of the protecting tube vary consider ably according to the temperature checking places. It is necessary to select materials and shapes. which suit the operating temperature atmosphere and the purpose use. * The bolts and plugs :
There are used for fixing the measuring spot.
* The terminal head : This is the head to connect the thermocouple to the outer leading wire. * Insulators : This insulators used to insulated between the thermocouple wires and between protecting tubes to prevent short-circuit, use high-purity aluminium or insulators.
-1-
3. Installation and wiring Please pay your attention for the followings in case of the installation (1). It is necessary to choose the suitable place and the method for the installation which can transmit the temperature correctly and can follow the variation of the temperature as quickly as possible. Please take care not to bend the tube in view of the construction of the thermocouple. (2). Please choose the suitable place which has the smallest vibration, the least dirts, and the lowest moisture. Then, please install the thermocouple at the place which is convenient for the maintenance and inspection. (3) In case of the connection of wires, please confirm the wire sign in order to avoid the wires, and connect the wires firmly by using the compression terminals to avoid the trouble such as the breaking wire and the short -circuit.
4. Type of Thermocouple 1) "N" Type : This is called Nicrosil. nisil
Thermocouple, and it`s composition and
characteristics are very similar to those of type "K". 2) "K" Type : Thermocouple which combines a positive wire of an alloy consisting mainly of nickel and chromium with negative wire of an alloy consisting mainly of nickel. 3) "J" Type : Thermocouple which combines a positive wire of iron with thermocouple is resistant in reducing atmosphere and is also resistant to hydrogen and carbon. However it should not be used atmospheres that will oxidize. 4) "T" Type : Thermocouple which combines a positive wire of copper with a negative wire of an alloy mainly of copper and nickel. It is suitable for low temperatures from -200℃~-100℃. 5) "E" Type : Thermocouple which combines a positive wire of thermocouple "K"with a negative wire of thermocouple "J"
-2-
5. Presumption cause about the trouble state Trouble state
Presumption cause
Breaking out of the
Thermal vibration and shock
wires
Bad insulation
Short-circuit
A.
Exchange the bad
As for the low temperature the
one for the spare
infiltration of the sea water,
part.
and the oil due to the badness of
The pointer of the
the instruments
tester does not move in case of
B.
breaking the wire
As for the high temperature the
and it shows less
chemical change of the insulation,
than 1 ㏁ in case of the bad
due to the high temperature
insulation
Badness of the distance of the leading-wire. Connect the standard
A.
resistor instead of the resistance
Badness of the indicator
bulb,
B. In case that the
Badness of the resistance bulb
allowance increase gradually
(1) The increase of the internal
while using
Treatment
resistance (2) The decrease of the internal resistance (3) The increase of the dirt attached to the protection tube
and find which of the measuring device or the device or the detector is bad. Exchange for the spare parts. Take off the protection tube and take away the dirt.
A. In case that the allowance increases suddenly while using
Abnormality of the measuring device B.
Exchange for the spare
Badness of the resistance bulb
part.
C. Bad connection of the wire, due to the looseness of the screw.
-3-
5-1. method of repairing (1) Do in accordance with the receiving order of that of opening. (2) Concerning the one for the high temperature, the protection against burning out should be carried out around the installation screws at the side of the engine.
5-2. Confirmation items (1) Confirm whether the leading-wire is connected correctly. (2) Confirm the tightness of the cover (3) Confirm the fixed part of the bolts, plugs, etc (4) Turn on the switch for the electric source
-4-
Specification of Type (HT201) 1. Scope This specification applies to that thermocouple which used to every part of machinery.
2. Specification (1). Element wire : Alumel/Calomel (K-Type) (2). Nominal value: 0 ㎶ at 0℃ (3) Thermocouple of standard element: according to JIS C 1605-1995 (4) Tolerance temperature : ±0.0075t Note 1. Tolerance is referred to as the maximum allowable deviation between measuring junction temperature and the temperature derived from the emf table 2. t= means measuring temperature indicator with the temperature. (5) Wireing Thermocouple which combines a positive wire of an alloy consisting mainly of nickel and chromium with negative wire of an alloy consisting mainly of nickel.
-- Possible items to test in our company-* Insulation resistance: It is to be the following table. Insulation resistance(㏁) 500V / over 10 ㏁ *High Voltage : It is to be the following table. High Voltage 500V / 1minutes *Performance test : It is to be the following table Performance test Temperature : 0℃ --> 0 ㎶(allowable error: 0.3%)
-5-
This Thermocouple is made up of
Element wire (Alumel/Calomel) , protecting tube
terminal head and it has the advantage of following items at fitting state. Item I(Change Spare) Loosen the nut like us following diagram, than internal element can be pulled out from outer protecting tube. The element can be changed to new spare one at fitting place, at this time, take off the cable from terminal head and lossen the fitting screw of terminal cover from terminal head then can be changed to spare one. Item II It can performance test easily with out disconnection of cable from terminal head at fitting place. Multimeter is used to voltage(uV) to measurement .
Fitting State
Item I (Change Spare)
-6-
INSTRUCTION MANUAL FOR RESISTANCE BULB
HERIANA CO., LTD #688-1,JURE1-DONG, SASANG-KU, BUSAN, KOREA TEL : 82-51-313-6690~1 FAX : 82-51-313-6693 E-mail :
[email protected] http://www.heriana.co.kr
-CONTENTS LIST1. General
2. Constitution
3. Installation and wiring
4. Wiring method of resistance bulb
5. Maintenance method
6. Presumption cause about the trouble state
1. General In general metal electric resistance of the metal is variable in proportion to the temperature. So, it possible to tell the temperature by measuring the resistance , after the investigation of the relation between the electric resistance and the temperature There is detector used the theory of resistance variation in proportion to the temperature of the platinum wire in the result, and this is called "PLATINUM RESISTANCE BULB". The resistance bulb consists of the resistance element ( the resistance wire wound to the bobbin ) the internal leading wire, the protecting tube, the terminal head ,etc. The resistance bulb has the high pure platinum wire as the resistance element which is put in the sus tube in order to protect against the circumstance condition such as the moisture, the vibration and the shock. Moreover, it has the terminals for the connection of the wire and steel equipment for fixing the part of detecting the temperature
2. Constitution The resistance element to internal leading wire inside of the platinum and outside consists of the protecting tube the bolts , the plugs the terminal box, and etc. *
Protecting tube : This is used for protecting so that the resistance element to internal leading wire inside of the platinum. This is not touch the measure thing directly.
*
The bolts and plugs : There are used for fixing the measuring spot.
*
The terminal head : This is the head to connect the resistance bulb to the outer leading wire.
* insulator : This is used to insulate between internal lead wire and wires and to prevent short-circuit. Teflon tube is used.
-1-
3. Installation and wiring Please pay your attention for the followings in case of the installation (1). It is necessary to choose the suitable place and the method for the installation which can transmit the temperature correctly and can follow the variation of the temperature as quickly as possible. Please take care not to bend the tube in view of the construction of the resistance bulb. (2). Please choose the suitable place which has the smallest vibration, the least dirts, and the lowest moisture. Then, please install the resistance bulb at the place which is convenient for the maintenance and he inspection. (3) In case of the connection of wires, please confirm the wire sign in order to avoid the wires, and connect the wires firmly by using the compression terminals to avoid the trouble such as the breaking wire and the short -circuit.
4. Wiring method of resistance bulb 4-1) Three -conductor Type : use to eliminate the effect of conductor, care should be taken for long-distance transmission because a variation of resistance conductors has an effect on accuracy.
-2-
4-2) Four -conductor Type : This type of connection is used four high-accuracy measurement and standards because it is not afftected by conductor resistance, Generally, a constant current is applied and resistance value is measured by a potential difference.
5. Maintenance method * Ture off the electric switch. * Do taping around the end of the outer lead-wire which is taken off. * Never open the internal resistance element at the spot. * Taken off the cover of the terminal head. * loosen the terminal screw of the cable. * loosen the cable grand
-3-
6. Presumption cause about the trouble state Trouble state
Presumption cause
Breaking out of the
Thermal vibration and shock
wires
Bad insulation
Short-circuit
Treatment
A.
Exchange the bad
As for the low temperature the
one for the spare
infiltration of the sea water,
part.
and the oil due to the badness of
The pointer of the
the instruments
tester does not move in case of
B.
breaking the wire
As for the high temperature the
and it shows less
chemical change of the insulation,
than 1 ㏁ in case of the bad
due to the high temperature
insulation
Badness of the distance of the leading-wire. Connect the standard
In case that the allowance increase gradually while using
A.
resistor instead of the resistance
Badness of the indicator
bulb,
B.
and find which of the measuring
Badness of the resistance bulb
device or the
(1) The increase of the internal
device or the detector
resistance
is bad.
(2) The decrease of the internal resistance
Exchange for the spare parts.
(3) The increase of the dirt attached to the
Take off the protection
protection tube
tube and take away the dirt.
A. In case that the allowance increases suddenly while using
Abnormality of the measuring device B.
Exchange for the spare
Badness of the resistance bulb
part.
C. Bad connection of the wire, due to the looseness of the screw.
-4-
6-1. Method of repairing (1) Do in accordance with the receiving order of that of opening. (2) Concerning the one for the high temperature, the protection against burning out should be carried out around the installation screws at the side of the engine.
6-2. Confirmation items (1) (2) (3) (4)
Confirm Confirm Confirm Turn on
whether the leading-wire is connected correctly. the tightness of the cover the fixed part of the bolts, plugs, etc the switch for the electric source
-5-
Specification of Type (HR101/HC301) 1 . Scope This specification applies to the resistance blub which used to every part of machinery. 2. Specification * Element wire : platinum * Nominal resistance value: Pt 100Ω at 0℃ * Regulated current : 2 ㎃ * Operating temperature : 0~200℃
class B
* Resistance value of standard element: according to JIS C 1604-1997 * Allowance against temperature : ±0.12Ω(±0.3+0.005 t)℃ note. 1.Allowance is defined as the maximum allowable deviation from the temperature vs. resistance reference table. 2. t= modulus of temperature in degrees Celsius without regard sign. *Wiring : Three -conductor Type : use to eliminate the effect of conductor, care should be taken for long-distance transmission because a variation of resistance conductors has an effect on accuracy.
-6-
--
Possible items to test in our company--
* Insulation resistance: It is to be the following table. Insulation resistance(㏁) 500V / over 10 ㏁
*High Voltage : It is to be the following table. High Voltage 500V / 1minutes *Performance test : It is to be the following table Performance test Temperature : 0℃ -->100.00Ω (allowable error: 0.3%)
-7-
This HR101-P Resistance bulb is made up of internal element , protecting tube terminal head and it has the advantage of following items at fitting state. Item I(Change Spare) Loosen the nut like us following diagram, than internal element can be pulled out from outer protecting tube. The element can be changed to new spare one at fitting place, at this time, take off the cable from terminal head and lossen the fitting screw of terminal cover from terminal head then can be changed to spare one. Item II It can performance test easily with out disconnection of cable from terminal head at fitting place. Multimeter is used to resistance(Ω) to measurement
Fitting State
Item I (Change Spare)
-8-
Item II (Performance Test)
-9-
Technical Manual 26415 (Revision E) Original Instructions
Atlas-II™ Digital Control
Control Part Numbers 8273-552, -553, -555, -556, -557, -560, -562, -565, -570, -571, -584, -586
Installation and Operation Manual
DEFINITIONS
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. DANGER—Indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING—Indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION—Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE—Indicates a hazard that could result in property damage only (including damage to the control). IMPORTANT—Designates an operating tip or maintenance suggestion.
The engine, turbine, or other type of prime mover should be equipped with an overspeed shutdown device to protect against runaway or damage to the prime mover with possible personal injury, loss of life, or property damage. The overspeed shutdown device must be totally independent of the prime mover control system. An overtemperature or overpressure shutdown device may also be needed for safety, as appropriate.
Read this entire manual and all other publications pertaining to the work to be performed before installing, operating, or servicing this equipment. Practice all plant and safety instructions and precautions. Failure to follow instructions can cause personal injury and/or property damage.
This publication may have been revised or updated since this copy was produced. To verify that you have the latest revision, be sure to check the Woodward website: www.woodward.com/pubs/current.pdf The revision level is shown at the bottom of the front cover after the publication number. The latest version of most publications is available at: www.woodward.com/publications If your publication is not there, please contact your customer service representative to get the latest copy.
Any unauthorized modifications to or use of this equipment outside its specified mechanical, electrical, or other operating limits may cause personal injury and/or property damage, including damage to the equipment. Any such unauthorized modifications: (i) constitute "misuse" and/or "negligence" within the meaning of the product warranty thereby excluding warranty coverage for any resulting damage, and (ii) invalidate product certifications or listings.
To prevent damage to a control system that uses an alternator or battery-charging device, make sure the charging device is turned off before disconnecting the battery from the system.
To prevent damage to electronic components caused by improper handling, read and observe the precautions in Woodward manual 82715, Guide for Handling and Protection of Electronic Controls, Printed Circuit Boards, and Modules.
Revisions—Text changes are indicated by a black line alongside the text.
Woodward Governor Company reserves the right to update any portion of this publication at any time. Information provided by Woodward Governor Company is believed to be correct and reliable. However, no responsibility is assumed by Woodward Governor Company unless otherwise expressly undertaken.
© Woodward 2007 All Rights Reserved
Manual 26415
Atlas-II Digital Control
Contents IOLOCK. When a CPU or I/O module fails, watchdog logic drives it into an IOLOCK condition where all output circuits and signals are driven to a known de-energized state as described below. The System MUST be designed such that IOLOCK and power OFF states will result in a SAFE condition of the controlled device.
CPU and I/O module failures will drive the module into an IOLOCK state. CPU failure will assert an IOLOCK signal to all modules and drive them into an IOLOCK state. Discrete outputs / relay drivers will be non-active and de-energized. Analog and actuator outputs will be non-active and de-energized with zero voltage or zero current.
The IOLOCK state is asserted under various conditions including: CPU and I/O module watchdog failures PowerUp and PowerDown conditions System reset and hardware/software initialization Entering configuration mode NOTE: Additional watchdog details and any exceptions to these failure states are specified in the related CPU or I/O module section of the manual.
REGULATORY COMPLIANCE ........................................................................ V ELECTROSTATIC DISCHARGE AWARENESS ................................................ VIII CHAPTER 1. GENERAL INFORMATION ........................................................... 1 Introduction .............................................................................................................1 Atlas-II Control Description .....................................................................................1 Control Versions .....................................................................................................2 Control Accessories................................................................................................6
CHAPTER 2. INSTALLATION.......................................................................... 7 Introduction .............................................................................................................7 General Installation.................................................................................................7 Shipping Carton ......................................................................................................7 Mounting .................................................................................................................8 Environmental Specifications .................................................................................8 Electrical Connections ............................................................................................9 Grounding .............................................................................................................11 Non-Marine Enclosure Application Information ....................................................13 Marine Enclosure Application Information ............................................................14 General Enclosure Application Information ..........................................................15 Input Power ..........................................................................................................20 Maintenance .........................................................................................................22 Application Guidelines ..........................................................................................23
CHAPTER 3. POWER SUPPLY BOARD ......................................................... 27 General Description ..............................................................................................27 Specifications .......................................................................................................28 Troubleshooting Guide .........................................................................................28
CHAPTER 4. SMARTCORE CPU A5200 BOARD ......................................... 31 General Description ..............................................................................................31 Woodward
i
Atlas-II Digital Control
Manual 26415
Contents Hardware Specifications .......................................................................................38 SmartCore CPU A5200 Board Operation .............................................................42 Troubleshooting Guide .........................................................................................53
CHAPTER 5. ANALOG COMBO BOARD ........................................................56 General Description ..............................................................................................56 Specifications........................................................................................................57 Analog Combo Board Operation ..........................................................................62 Troubleshooting Guide .........................................................................................67
CHAPTER 6. POWERSENSE BOARD ............................................................69 General Description ..............................................................................................69 Features................................................................................................................69 Physical ................................................................................................................69 Hazardous Live .....................................................................................................69 Specifications........................................................................................................73 PowerSense Board Operation ..............................................................................76 Power Calculations ...............................................................................................84 Troubleshooting Guide .........................................................................................91
CHAPTER 7. 12-CHANNEL RELAY MODULE ................................................93 General Information ..............................................................................................93 Relay Information..................................................................................................94 Shielding ...............................................................................................................94 Board Status Lights ..............................................................................................94 Wiring ....................................................................................................................94
CHAPTER 8. DLE SERIAL COMMUNICATION BOARD....................................96 General Information ..............................................................................................96 Application Developer Information........................................................................99
CHAPTER 9. PC104 PROFIBUS INTERFACE...............................................100 Introduction .........................................................................................................100 Profibus Software and Hardware Requirements ................................................100 Hardware for End Users .....................................................................................100 Software for Application Developers ..................................................................105
CHAPTER 10. SERVICE OPTIONS ..............................................................107 Product Service Options .....................................................................................107 Woodward Factory Servicing Options ................................................................108 Returning Equipment for Repair .........................................................................108 Replacement Parts .............................................................................................109 Engineering Services ..........................................................................................109 How to Contact Woodward .................................................................................110 Technical Assistance ..........................................................................................110
APPENDIX A. ACRONYMS AND GLOSSARY OF TERMS ...............................111 Acronyms ............................................................................................................111 Glossary of Terms ..............................................................................................112
APPENDIX B. WIRING DIAGRAMS..............................................................113 APPENDIX C. FLASH CODES ....................................................................118 APPENDIX D. BOARD ADDRESSES............................................................120 DECLARATIONS .......................................................................................121
ii
Woodward
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Illustrations and Tables Figure 1-1. Atlas-II, Example Module Layout .........................................................3 Figure 1-2a. Physical Dimensions ..........................................................................4 Figure 1-2b. Physical Dimensions ..........................................................................5 Figure 2-1. Screw Connection Terminal Block Used on A5200 SmartCore Board .................................................................................................9 Figure 2-2. Spring Clamp Terminal Block ............................................................10 Figure 2-3. Fixed Terminals..................................................................................11 Figure 2-4. Descriptions of Main Cabinet Cabling Options ..................................17 Figure 3-1. Atlas-II Power Supply Board (601-1008) ...........................................27 Figure 3-2. Discrete Output Wiring Example ........................................................29 Figure 4-1. SmartCore CPU A5200 board, Connectors .......................................31 Figure 4-2. Block Diagram—Atlas-II SmartCore CPU A5200 Board....................33 Figure 4-3. SmartCore CPU A5200 Communications Ports (SIO1, SIO2) ..........35 Figure 4-4. CPU Service Port (mini-DIN6F) .........................................................36 Figure 4-5. CAN Communication Ports ................................................................36 Figure 4-6. MPU Minimum Input Magnitude in Vrms ...........................................38 Figure 4-7. MPU Maximum Input Magnitude in Vrms ..........................................39 Figure 4-8. MPU Typical Input Impedance Magnitude and Phase ......................39 Figure 4-9. Wiring Example–MPU Interface to the SmartCore Board .................43 Figure 4-10. Wiring Example–Open Collector Proximity Probe to the SmartCore CPU A5200 Board ...........................................................................43 Figure 4-11a. Wiring Example–4–20 mA Input Interface to the SmartCore CPU A5200 Board ....................................................................................44 Figure 4-11b. Wiring Example–4–20 mA Input Interface using External Loop Power ...............................................................................................45 Figure 4-12. Wiring Example–Analog Output Interface to the SmartCore CPU A5200 Board ....................................................................................45 Figure 4-13. Wiring Example–Actuator Output Interface to the SmartCore CPU A5200 Board ....................................................................................46 Figure 4-14. Wiring Example–Discrete Input Interface to the SmartCore CPU A5200 Board ....................................................................................47 Figure 4-15. Serial #1–RS-232 Pinouts................................................................48 Figure 4-16. Serial #1–RS-422 Pinouts................................................................48 Figure 4-17. Serial #1–RS-485 Pinouts................................................................49 Figure 4-18. Serial #2–RS-232 Pinouts................................................................49 Figure 4-19. Serial #2–RS-422 Pinouts................................................................50 Figure 4-20. Serial #2–RS-485 Pinouts................................................................50 Figure 4-21. Wiring Example–RS-232 Interface to the SmartCore CPU A5200 Board ...............................................................................................51 Figure 4-22. Wiring Example–RS-422 Interface to the SmartCore CPU A5200 Board ...............................................................................................51 Figure 4-23. Wiring Example–RS-485 Interface to the SmartCore CPU A5200 Board ...............................................................................................51 Figure 4-24. Wiring Example–Alternate Multipoint Wiring....................................51 Figure 5-1. Atlas-II Analog Combo Board Connections .......................................56 Figure 5-2. Atlas-II Analog Combo Board Block Diagram ....................................57 Figure 5-3. Minimum MPU Voltage ......................................................................61 Figure 5-4. Wiring Example–MPU Interface to the Analog Combo Board ...........62 Figure 5-5a. Wiring Example–Analog Input Interface ..........................................63 Figure 5-5b. Wiring Example–Analog Input Interface with External Loop Power 64 Figure 5-6. Wiring Example–4–20 mA Input Interface .........................................64 Figure 5-7. Wiring Example–RTD Input Interface ................................................64 Figure 5-8. Wiring Example–Analog Output Interface ..........................................66
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Illustrations and Tables Figure 6-1. Terminal Block Covers .......................................................................70 Figure 6-2. PowerSense Board Connections .......................................................71 Figure 6-3. PowerSense Board Block Diagram....................................................72 Figure 6-4. Wiring Example–Wye Connected System .........................................78 Figure 6-5. Wiring Example–Wye Connected System .........................................79 Figure 6-6. Example Wiring–Wye Connected System .........................................80 Figure 6-7. Wiring Example–Delta Connected System ........................................81 Figure 6-8. Wiring Example–Delta Connected System ........................................82 Figure 6-9. Wiring Example–CT Interface to the PowerSense Board ..................85 Figure 6-10. Wiring Example–CT Interface to the PowerSense Board ................86 Figure 6-11. Wiring Example–Speed Bias Output Interface ................................87 Figure 6-12. Wiring Example–Speed Bias Output Interface ................................88 Figure 6-13. Wiring Example–Voltage Bias Output Interface ...............................89 Figure 6-14. Wiring Example–Voltage Bias Output Interface ...............................89 Figure 6-15. Wiring Example–LON Interface to the PowerSense Board .............90 Figure 7-1. 12-Channel Relay Module .................................................................93 Figure 7-2. 12-Channel Relay Module Wiring Diagram........................................95 Figure 8-1. DLE Connections ...............................................................................96 Figure 8-2. Terminator Locations .........................................................................97 Figure B-1. SmartCore CPU A5200 board Connections ....................................113 Figure B-2. Analog Combo Board Connections .................................................114 Figure B-3. PowerSense Board Connections.....................................................115 Figure B-4. 12-Channel Relay Module Connections ..........................................116 Figure B-5. DLE Connections .............................................................................117 Figure D-1. Board Address Numbers .................................................................120 Table 1-1. Atlas-II Modules.....................................................................................2 Table 1-2. VxWorks Atlas-II Item Numbers ............................................................2 Table 2-1. Power Supply Requirements ...............................................................21 Table 4-1. Ethernet Port Pinout ............................................................................35 Table 4-2. SmartCore CPU A5200 Failure Codes ...............................................53 Table 5-1 Analog Combo Failure..........................................................................67 Table 6-1. PowerSense Failure Codes ................................................................90 Table 8-1. DLE Failure Codes ..............................................................................98 Table 9-1. Profibus—Type A Cable ....................................................................101 Table 9-2. Profibus—Type B Cable ....................................................................101 Table 9-3. Belden Profibus Cable.......................................................................102 Table 9-4. Profibus—Siemens RS-485 Bus Connector / Plastic ........................102 Table 9-5. Profibus—Siemens RS-485 Bus Connector / Metal .........................103 Table 9-6. I/O Connector Pinout .........................................................................103 Table C-1. SmartCore CPU A5200 Failure Codes .............................................118 Table C-2 Analog Combo Failure Codes ...........................................................118 Table C-3. PowerSense Failure Codes ..............................................................118 Table C-4. DLE Failure Codes ...........................................................................119
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Regulatory Compliance European Compliance for CE Marking: These listings are limited only to those units bearing the CE Marking. EMC Directive:
ATEX - Potentially Explosive Atmospheres Directive:
Declared to 2004/108/EC COUNCIL DIRECTIVE of 15 December 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility and all applicable amendments. Declared to 94/9/EC COUNCIL DIRECTIVE of 23 March 1994 on the approximation of the laws of the Member States concerning equipment and protective systems intended for use in potentially explosive atmospheres. Zone 2, Category 3, Group II G, Ex nA IIC T3 X
North American Compliance: These listings are limited only to those units bearing the UL identification. UL:
UL Listed for Class I, Division 2, Groups A, B, C, & D, T3C at 70C surrounding air temperature. For use in Canada and the United States. UL File E156028 The 16-channel relay interface modules are suitable for ordinary or non-hazardous locations only.
Marine Compliance American Bureau of Shipping Det Norske Veritas
Lloyd’s Register of Shipping
ABS Rules 2006 SVR 4-2-1/7.3, 7.5.1, 7.9.3/17, 4-9-4/23, 4-9-7/Table 9 Standard for Certification No. 2.4, 2006: Temperature Class B, Humidity Class B, Vibration Class A, and EMC Class A LR Type Approval Test Specification No. 1, 2002 for Environmental Categories ENV1, ENV2, and ENV3
Special Conditions For Safe Use: This Equipment is Suitable For Use in Class I, Division 2, Groups A, B, C, D or Non-Hazardous Locations Only. This equipment is suitable for use in European Zone 2, Group IIC environments. This equipment is intended to be installed in a metal cabinet or enclosure to provide protection against the entry of dust or water and to protect against mechanical impact. For ATEX compliance, a minimum ingress protection rating of IP54 is required for the enclosure. For ATEX compliance, this equipment must be protected externally against transient disturbances. Provisions shall be made to prevent the power input from being exceeded by transient disturbances of more than 40% of the rated voltage Wiring must be in accordance with North American Class I, Division 2, or European Zone 2, Category 3 wiring methods as applicable, and in accordance with the authority having jurisdiction.
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A fixed wiring installation is required and a switch or circuit breaker shall be included in the building installation that is in close proximity to the equipment and within easy reach of the operator and that is clearly marked as the disconnecting device for the equipment. The switch or circuit breaker shall not interrupt the protective earth conductor. Do not connect more than one main power supply to any one fuse or circuit breaker. Protective Earth Grounding is required by the input PE terminal (see Chapter 2, Installation). Ground leakage current exceeds 3.5 mA. For Communications wires, use wires with a temperature rating of at least 5 °C above surrounding ambient. All others use wires with a temperature rating of at least 10 °C above surrounding ambient. The Atlas-II A5200 board contains a single cell primary battery. This battery is not to be charged and is not customer replaceable. Control is suitable for installation in pollution degree 2 environments. Unmarked inputs are classified as permanently connected IEC measurement Category I. To avoid the danger of electric shock, do not use inputs to make measurements within measurement categories II, III, or IV. See individual inputs for additional information on transient overvoltage input ratings. EXPLOSION HAZARD—Do not connect or disconnect while circuit is live unless area is known to be non-hazardous. Substitution of components may impair suitability for Class I, Division 2 applications.
RISQUE D’EXPLOSION—Ne pas raccorder ni débrancher tant que l’installation est sous tension, sauf en cas l’ambiance est décidément non dangereuse. La substitution de composants peut rendre ce matériel inacceptable pour les emplacements de Classe I, applications Division 2.
The Atlas-II is designed for installation in a standard metal cabinet. If the cabinet door is open or Atlas-II is not installed in a metal cabinet, some degraded performance can occur on RTD and thermocouple inputs in the presence of radio wave energy. Radio wave energy may be from transmitters such as cell phones or push to talk radios. This degraded performance is in the form of a slight change in the accuracy of the RTD and thermocouple input measured temperature. It is recommended that operation of such radio wave devices be kept more than 3 m (10 ft) from the Atlas-II control. This will prevent performance degradation. Installation of the Atlas-II control in a metal enclosure, as intended, will also prevent performance degradation.
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The Atlas-II Actuator and Analog outputs are intended to drive loads that are isolated from protective earth, like actuators and meters.
The Atlas-II is protected from indirect lighting strikes. However, during a lighting strike to protective earth (PE), or similar transient events, if the Actuator or Analog outputs are connected to earthreferenced devices, the device may significantly reduce performance of the Atlas-II. Protective earth connections separated by a significant distance (>30 m) can see a large voltage difference due to transient surge events. The non-isolated device may cause a ground fault with significant current flow through the analog signal lines, causing signal input measurement errors beyond Analog I/O to occur. Adding an isolator between the Atlas-II and its analog loads will solve this issue. Alternatively adding clamping circuitry, like Metal Oxide Varistors (MOV) or Transient Voltage Suppression (TVS) diodes, from chassis to signal lines at both ends will also solve this issue. (See the appropriate sections for more details.)
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Electrostatic Discharge Awareness All electronic equipment is static-sensitive, some components more than others. To protect these components from static damage, you must take special precautions to minimize or eliminate electrostatic discharges. Follow these precautions when working with or near the control. 1.
Before doing maintenance on the electronic control, discharge the static electricity on your body to ground by touching and holding a grounded metal object (pipes, cabinets, equipment, etc.).
2.
Avoid the build-up of static electricity on your body by not wearing clothing made of synthetic materials. Wear cotton or cotton-blend materials as much as possible because these do not store static electric charges as much as synthetics.
3.
Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam cups, cup holders, cigarette packages, cellophane wrappers, vinyl books or folders, plastic bottles, and plastic ash trays) away from the control, the modules, and the work area as much as possible.
4.
Do not remove the printed circuit board (PCB) from the control cabinet unless absolutely necessary. If you must remove the PCB from the control cabinet, follow these precautions:
Do not touch any part of the PCB except the edges.
Do not touch the electrical conductors, the connectors, or the components with conductive devices or with your hands.
When replacing a PCB, keep the new PCB in the plastic antistatic protective bag it comes in until you are ready to install it. Immediately after removing the old PCB from the control cabinet, place it in the antistatic protective bag. To prevent damage to electronic components caused by improper handling, read and observe the precautions in Woodward manual 82715, Guide for Handling and Protection of Electronic Controls, Printed Circuit Boards, and Modules.
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Chapter 1. General Information Introduction This manual describes the Woodward Atlas-II™ Digital Control. It provides a variety of useful information for the user ranging from simple basic descriptions to detailed information on wiring, specifications, and functionality. Included are: General information on the Atlas-II platform and available versions A physical description of the control hardware A description of all Atlas-II modules A listing of accessories that may be used with the platform Information on Atlas-II communications and distributed I/O interfaces Installation and maintenance Troubleshooting information For information on programming, networking, and communication protocols, refer to the software manual provided with the control.
Atlas-II Control Description The Atlas-II digital control platform fits a wide range of prime mover applications. These include small mechanical-drive units with a minimum of complexity on up to large two-shaft gas turbine generator sets that require unit sequencing and load control. The Atlas-II control is programmed to the specific needs of the prime mover and its driven load. At the heart of the Atlas-II control is a 32-bit microprocessor that runs a powerful Real Time Operating System. This operating system is specifically designed to control the proper timing of all application code so that dynamic performance of the final control system is absolutely guaranteed. Each piece of the application code is “scheduled” under a Rate Group structure that ensures execution of the code at a predetermined time. Application programming is accomplished via Woodward’s GAP™ Graphical Application Program. GAP is a pictures-to-code system that provides a high-level programming environment for users who have control expertise but do not have specific programming skills. Once the application program has been generated and loaded into the Atlas-II control, the user can view variables and tune the control with a variety of Woodward service tools. Connection to other devices, ® such as an HMI, is accomplished by means of serial Modbus * or Ethernet ports on the control. The desired information flow is programmed into the control via GAP. If required, distributed I/O can be connected using optional communication modules that support Profibus and DLE Communications. *—Modbus is a trademark of Schneider Automation Inc.
The hardware platform is based on the industry-standard PC/104 bus structure. In the Atlas-II control, the backplane is the SmartCore board. The PC/104 modules are “stacked” onto the SmartCore board in order to add I/O or other functionality. Each of the stacked modules has an on-board DIP switch that is positioned to the unique address of that particular module. The Atlas-II control uses a second stack called the Power Bus Stack. This stack is used primarily for power-related I/O. The control runs on low-voltage DC power (18–32 Vdc). Atlas-II field wiring is accomplished via terminal blocks that plug into the control modules.
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Control Versions The Atlas-II control provides a flexible platform that can be structured into a wide variety of configurations of I/O and communications. The required number of I/O modules and the types of communication modules that are required will depend entirely on the specific application scenario. Table 1-1 shows the various modules that are available.
Atlas-II Module List Power Supply SmartCore CPU A5200 PowerSense Analog Combo I/O DLE Communications Profibus Table 1-1. Atlas-II Modules
Atlas-II Item Number
Operating System
8273-552
VxWorks
1
2
8273-553
VxWorks
1
1
8273-555
VxWorks
1
3
8273-556
VxWorks
1
1
1
8273-557
VxWorks
1
1
2
8273-560
VxWorks
1
8273-562
VxWorks
1
Atlas-II A5200
PowerSense
1
Analog Combo
DLE Com
Profibus
Cooling Fan
2
X
1 X
X
3
1
X
2
1
X
1
X
8273-565
VxWorks
1
1
8273-570
VxWorks
1
1
8273-571 8273-584 8273-586
VxWorks VxWorks VxWorks
1 1 1
2 1
Description ATLAS II, 2 X 5, A5200, LV, 2 COMBO, 2 PROFIBUS ATLAS II, 2 X 4, A5200, LV, 1 COMBO, 1 DLE ATLAS II, 2 X 4, A5200, LV, 3 COMBO ATLAS-II, 3 X 4, A5200, LV, PSENSE, 1 COMBO ATLAS-II, 3X4 A5200, PSENSE, LV, 2 COMBO ATLAS-II, 2X5, A5200, LV, 3 COMBO, 1 PROFIBUS ATLAS II, 3 X 5, A5200, PSENSE, LV, 2 COMBO, 1 PROFIBUS ATLAS-II, 2 X 2, A5200, LV, 1 COMBO ATLAS-II, 2 X 4, A5200, LV, 1 COMBO, 1 PROFIBUS ATLAS-II, 2 X 4, A5200, LV, 2 COMBO ATLAS II, 2 X 2, A5200, LV ATLAS-II, 3 X 2, A5200, LV, PSENSE
Table 1-2. VxWorks Atlas-II Item Numbers NOTE—Depending on the configuration, the control may or may not contain a fan. See Table 1-2 above.
Figure 1-1 shows diagrammatically the physical arrangement of the modules in the Atlas-II control hardware. The hardware uses two stacked-bus arrangements to provide the required structure. The Power Bus Stack is used for the powerrelated I/O as well as the discrete output drivers. The PC/104 Stack is used primarily for the signal I/O, the main processor, and communications modules. All configurations contain a SmartCore CPU A5200 module that spans both the Power Bus Stack and the PC/104 Stack. If real power sensing is required in the application, a PowerSense module is stacked above the SmartCore module and also spans both bus stacks. If a PowerSense module is not specified, then an additional Analog I/O module can be substituted. Figure 1-1 shows a “maximum” example configuration (5 levels high).
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Figure 1-1. Atlas-II, Example Module Layout
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Figure 1-2a. Physical Dimensions
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Figure 1-2b. Physical Dimensions
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Control Accessories The Atlas-II digital control platform is designed to interface with several Woodward service tools and commercial software products. Available tools are listed below with a brief description of their functionality: Monitor GAP—An Ethernet connection to the control allows on-line GAP monitoring, debug, and tunable configuration. Watch Window—Provides an Ethernet or serial connection to the control to allow 1) initial configuration of the unit; 2) monitoring and tuning of system variables; and 3) management of configuration and setpoints. Control Assistant—Ethernet connection to the control for Tunable Management, viewing of high-speed data captures, and other useful utilities. Application Manager—Ethernet access to the control for program loading, network configuration and support, and system diagnostics. HMI (Human Machine Interface)—Commercially available HMI programs interface to the Atlas-II control through Ethernet or serial connections to provide operator access and control of the application machinery.
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Chapter 2. Installation Introduction This chapter provides the general information for mounting location selection, installation, and wiring of the Atlas-II™ control. Hardware dimensions, ratings, and requirements are given for mounting and wiring the control in a specific application.
General Installation When selecting a location for mounting the Atlas-II control, consider the following: Protect the unit from direct exposure to water or to a condensation-prone environment. The control is deigned for installation in a protective metal enclosure such as a standard cabinet with ingress protection rating of IP54. A standard “EMC” cabinet is required when installing into a Marine Type Approval applications. Provide an ESD strap inside the cabinet for handling the equipment and plugging/unplugging the connectors. The operating range of the Atlas-II control is –40 to +70 °C (–40 to +158 °F) except when the Profibus module is used. See the Environmental Specifications for more details. Provide adequate ventilation for cooling. Shield the unit from radiant heat sources. Do not install the unit or its connecting wires near inductive, high-voltage, or high-current devices. If this is not possible, shield both the system connecting wires and the interfering devices or wires. Allow adequate space around the unit for servicing and wiring. Do not install where objects can be dropped on the terminals. Ground the chassis for proper safety and shielding. When installing on a generator set package, provide vibration isolation.
Shipping Carton Before unpacking the control, refer to the inside front cover and page vi of this manual for WARNINGS and CAUTIONS. Be careful when unpacking the control. Check for signs of damage such as bent or dented panels, scratches, and loose or broken parts. If any damage is found, immediately notify the shipper. The Atlas-II control was shipped from the factory in an anti-static foam lined carton. This carton should always be used for transport of the control or for storage when the control is not installed.
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Mounting Figure 1-2 shows the Atlas-II control layout and mounting pattern. The Atlas-II digital control is to be mounted in an appropriate enclosure for the installed environment. This equipment is designed for installation within a control room panel or cabinet. This equipment is intended to be installed in a metal cabinet or enclosure to provide protection against the entry of dust or water and to protect against mechanical impact. For ATEX compliance, a minimum ingress protection rating of IP54 is required for the enclosure. The standard Atlas-II package must be mounted to allow sufficient room for wiring access. Eight front panel mounting holes permit secure mounting. Depending on its configuration, the Atlas-II weighs between 3.4 and 4.5 kg (7.5 and 10 pounds). A minimum of 25 mm (1 inch) of clear space around the outer surfaces of the Atlas-II is adequate for ventilation, however approximately 75 mm (3 inches) of space may be required for wiring, depending on wire size.
Environmental Specifications Operating Temperature The Atlas-II Control Platform operates in a specified ambient temperature of –40 to +70 °C (–4 to +158 °F) with forced convection cooling. When the Atlas-II contains a single Profibus module, the operating temperature is limited to –20 to +60 °C (–4 to +140 °F). When the Atlas-II contains (2) Profibus modules, the operating temperature is limited to –20 to +55 °C (–4 to +131 °F). Continuous operation with insufficient airflow or higher operating temperatures will lead to reduced reliability and possible damage to the control. Storage Temperature The Atlas-II Control Platform is designed to be stored without applied power at the temperature range of –40 to +85 °C (–40 to +185 °F). Any unit with Profibus is limited to –20 to +70 °C (–4 to +158 °F). Component life is adversely affected by high-temperature, high-humidity environments. Room temperature storage is recommended for long life. If the unit is to be stored for a long period of time, operating power must be applied at least for one hour every 18 to 24 months. Shock The Atlas-II Control Platform was designed to meet the shock requirements specified by MIL-STD-810C procedure 516.2, procedure 1 (30g, 11 millisecond half sine pulse). During Shock, relay bounce shall be limited to less than 100 ms. Vibration (Sinusoidal) The Atlas-II Control Platform was designed and tested to meet Lloyd’s Test Specification No. 1, 2002, Vibration Test 1. The Vibration test profile includes 3– 16 Hz, ±1 mm and 16–150 Hz, ±1.0g.
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Audible Noise Emission The Atlas-II Control Platform does not emit an audible noise above 70 dBA as measured 1 meter away, with or without a fan. Enclosure Protection In order to meet Zone 2 European Group IIC, the Atlas-II Control must be mounted in an enclosure that meets or exceeds IP 54. Altitude The Atlas-II Control Platform is designed to operate up to 3000m / 9800 feet.
Electrical Connections Most of the Atlas-II control’s terminal blocks are designed to be removed by hand. The Atlas-II Control uses two different styles of pluggable terminal blocks: Screw Connection (limited to the A5200 SmartCore board) and “CageClamp”. The pluggable terminal blocks on the SmartCore CPU A5200 board all utilize the Screw Connection style terminal blocks (see Figure 2-1 for torque and screwdriver requirements). The Screw Connection terminal blocks accept wires from 0.08–1.5 mm² (28–16 AWG). Two 0.8 mm² (18 AWG) wires or three 0.3 mm² (22 AWG) wires can be easily installed in each terminal. The pluggable terminal blocks on the modules (other than the A5200 SmartCore) are screwless, CageClamp style blocks. The spring clamp can be actuated by using a standard 2.5 mm (3/32 inch) flat bladed screwdriver (see Figure 2-2). These terminal blocks accept wires from 0.08–1.1 mm² (28–18 AWG). Two 0.5 mm² (20 AWG) wires or three 0.3 mm² (22 AWG) wires can be easily installed in each terminal. Most of the Atlas-II control’s terminal blocks are designed to be removed by hand. After Atlas-II input power is disconnected, the terminal blocks can be removed one at a time by pulling them straight out. Be careful not to pull the plug out at an angle, as this will fracture the end terminal. Wires for the all the pluggable I/O terminal blocks should be stripped at 8 mm (0.3 inch).
Torque range for screws of Screw Connection Terminal Blocks: 0.22–0.25 Nm (1.95–2.21 lb-in). Screwdriver blade: 0.4 X 2.5 mm (0.016 X 0.10 inch) Screwdriver available as Woodward PN 8992-005
Figure 2-1. Screw Connection Terminal Block Used on A5200 SmartCore Board
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Metthod #1 F Free Hand (ho olds spring op pen)
Method #2 opens Bench (momentarily ( spring while w force is applied) a
Figure 2-2. Spring Clamp Terminal Block
A fixed te erminal blockks used for the e power supp ply input accept wires The Atlas-II from 0.08–1.1 0 mm²² (28–18 AWG G). Two 0.5 mm² m (20 AWG G) wires or thrree 0.3 mm² (22 ( AWG) wirres can be ea asily installed in each termiinal. Wires forr the fixed moun nted power terrminals should be stripped d 5 mm (0.2 in nch).
W Wiring Fixed Terminal
Do D not tin (so older) the wirres that term minate at the Atlas-II term minal blocks. b The spring-loade s d CageClamp terminal blocks are de esigned to flatten stra anded wire, and a if those strands s are tinned t togeth her, the connection c lo oses surface e area and is degraded.
EXPLOSION E HAZARD—D Do not conne ect or discon nnect while circuit c is liive unless arrea is known n to be non-h hazardous.
RIS SQUE D’EXPL LOSION—Ne e pas raccord der ni débran ncher tantt que l’installation est so ous tension, sauf s en cas l’am mbiance est décidément d non dangere euse.
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All AC wiring for voltages and currents is done with fixed screw barrier blocks rather than pluggable terminal blocks. The fixed screw barrier blocks accept wires terminated into terminal lugs for #6 screws.
Figure 2-3. Fixed Terminals
Grounding Protective Earth (PE) must be connected to the termination point on the backside of the unit next to the label with the symbol to reduce the risk of electric shock. This connection will be made using a thread-forming screw (M4 x 6 mm). The conductor providing the connection shall have a properly sized ring lug and wire larger than or equal to 3.3 mm² (12 AWG). The unit also needs low impedance grounding to earth, e.g. the cabinet or enclosure used. The low impedance ground can be accomplished by one or more of the following: A short 15 cm (6 inch) protective earth wire A 1.3 cm (0.5 inch) wide flat hollow braid less than 1 m long A 1.3 cm (0.5 inch) wide flat tin or lead/tin plated copper strap less than 1 m long The use of the eight mounting bolts and paint breaking washers. Do not connect chassis ground or PE ground to signal common.
Safety Ground Wire Installation Safety wires must be routed against the grounded cabinet structure. Locate safety ground wire 150 mm (6 inches) from unshielded cabling and 75 mm (3 inches) from shielded cabling inside the cabinet, and 150 mm (6 inches) from any I/O cabling exiting the cabinet.
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Manual 26415
Recommended Grounding Practices Providing the proper ground for the Atlas-II control is important. Improper connection of the control chassis to the protective earth / building ground plane may lead to stray currents between the reference point for the AC signal sources (current and voltage transformers), and the reference point for the sensing inputs on the Atlas-II control. Differences in potential between these two points results in equalizing current flow which then produces unacceptably high common mode voltages. Common mode voltages may result in improper readings for the sensed AC inputs, or even damage to the Atlas-II control in extreme cases. To minimize this problem, it is necessary to provide a low resistance path between the AC signal reference point, and the chassis of the Atlas-II control. Typically this point is the designated ground for the generator set and related instrument transformers.
Shields and Grounding All signal lines except PT/CT, relay outputs, contact inputs, and power supply wiring should be shielded to prevent picking up stray signals from adjacent equipment. Shielding of PT/CT, relay outputs, contact inputs, and power supply wires inside the metal enclosure is required for Marine Type Approval installation applications. Relay outputs, contact inputs, and power supply wiring do not normally require shielding for other installations, but may be shielded if desired. All shielded cable must be twisted conductor pairs. The Atlas-II control is designed with shield terminations to earth ground at the control. An individual shield termination to earth is provided at the terminal block for each of the signals requiring shielding. Do not tin (solder) or attempt to tin the braided shield for connection into the terminal block. Wire exposed beyond the shield should be as short as possible, not exceeding 50 mm (2 inches). If intervening terminal blocks are used in routing a signal, the shield should be continued through the terminal block. If shield grounding is desired at the terminal block, it should be AC coupled to earth. All shield terminations not at the Atlas-II or entry into its metal enclosure should be AC coupled to earth through a capacitor. (A 1000 pF, 500 V capacitor is typically sufficient. The intent is to provide a low impedance path to earth for the shield at frequencies of 150 kHz and higher.) Multiple, spread out, direct or high capacitance connections of a shield to earth should be avoided. Multiple connections risks high levels of low frequency ground current, like 50/60 Hz, flowing within the shield. Shield termination can be a deterministic process. AC shield connections (capacitors) may be dictated at the control, instead of the direct earth connection provided. Typically, shields at signal inputs are connected directly to earth, and shields at signal outputs are AC-coupled to earth or floating. See Woodward application notes 50532, Interference Control in Electronic Governing Systems, and 51204, Grounding and Shield Termination, for more information.
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Woodward
Manual 26415
Atlas-II Digital Control
Shielded Wire Preparation Where shielded cable is required, cut the cable to the desired length and prepare the cable as instructed below. 1. Strip outer insulation from both ends, exposing the braided or spiral wrapped shield. Do not cut the shield or nick the wire inside the shield. 2. Using a sharply pointed tool, carefully spread the strands of the braided shield to form a hole. 3. Pull inner conductor(s) out of the shield. If the shield is the braided type, twist it to prevent fraying. 4. Remove 6 mm (1/4 inch) of insulation from the inner conductors. 5. Connect wiring and shield as shown in plant wiring diagram. 6. If a shield connection is not required or desired, fold back and secure or remove the excess shield as needed.
General Wiring Guidance For noise suppression reasons, it is recommend that all low-current wires be separated from all high-current wires and high-voltage be separated from lowvoltage. Input power ground terminal, not power return, should also be wired to earth ground. Installations with severe electromagnetic interference (EMI) may require additional shielding precautions, such as wire run in conduit or double shielding. Contact Woodward for more information. Shields from the control to its loads or inputs can be directly grounded to earth at both ends, if the cable length is sufficiently short to prevent ground loop current in the shield (e.g. within a single cabinet). Enclosure Installations: If the control is installed in a metal enclosure, as intended, shielded I/O must be AC or DC terminated directly to the cabinet (earth ground) at the entry to the cabinet, as well as at the control shield pins. Specifics are provided in each individual installation section.
Non-Marine Enclosure Application Information Cabinet Structural Grounding The cabinet needs to be a six-sided metal enclosure. Do not use cabinet doors with windows—doors should be solid metal. The enclosure floor and/or top panels must provide holes for cable entry. Top and bottom cable entry areas must be restricted in size. Cable entry aperture sizes should be minimized to the extent possible, the largest dimension of any aperture (hole) is no greater than 152 mm (6 inches). This is particularly important when RF transmitters, like push to talk radios or cell phones, can be located near the cable access areas. An enclosed metal cable area or cable way joining to the cabinet may be thought of as part of the enclosure; If it has no holes larger than 152 mm (6 inches) and no RF transmitters can be present with in it. This allows larger holes in the enclosure cable access plate. The enclosed cableway effectively becomes part of the enclosure. The cabinet enclosure frame and device mounting areas must be bonded (grounded) together. The frame shall be electrically connected at each structural interface (
