This document provides assembly instructions for Accelleron A100-L series turbochargers, including models A165-L, A170-L, A175-L, A180-L, A185-L, and A190-L. It is intended for engineers and mechanics responsible for fitting the turbocharger on an engine, requiring basic mechanical training. The instructions ensure correct installation without health and safety risks, complementing existing national regulations for occupational safety, accident prevention, and environmental protection.
Function Description
The Accelleron turbocharger is designed to be fitted to an engine, enhancing its performance. The assembly instructions detail the process of placing the turbocharger on its bracket, fastening it, and connecting necessary components. The turbocharger's rotor can rotate due to stack draught, which necessitates securing it against turning during assembly to prevent injury.
Important Technical Specifications
The document provides detailed specifications for various A100-L series turbochargers, particularly concerning their weight and fastening requirements.
Weight and Transportation
Lifting gear with a sufficient load limit must be used for removing, installing, and transporting the turbocharger. The specified weights apply to the heaviest variant; actual weights may be lower as indicated on the rating plate.
- A165-L: 2300 kg
- A170-L: 3300 kg
- A175-L: 5600 kg
- A180-L: 7500 kg
- A185-L: 10500 kg
- A190-L: 13500 kg
Fastening Specifications
The fastening elements for the turbocharger must meet specific requirements:
- Turbocharger fixing elements: ISO property class ≥ 8.8
- Washers: Hardened, thickness ≥ 15% nominal thread diameter
- Dimension a (compressor end): Height of turbocharger foot a
- Dimension a (turbine end): Height of turbocharger foot F + spacer sleeve D
- Dimension b: Hole in bracket
- Dimension c: Thread length, ≥ 1.5 x nominal thread diameter
- Coefficient of friction: 0.12 (lightly oiled)
The document specifies tightening torques for different thread sizes and foot heights:
- A165-L (M22, 86 mm): 440 Nm
- A170-L (M27, 100 mm): 830 Nm
- A175-L (M30, 120 mm): 1100 Nm
- A180-L (M33, 136 mm): 1500 Nm
- A185-L (M39, 151 mm): 2500 Nm
- A190-L (M42, 167 mm): 3100 Nm
For angle-controlled tightening, the following values are provided:
- A165-L (M22, 86 mm): Pre-tightening torque 120 Nm, Tightening angle height a 30 DEG, Additional tightening angle for every 10 mm of screw length b 3.7 DEG
- A170-L (M27, 100 mm): Pre-tightening torque 220 Nm, Tightening angle height a 30 DEG, Additional tightening angle for every 10 mm of screw length b 3.1 DEG
- A175-L (M30, 120 mm): Pre-tightening torque 300 Nm, Tightening angle height a 30 DEG, Additional tightening angle for every 10 mm of screw length b 2.6 DEG
- A180-L (M33, 136 mm): Pre-tightening torque 400 Nm, Tightening angle height a 35 DEG, Additional tightening angle for every 10 mm of screw length b 2.6 DEG
- A185-L (M39, 151 mm): Pre-tightening torque 600 Nm, Tightening angle height a 35 DEG, Additional tightening angle for every 10 mm of screw length b 2.4 DEG
- A190-L (M42, 167 mm): Pre-tightening torque 700 Nm, Tightening angle height a 35 DEG, Additional tightening angle for every 10 mm of screw length b 2.2 DEG
Usage Features
The turbocharger is designed for integration into an engine system. Its installation involves several key steps:
- Preparation: Remove covers from oil connections.
- Placement: Align the turbocharger and place it on the engine bracket.
- Fastening: Tighten the fixing screws (using either torque-controlled or angle-controlled methods) while slightly loosening the lifting gear. If the turbocharger is pinned at its feet, one pin hole per foot must be used.
- Final Connections: Remove lifting gear, connect the cable to the speed sensor, and connect all gas, air, and oil pipes.
Maintenance Features
The document outlines important aspects related to the storage and handling of new turbochargers and spare parts, which are crucial for their longevity and proper functioning.
Storage of New Turbochargers and Spare Parts
- Short-term storage (up to 6 months): New turbochargers and spare parts can be stored in their closed packages for up to 6 months from delivery without additional mothballing measures. Storage must be in dry rooms with relative humidity between 40-70% and no condensation.
- Long-term storage (more than 6 months): If requested in the purchase order, turbochargers can be prepared for long-term storage, with the package equipped with a hygrometer. For parts with a Volatile Corrosion Inhibitor (VCI) label, specific instructions must be followed.
VCI Handling and Maintenance
- Health Protection: VCI products are not hazardous but require proper handling: observe material safety data sheets, ensure proper ventilation, do not eat/drink/store food at the workplace, clean hands and face after working with VCI. More information is available at www.branopac.com.
- Regular Checks (every 6 months):
- Check the hygrometer (02) in the sight-glass through an opening (01) in the wooden crate. If the display field changes color at the 70% level, the maximum permissible humidity has been exceeded, requiring inspection and repacking by an Accelleron service station.
- Inspect the package for damage. A damaged package also requires inspection and repacking by an Accelleron service station.
- Open the package, remove the old VCI corrosion protection emitter, replace it with a new one (obtainable from www.branopac.com), and dispose of the old emitter environmentally.
- Seal the package tightly for prolonged protection.
- Every 3 years: An Accelleron service station must inspect the component, replace the desiccant agent, and repackage the component.
- Unpacking: The corrosion protection effect ends once the material is unpacked from the VCI package. To prevent condensation, the surroundings and package contents must be at the same temperature during unpacking.
Safety and Occupational Safety
- General Safety: Always wear safety footwear and protective clothing to protect against mechanical hazards. Keep personal protective equipment in perfect condition and obey mandatory signs. Observe general rules for occupational safety and accident prevention. Only perform operations described in the document and for which you have received instruction or training.
- Lifting Loads: Use properly functional lifting gear with sufficient load limits. Ensure correct attachment of loads on the crane hook. People must not stand beneath suspended loads. If multiple suspension points are used, the attachment angle of 45° must not be exceeded. Use suitable edge guards for sharp edges. Assembly devices must be fully screwed in and not unscrew during use.
- Risk of Falling: Do not climb onto the turbocharger or attached parts. Use suitable climbing aids and working platforms for work above body height.
- Workplace Conditions: Only work when physically and psychologically stable, with suitable and properly functioning tools. Keep the workplace clean, clear of loose objects and obstacles. Have oil binding agents and oil pans ready.
- Welding: When welding near the turbocharger, cover the filter silencer to prevent damage to the filter mat. Keep flammable objects away from flying sparks. Cover all connections to prevent foreign objects from entering. Wear personal protective equipment (PPE) for welding.
- Rotating Parts: Secure the rotor against turning to prevent severe injury from contact with rotating parts.
- Operating Materials: Handle oils, greases, coolants, cleaning agents, solvents, and acids with care. Avoid inhaling vapors and skin contact. Ensure proper ventilation. Observe material safety data sheets and comply with local legislation. Wear safety goggles, gloves, and a respiratory mask if necessary.
The Operation Manual for the turbocharger, identified by its serial number on the rating plate, is available online at www.accelleron-industries.com and must be consulted for commissioning, operation, maintenance, and ordering spare parts.
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