(1-2) Main Engine (Wartsila)

WARTSILA 46
Diesel-Engine Material
Installation:
FLENDER WERFTAB
NB682
Ensine tvne:
4xl2V46C
Eneine number:
91361 - 91364
MANUAL
Superfast XI
-f
/*
WAtlTSILA
WARTSILA 46
DIESEL-ENGINE MATERIAL
PROJECT:
FLENDER WERFTAB, NB682,
4xl2V46C, eng.nns 91361 - 91364
DELIVERY DOCUMENTS FOR

WARTSILA 46-ENGINE
Wartsila Finland Oy
StAlarminkatu 45. FIN-20810 Turku, Finland
Tel. +358 10 709 3111. Tlx 62640 wdfi fi
Fax (Service) +358 10 709 3279
Fax (Spare parts) +358 10 709 3181
WARTSILA
1
wArtsilA
Turbolader
Turbocharger
Betriebshandbuch
Operation Manual
TPL 73 - A..
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ABB Turbo Systems Ltd
Wir bestdtigen. dass dieses Betriebshandbuch in Ohentierung We herewith confirm that this Operation Manual has been drawn
an das Produkthaftungs-Gesetz vom 1.1.90 sowie an die ”Euro- up orientated towards the Product Liability Law 1/1/90 as well
paische Maschinen-Richtlinie" erstellt wurde. as to the "European Machinery Directives".
Alle Rechte vorbehalten. We reserve all rights in this document and in the information
Dieses Betriebshandbuch darf- auch auszugsweise - ohne aus- contained herein.
druckliche Genehmigung der ABB Turbo Systems AG weder Reproduction, use or disclosure to third parties without express
vervielfaitigt noch Dritten zuganglich gemacht werden. authority by ABB Turbo Systems Ltd is strictly forbidden.
© Copyright by ABB TURBO SYSTEMS AG 2000 © Copyright by ABB TURBO SYSTEMS Ltd 2000
Anderungen die dem technischen Fortschritt dienen, bleiben vor Design and specifications are subject to change without notice.
behalten.
GedrucKt in der Schweiz auf umweltfreundlichem Naturweisspapier. aus Schwach* und Printed in Switzerland on envirommental fnendliness r«ture white paper, from forest
Sageresthotz. 100% chiorfrei gebleicht thinnings and sawmill offcuts. 100% chlorine free bleached
»IPIP
ABB Turbo Systems AG
Haselstr. 16
CH-5401 Baden
Switzerland
Turbocharger TPL 73 - A.. Seite / Page 3
Inhattsverzeichnis Table of contents
Vorbemerkungen Preliminary remarks 0

HZTL10409
Sicherheits- und Gefahren- Instructions on safety and 1

hinweise hazards
HZTL 10307
Inbetriebnehmen Putting into operation 2

HZTL 10414
Betrieb und Unterhalt Operation and maintenance 3

HZTL 10412
Beheben von Storungen Troubleshooting 4

HZTL 10403
Demontage und Montage Disassembly and assembly 5

HZTL 10411
Ausserbetriebnehmen Taking out of operation 6

HZTL10416
Anhang Appendix 7
HZTL 10415
Service - Stellen Verzeichnis Guide to service stations 8

HZTL 97350
Betriebshandbuch Kurzfassung Operation manual abridged 9

version
ABB Turbo Systems Ltd ZTL 2460-CH A nil

-C-
Vorbemerkungen
Preliminary remarks
Turbocharger TPL Seite / Page 1
Vorbemerkungen Kap. / Chap. 0 Preliminary remarks
0 0
Vorbemerkungen Preliminary remarks
Inhalt Seite Contents Page
1 1
Vorwort 3 Foreword 3
2 2
Funktionsbeschreibung 5 Mode of operation 5
3 3
BestimmungsgemasseVerwendung 6 Correct application 6
4 4
Organisatorische Massnahmen 7 Organizational measures 7
5 5
Originalteile und Sicherheit 7 Original parts and safety 7
6 6
Befahigung des Personals 8 Qualification of personnel 8
7 7
Kundendienst 8 After-sales service 8
8 8
Ausfuhrungsvarianten 8 Various models 8
9 9
Lagern neuer Storage of new
Turbolader 9 turbochargers 9
10 10
Abkurzungen 9 Abbreviations 9
11 11
Leistungsschild Turbolader 10 Rating plate Turbocharger 10
Volume; 11 pages
Edition: 11 / 99
HZTL 10409 A »ll

ABB Turbo Systems Ltd -E-
Seite / Page 2 Turbocharger TPL
Vorbemerkungen Kap. / Chap. 0 Prelininary remarks
A IM» 10409
-E- ABB Turbo Systems Ltd
1 1
Vorwort Foreword
Dieses Betriebshandbuch hilft Ihnen, den von ABB This operation manual will help you to become familiar
Turbo Systems AG gelieferten Turbolader besser ken- with your turbocharger supplied by ABB Turbo Sy
nenzulernen und seine bestimmungsgemasse Einsatz- stems Ltd and to utilize it to full effect in its intended
moglichkeit wirkungsvoll zu nutzen. application.
Dieses Betriebshandbuch gibt Ihnen wichtige Hinwei- This operation manual provides important instructions
se, damit Sie diesen Turbolader sicher, sachgerecht as to the safe, correct, and economical operation of
und wirtschaftlich betreiben konnen. Sie finden hilfrei- the turbocharger. It contains helpful information on
che Informationen, mit denen Sie Gefahren fruhzeitig how to recognize hazards at an early stage and avoid
erkennen und vermeiden kdnnen, Reparaturkosten und them, how to reduce repair costs and standstill times,
Ausfallzeiten vermindern sowie Zuverlassigkeit und and howto improve the reliability and the service life
Lebensdauer des Turboladers erhdhen kdnnen. of the turbocharger.
Dieses Betriebshandbuch erganzt und erweitert be- This operation manual is a complement to, and an
reits bestehende nationale Vorschriften zum Unfall- extension of, existing national regulations on accident
schutz und zur Unfallverhutung. protection and prevention.
Dieses Betriebshandbuch muss standig am Einsatz- This operation manual must be available at all times
ort des Turboladers verfugbar sein. at the site of operation of the turbocharger.
Dieses Betriebshandbuch ist unbedingt vor Arbeits- It is essential that this operation manual is read before
beginn von alien Personen zu lesen, die mit dem beginning operation by all persons working with or at
Oder am Turbolader arbeiten. the turbocharger.
Auch Personal, das nur gelegentlich (z.B. bei Monta Even personnel only working occasionally (e.g.
ge und Wartung) an der Maschine tatig ist, muss das installation and maintenance) must have read and
Betriebshandbuch gelesen und verstanden haben. fully understood the manual before working on the
turbocharger.
Die Anweisungen sInd unbedingt zu befolgen.
All instructions must be strictly observed.
Das gilt besonders fur die allgemeinen und speziellen
Sicherheltshinweise vor und in den entsprechenden This applies especially to the general and special
Kapiteln. safety instructions preceding, and in the course of,
the respective chapters.
Fragen Sie In Zweifeisfallen den fur Ihren Bereich zu-
standigen Beauftragten fur Sicherheit und Unfall- In the event of doubt, consult the officer for safety
schutz. and accident protection responsible for your area.
10409 A III!
Selte / Page 4 Turbocharger TPL
Fig. 0-1
Schnittdarstellung Turbolader
Section of the Turbocharger
A »l» 10409
2 2
Funktionsbeschreibung Mode of operation
Der Turbolader besteht aus zwei Stromungs- The turbocharger consists of two machines, a turbine
maschinen, einer Turbine und einem Verdichter, die and a compressor which are mounted on a common
auf einer gemeinsamen Welle angebracht sind. shaft.
Die Abgase des Diesel- Oder Gasmotores strbmen The exhaust gases from the diesel or gas engine flow
durch das Gaseintrittsgehause (7) und den DCisenring through the gas inlet casing (7) and nozzle ring (8) to
(8) auf das Turbinenrad. the turbine wheel.
Das Turbinenrad (9) nutzt die im Abgas enthaltene The turbine (9) uses the energy contained in the
Energie zum Antrieb des Verdichterrades (12), wobei exhaust gas to drive the compressor (12), whereby
durch den Verdichter Frischluft angesaugt und vor- the compressor draws in fresh air, compresses it
verdichtete Luft in die Zylinder gedruckt wird. before being forced into the cylinders.
Die Abgase gelangen durch die am Gasaustritts- The exhaust gases exit the turbocharger via the gas
gehSuse (6) angeschlossene Abgasleitung ins Freie. outlet casing (6).
Der Turbolader ist gasdicht. The turbocharger is gastight.
Die Luft, die fur den Betrieb des Diesel- Oder Gasmo- The air which is necessary for the operation of the
tors benotigt und im Turbolader verdichtet wird, ge- diesel or gas engine and which is compressed in the
langt durch den Saugstutzen Oder den Schall- turbocharger, is drawn through the suction branch or
dampfer (1) in das Verdichterrad (12). Sie durchstrbmt the silencer (1) into the compressor wheel (12). It
den Diffusor (11) und verlasst den Turbolader durch then passes through the diffuser (11) and leaves the
den Druckstutzen am Luftaustrittsgehause (13). turbocharger through the volute of the air outlet housing
(13).
Der Rotor lauft in zwei radialen Gleitlagern (2/5) wei-
che sich in der Lagerbuchse (4) zwischen Verdichter The rotor runs in two radial plain bearings (2/5)
und Turbine befinden. Das axiale Schublager (3) be- which are located in the bearing bush (4) between the
findet sich auf der Verdichterseite. compressor casing and turbine casing. The axial
thrust bearing (3) is on the compressor side.
Die Gleitlager sind an einem zentralen Schmierbl-
kanal angeschlossen, der vom Schmierolkreislauf des The plain bearings are connected to a central
Motors gespeist wird. Der Olaustritt liegt immer an lubricating oil feed in which the oil is supplied by the
dertiefsten Stelle des Lagergehauses (10). oil system of the engine. The oil outlet is always at
the lowest point of the bearing casing (10).
10409 iV IIII
ABB Turbo Systems Ltd -E- P\MWW
Vorbemerkungen Kap. I Chap. 0 Prelininary remarks
3 3
Bestimmungsgemasse Correct application
Verwendung
Dieser von ABB Turbo Systems gelieferte Turbolader This turbocharger supplied by ABB Turbo Systems
ist ausschliesslich fur den Einsatz an Dieselmotoren has been developed exclusively for use on diesel
entwickelt worden, urn die fur den Betrieb des Diesel- engines to generate the volume of air and the pressure
motors benotigte Luftmenge und den notwendigen necessary for the operation of the diesel engine.
Ladedruck zu erzeugen.
Any other usage shall be regarded as a special
Jeder dariiber hinausgehende Gebrauch gilt als application which must be clarified with ABB Turbo
Sonderanwendung, die ABB Turbo Systems abkiaren Systems. The manufacturer accepts no liability for
muss. Fur weitergehende Anwendungen haftet der other applications.
Hersteller nicht.
This turbocharger was built in accordance with state
Dieser Turbolader ist nach dem Stand der Technik of the art technology and the recognized safety
und nach den anerkannten sicherheitstechnischen regulations and is safe for operation.
Regein gebaut und betriebssicher.
Nonetheless, the turbocharger can cause injury or
Vom Turbolader kbnnen dennoch Gefahren fur Leib death to the user or a third party, or damage to the
und Leben des Benutzers Oder Drifter ausgehen Oder turbocharger itself or to other property if it is not
der Turbolader und andere Sachwerte beschadigt wer- operated by trained personnel, or if it is used
den, wenn er nicht von geschultem Personal Oder incorrectly, or for purposes other than that for which
nicht sach- und bestimmungsgemSss eingesetzt wird. it was intended.
Bestimmungsgemasses Verwenden des Turboladers Correct application of the turbocharger also includes
schliesst auch das Einhalten der Betriebs-, Wartungs- observation of the operating, maintenance and repair
und Instandhaltungsbedingungen ein, die vom Her conditions specified by the manufacturer.
steller vorgeschrieben sind.
The turbocharger should only be operated and used
Der Turbolader darf nur in technisch einwandfreiem in a technically perfect condition, for its intended
Zustand, seiner Bestimmung entsprechend und unter purpose and in compliance with the operation manual.
Beachtung des Betriebshandbuches bedient und be-
nutzt werden. Defects which could affect safety must be eliminated
immediately.
Stdrungen, die die Sicherheit beeintrachtigen konnen,
sind umgehend zu beseitigen. The manufacturer shall not accept liability for damages
resulting from unauthorized alterations to, or
Eigenmachtige Veranderungen am Turbolader interference with, the turbocharger.
schliessen eine Haftung des Herstellers fur daraus
entstehende Schaden aus. The turbocharger has been designed for the diesel
engine described including speed and output. If it is
Der Turbolader ist fur den Dieselmotor, einschliess- used otherwise ABB Turbo Systems reserves the rigth
lich Drehzahl und Leistung, spezifiziert. Wird er an- to reject all guarantee claims.
derweitig verwendet, lehnt ABB Turbo Systems alle
Garantieanspriiche ab.
A ll» 10409
4 4
Organisatorische Organizational
Massnahmen measures
Erganzend zum Betriebshandbuch sind zusatzlich die In addition to this manual, the general, statutory
allgemeinen, gesetzlichen Vorschriften zur Unfallver- regulations applicable in the respective country for
hutung und zum Umweltschutz im Verwenderland zu the prevention of accidents and the protection of the
beachten. environment must be observed.
Das gilt auch fur das Bereitstellen und Tragen von This also applies to the provision and wearing of
persdniichen Schutzausrustungen. personnel protection equipment.
Unter Beachtung des Betriebshandbuches ist der The safety and risk consciousness of the personnel
sicherheits- und gefahrenbewusste Umgang des Per working at and with the turbocharger shall be checked
sonals an und mit dem Turbolader regelmassig zu regularly in accordance with the manual.
uberprufen.
The turbocharger must be shut down immediately in
Der Turbolader ist bei sicherheitsrelevanten Verande- the event of alterations affecting safety or of
rungen Oder bei entsprechendem Betriebsverhalten so- corresponding operating behaviour. The fault should
fort stilizusetzen. Die Stdrung ist der dafur zustandi- be reported to the person or department responsible.
gen Person Oder Stelle zu melden.
Additions to, and alterations and conversions of the
Veranderungen und An- und Umbauten am Turbo turbocharger, which could impair safety, require the
lader. die die Sicherheit beintrachtigen konnten, mus- prior approval of ABB Turbo Systems.
sen vorher von ABB Turbo Systems genehmigt wer-
den.
5 5
Originalteile und Sicherheit Original parts and safety
Originalteile und Zubehor sind speziell fur den von Original parts and accessories are especially designed
ABB Turbo Systems AG gelieferten Turbolader konzi- for the turbocharger supplied by ABB Turbo Systems
piert. Ltd.
Wir machen ausdrucklich darauf aufmerksam, dass We wish to state clearly that parts and accessories
nicht von uns gelieferte Originalteile und Zubehor auch not supplied by us have not been tested and approved
nichtvon uns gepruft und freigegeben sind. by us.
Der Einbau und / Oder die Verwendung solcher Pro- The installation and / or the use of such products can
dukte kann daher die konstruktiv vorgegebenen Ei- thus have a negative effect on design features of the
genschaften des Turboladers negativ verandem. turbocharger.
Dadurch kann die aktive und / Oder passive Sicher This in turn can be detrimental to the active and / or
heit des Turboladers nachteilig beeinflusst werden. passive safety of the machine.
Fur Schaden, die durch das Verwenden von Nicht- ABB Turbo Systems shall not be liable for any damage
Originalteilen und entsprechendem Zubehor entste- caused by using non-original parts and accessories.
hen, schliesst ABB Turbo Systems jede Haftung aus.
ABB Turbo Systems Ltd 10409 Al IM»

-E-
Vorbemerkungen Kap. / Chap. 0 Prelintnary remarks
6 6
Befahigung des Personals Qualification of personnel
Der Turbolader darf nur von ausgebildetem und autori- The turbocharger may only be operated and maintained
siertem Personal bedient und gewartet werden. by skilled and authorized personnel.
Arbeiten an mechanischen Bauteilen, wie Lagern Oder Work on mechanical components, such as bearings
Rotoren durfen nur von Fachpersonal durchgefuhrt or rotors may only be carried out by expert personnel
werden, das von ABB ausgebildet ist. trained by ABB.
Es ist sicherzustellen, dass nur dazu beauftragtes It must be ensured that only authorized personnel
Personal am Turbolader tatig wird. work on the turbocharger.
7 7
Kundendienst After-sales service
Fur Ersatzteilbestellungen, technische Ruckfragen und For spare parts orders, technical inquiries and
Wartungsarbeiten finden Sie am Ende von diesem maintenance work there is a list at the end of this
Handbuch (s. Kap. 8) eine Liste mit einer aktuali- manual (see chap. 8) with an updated, worldwide
sierten, weltweiten Ubersicht von Service-Stationen guide to service stations of ABB Turbo Systems Ltd.
der ABB Turbo Systems AG.
8 8
Ausfuhrungsvarianten Various models
Dieses Betriebshandbuch und das Verzeichnis der This instruction manual and the parts directory (see
Teilenummern (s. Kap. 7) sind gultig fur unterschied- chap. 7) are valid for various turbocharger models.
liche Ausfuhrungsvarianten von Turboladern.
For this reason it can occur that parts are listed in
Deshalb kann es vorkommen, dass im Verzeichnis the parts directory which are not present on the
der Teilenummern auch Teile aufgelistet sind, die turbocharger supplied.
beim gelieferten Turbolader nicht vorhanden sind.
Jk IIII 10409
/MPIP -E- ABB Turbo Systems Ltd
T urbocharger TPL Seite / Page 9
9 9
Lagern neuer Turbolader Storage of new turbochargers
Von ABB Turbo Systems neu gelieferte Turbolader Turbochargers supplied by ABB Turbo Systems can
sind ab Lieferdatum 6 Monate lang, ohne zusatzliche be stored for 6 months as from the date of delivery
Konser-vierungsmassnahmen, an trockenen Often mit without any additional conservation measures in a
einer durchschnittlichen Luftfeuchtigkeit von 40 bis dry place with an average air humidity of 40 to 70 %.
70% lagerbar. After 6 months and every following period of 6 months
Nach Ablauf von 6 Monaten und dann alle 6 Monate, spray rust -proofing oil on the surfaces (remove
die Oberflache (Isolation entfernen) und alle zugang- insualtion) and on all accessible areas.
lichen Raume mit Korrosionsschutzdl einspruhen.
10 10
Abkurzungen Abbreviations
Folgende Abkurzungen werden verwendet: The following abbreviations are being used:
Abschn. Abschnitt CE Compressor end

chap. Chapter
bzw. beziehungsweise
eg- For example
Fig. Abbildung
îg Figure
Kap Kapitel
kpl. komplett
No. Number
Nr. Nummer sec. Section
s. siehe Temp. Temperature

TC Turbocharger
Tab, Tabelle TE Turbine end
Temp. Temperatur
TL Turbolader Working steps / Enumerations
TS Turbinenseite Add. working steps for options
u.d.M. uber dem Meer - J- Notes for assembling
VS Verdichterseite
C€ Conformite Europeenne
zB zum Beispiel
Arbeitsschritte / Aufzahlungen
+ zus. Arbeitsschritte bei Optionen
- J- Hinweise ftir den Zusammenbau
Conformite Europeenne
ABB Turbo Systems Ltd 10409 Jk III!

-E- iP\IPIP
Seite/Page 10 Turbocharger TPL
11 11
Leistungsschild Turbolader Rating plate Turbocharger
ABB Turbo Systems Ltd -

Alin Turbocharger
Type HT
n (D 1 t Q)
Mmax Mmax
s
^ n Bmax t Bmax
(D °c
ji (7) (8) kg (T) ffl ~(J)
j Applicationaccordingto
I theOperstionManual
made in Switzerland
C€
Einsatzgrenzen: Application limits:
n Mmax’ t Mmax' Turbolader - Einsatzgrenzen n Mmax’ t Mmax' Turbocharger - application

bei Motoruberlast (110%). limit at engine overload
Nur im Priifstandbetrieb, (110%).
wenn nicht anders mit dem For test trials only, if not
Motorenbauer vereinbart. otherwise agreed with the
engine manufacturer.
(D
n Bmax’
t Bmax* Turbolader - Einsatzgrenzen
im Betrieb (D n Bmax’ t Bmax* Turbocharger - application
limits in service.
n = T urbolader - Drehzahl
n = Turbocharger speed
t = Abgastemperatur vor Turbine
t = Exhaust gas temperature before turbine
Kontrollintervalle und Wechsel- Inspection and replacement inter

zeiten von Turboladerkomponenten: vals for turbocharger components:
® Kontroll-lntervalle der Gleitlager in 1000 h (D Checking intervals for the plain bearings in 1000 h
Wechselzeit des Verdichters in 1000 h Replacement interval for the compr. wheel in 1000 h
^ Unless otherwise stated: lOO'OOO h
Ohne Angaben: lOO'OOO h
Wechselzeit der Turbine in 1000 h ® Replacement interval for the bladed shaft in 1000 h
Ohne Angaben: lOO'OOO h Unless otherwise stated: lOO'OOO h
Weitere Angaben: Further descriptions:

Kunden Part-Nummer ® Customer part-number
®
Feld fur die Sonderausfuhrungsbezeichnung ® Space for the special design designation
®
Gewicht des Turboladers in kg ® Weight of the turbocharger in kg
ik II l» 10409
#^lilP -E- ABB Turbo Systems Ltd
Kap./Chap. 0 Preliminary remarks

Vorbemerkungen
The conditions agreed with the engine

FCir die auf dem Leistungsschild angege- Note
Hinweis manufacturer apply to the values stated
benen Werte bezOglich Einsatzgrenzen,
the rating plate with regard to
Kontrollintervalle und Wechselzeiten gel- on
application limits, checking intervals and
ten die mit dem Motorenbauer verein-
replacement times. Otherwise the
barten Bedingungen. Andernfalls die Be-
conditions according to ISO 3046/1:
dingungen nach ISO 3046/1:
Umgebungsdruck = 100 kPa (1 bar) Ambient air pressure
= 25°C (298 K) Air intake temperature
Ansauglufttemperatur
= 25X (298 K) Cooling water inlet temp, at charge air cooler
Kuhlwasser-Eintrittstemp. zum Ladeluftkuhler tKWE
Angaben auf dem Leistungsschild Rating plate information
[U
Typ
Type
TPL73 A30
3 n Mmax 360
t 650 rc]
HT HT 442260 Mmax
Angaben in 1000 h n
342 11]
Bmax
Descriptions in 1000 h
Kontrollintervalle der Gleitlager rc]
t Bmax
Checking intervals for the plain bearings
Wechselzeit des Verdichters

Repl. interval for the compr. wheel
Wechselzeit der Turbine 50

Repl. interval for the bladed shaft
A
Vorsicht!
Der Turbolader darf nur bis zu den auf
dem Leistungsschild angegebenen Ein-
satzgrenzen n_Bmax’ tg^^ betiieben werden.
Caution I The turbocharger is to be used only up
to the application limits specified on the
rating plate n Bmax . t Bmax' These are
determined with the engine manufacturer
Diese sind mit dem Motorenbauer an-
for the specific application.
wendungsspezifisch festgelegt.
Unless otherwise agreed application
Einsatzgrenzen n„^^^ , t Mmax sind, wenn are allowed for test trials
nicht anders vereinbart, nur im Pruf- limits n
Mmax max
standbetrieb zulassig. only.
The checking intervals and replacement

Die Kontrollintervalle und Wechselzeiten
times for the turbocharger components
der angegebenen Turboladerkompo-
specified must be observed without fail!
nenten sind unbedingt einzuhalten!
Turbocharger components whose per
Turboladerkomponenten mit abgelaufe-
missible operating times have expired
Betriebsdauer dOrfen unter keinen
ner may not be used again under any cir
Umstanden waiter venwendet warden!
cumstances!
A IMI
Turbocharger TPL Seite/Page 11
Hinweis Fur die auf dem Leistungsschild angege- The conditions agreed with the engine
benen Werte bezuglich Einsatzgrenzen. manufacturer apply to the values stated
Kontroilintervalle und Wechselzeiten gel- on the rating plate with regard to
ten die mit dem Motorenbauer verein- application limits, checking intervals and
barten Bedingungen. Andernfalls die Be- replacement times. Otherwise the
dingungen nach ISO 3046/1: conditions according to ISO 3046/1:
Umgebungsdruck p^ = 100 kPa (1 bar) Ambient air pressure
Ansauglufttemperatur = 25”C (298 K) Air intake temperature
Kuhlwasser-Eintrittstemp. zum Ladeluftkuhler t KWE = 25X (298 K) Cooling water inlet temp, at charge air cooler
Typ
Type
TPL73 A30 n Mmax 360 a]
t
HT HT 442259 Mmax 650 rc]
Angaben in 1000 h 342

n Bmax
Kontroilintervalle der Gleitlager
Checking intervals for the plain bearings L 12 t
Bmax 620 [X]

50
Wechselzeit der Turbine

50
A
Vorsicht! Der Turbolader darf nur bis zu den auf
dem Leistungsschild angegebenen Ein
satzgrenzen n^^, tg^ betrieben werden.
Caution ! The turbocharger is to be used only up
rating plate These are
Diese sind mit dem Motorenbauer an- determined with the engine manufacturer
wendungsspezifisch festgelegt. for the specific application.
Einsatzgrenzen sind, wenn Unless otherwise agreed application
nicht anders vereinbart, nur im Pruf- limits n„ , 1. are allowed for test trials
standbetrieb zulSssig. only.
Die Kontroilintervalle und Wechselzeiten The checking intervals and replacement

der angegebenen Turboladerkompo- times for the turbocharger components
nenten sind unbedingt einzuhalten! specified must be observed without fail!
Turboladerkomponenten mit abgelaufe- Turbocharger components whose per
ner Betriebsdauer durfen unter keinen missible operating times have expired
Umstanden weiter verwendet werden! may not be used again under any cir
cumstances!
ABB Turbo Systems Ltd A IIII

Kap. / Chap. 0 Preliminary remarks

Vorbemerkungen

Fur die auf dem Leistungsschild angege- Note
benen Werte bezuglich Einsatzgrenzen,
conditions according to ISO 3046/1;
= 25X (298 K) Air intake temperature
Kuhlwasser-Eintrittstemp. zum Ladetuflkuhler tKWE
Typ n 360 [^]

TPL73 A30 Mmax
Type
t rc]
HT HT 442581 □ Mmax
650
Angaben in 1000 h
n
342 [1]
Bmax
Kontrollintervalle der Gleitlager ( t rc]
12 620
Checking intervals for the plain bearings 1. Bmax
Wechselzeit des Verdichters 50



rating plate n Bmax . t Bmax . These are
satzgrenzen n_Bmax' tg^^ betrieben werden. determined with the engine manufacturer
Einsatzgrenzen n Mmax’ max sind, wenn are allowed for test trials
nicht anders vereinbart, nur im Pruf- limits n
Mmax max
standbetrieb zuiassig. only.

Betriebsdauer durfen unter keinen
Umstanden welter verwendet werden!
cumstances!
a IIII
p\nn

Vorbemerkungen

Kuhlwasser-Eintrittstemp. zum Ladeluftkuhler tKWE
Typ n Mmax 360 [1]

TPL73 A30
Type
rc]
HT 442582 D t 650
c
Mmax
HT
n Bmax
Kontroliintervalle der Gleitlager rc]
12 t Bmax
620

RepL interval for the compr. wheel

A
satzgrenzen n , tg^ betrieben werden.
Caution 1 The turbocharger is to be used only up
rating plate n Bmax , t Bmax . These are
Einsatzgrenzen n„^^, , t Mmax sind, wenn are allowed for test trials
nicht anders vereinbart, nur im Pruf- limits n .tM
Mmax max

Turboladerkomponenten mil abgelaufe- Turbocharger components whose per
Umstanden weiter verwendet werden!
cumstances!
ik ll»
Kap./Chap. 0 Preliminary remarks

Vorbemerkungen

= 25'*C (298 K) Cooling water inlet temp, at charge air cooler
Kuhtwasser-Eintrittstemp. zum Ladeluftkohler t KWE
Typ TPL 73 A30 n Mmax 360

Type
t 650 rc]
HT HT 442391 Mmax
342
Angaben in 1000 h n Bmax [h
Kontrollintervalle der Gleitlager t 620 rc]
12 Bmax


A
satzgrenzen n Bmax , betrieben werden.
Caution I The turbocharger is to be used only up
rating plate n Bmax LBmax . These are
Einsatzgrenzen ..... sind, wenn
max
limits n t are allowed for test trials
nicht anders vereinbart, nur im Pruf- Mmax' wmax

cumstances!
ii ll»
ABB Turbo Systems Ltd F\nn

Vorbemerkungen

dingungen nach ISO 3046/1;
= 2S°C (298 K) Air intake temperature
= 25"C (298 K) Cooling water inlet temp, at charge air cooler
Kuhtwasser-Eintrittstemp. zum Ladeluftkuhler t KWE
Typ
Type
TPL73 A30
D n Mmax 360
t 650 rc]
HT HT 442390 Mmax

n Bmax
Kontrollintervalle der Gleitlager t
12 Bmax
620 rc]


A
Vorsicht I Der Turbolader darf nur bis zu den auf
satzgrenzen n_Bmax' tg^ betrieben werden.
rating plate n Bmax’. LBmax . These are
Einsatzgrenzen sind, wenn
max
limits n t^ _ are allowed for test trials
nicht anders vereinbart, nur Im Pruf- Mmax max

cumstances!
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Vorbemerkungen

Hinwreis Fur die auf dem Leistungsschild angege-
manufacturer apply to the values stated
benen Werte bezOglich Einsatzgrenzen,
dingungen nach ISO 3046/1;
Umgebungsdruck p^, = 100 kPa (1 bar) Ambient air pressure
= 25'’C (298 K) Air intake temperature
KCihlwasser-Eintrittstemp. zum Ladeluftkuhler t
KWE
[^1
Typ
Type
TPL73 A30
□ n Mmax 360
t 650 rc]
HT HT 442485 Mmax

n Bmax
Kontrollintervalle der Gleitlager t 620 rc]
12 Bmax

Wechseizeit der Turbine 50

A
satzgrenzen n , tg^ betrieben werden.
rating plate n Bmax LBmax . These are
Diese Sind mit dem Motorenbauer an-
Einsatzgrenzen n„„^^ Sind, wenn
limits n Mmax t are allowed for test trials
max
nicht anders vereinbart, nur im Pruf- ' ^max

cumstances!
A IM»
ABB Turbo Systems Ltd p\wn

Vorbemerkungen

on
Kontrollintervalle und Wechselzeiten gel-
Ansauglufttemperatur = 25'^C (298 K) Air intake temperature
= 25^C (298 K) Cooling water inlet temp, at charge air cooler
Kuhlwasser-Eintrittstemp. zum Ladeluflkuhler t KWE
Typ
Type
TPL73 A30
□ n Mmax 360
t 650 [°c]
HT HT 442484 Mmax

n Bmax
Kontroliintervalle der Gleitlager t 620 [X]
12 Bmax


A
satzgrenzen n Bmax’ tg^^ betrieben werden.
rating plate n Bmax , t Bmax . These are
wendungsspezifisch festgeiegt.
Einsatzgrenzen n„^ sind, wenn
limits n Mmax’ t are allowed for test trials
max
nicht anders vereinbart, nur im Pruf- ^max
standbetrieb zulSssig. only.

Turbocharger components whose per
Turboladerkomponenten mit abgelaufe-
Bethebsdauer durfen unter keinen
Umstanden weiter verwendet werdenl
cumstances!
A III!
Sicherheits- und Gefahrenhinweise
Instructions on safety and hazards 1
Turbocharger Seite / Page 1
Sicherheits- und Gefahrenhinweise Kap. / Chap. 1 Instructions on safety and hazards
1 1
Sicherheits- und Instructions on safety and

Gefahrenhinweise hazards
1 1
Grundlegende Basic safety
Sicherheitshinweise 3 instructions 3
2 2
Spezielle Special safety
Sicherheitshinweise 4 instructions 4
2.1 2.1
Sicherheit beim Safety when
Anschliessen 4 connecting 4
2.2 2.2
Inbetriebnehmen und beim Betrieb 5 commissioning and during operation 5
2.3 2.3
Reinigen 5 cleaning 5
2.4 2.4
Sicherheit bei Safety when disassembling and
Demontage und Montage 6 assembling 6
2.5 2.5
Stillsetzen 6 shutting down 6
3 3
Gefahrenhinweise und Hazards and
Gefahrenschutz 7 hazard protection 7
3.1 3.1
Mechanische Mechanical
Einflusse 7 influences 7
3.2 3.2
Werk- und Operation and
Arbeitsstoffe 8 process materials 8
3.3 3.3
Larm 10 Noise 10
Volume: 10 pages
Edition: 06/96
HZTL 10307 A llll

L!l: i
}L ■A ? a- i
■ ^;.- 4t « ■«■ •T
k 1 ^ Seite / Page 2 Turbocharger I u
% • 4 '■
herheits- und 4-..-I I. / Chap. 1 (ty and hazards
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10307
/\IPIP ABB Turbo Systems Ltd
1 1
Grundlegende Basic safety

Sicherheitshinweise instructions
Folgende Symbole und Benennungen werden in die- The following symbols and terms are used in this
sem Betriebshandbuch fur Sicherheitshinweise ver- operation manual for safety instructions:
wendet;
Warnung ! Ernsthafte Personenschaden Oder tbdli- Warning ! Serious injury or fatal accident may
che Unfalie kbnnen die Folge sein, wenn result if the working and operation
Arbeits- und Bedienungsanweisungen mit instructions marked with this symbol are
diesem Symbol nicht Oder ungenau be- not, or only partly, observed.
folgt werden.
Warnhinweise rniissen strengstens eingehalten Warning signs must be strictly observed.

werden.
A
Vorsicht! Folgenschwere Maschinen- Oder Sach-
schaden kbnnen die Folge sein, wenn
Arbeits- und Bedienungsanweisungen
A
Caution ! Serious damage to the machine or to
Other property may result if the working
and operation instructions marked with
mit diesem Symbol nicht Oder ungenau this symbol are not, or only partly,
befoigt werden. observed.
Vorsichtshinweise sind genauestens einzuhalten. Caution signs must be observed to the letter.
Hinweis Wirkungsvolleres und einfacheres Arbei- Work can be carried out more efficiently
ten ist die Folge, wenn Arbeits- und and simply when work and operation
Bedienungsanweisungen mit diesem instructions marked with this symbol are
Symbol befoigt werden. observed.
Hinweise erleichtern Ihre Arbeit. Notes help to simplify your work.
10307 Ak IIII
ABB Turbo Systems Ltd ^ÎPIP
Seite / Page 4 Turbocharger
2 2
Spezielle Special safety

Sicherheitshinweise instructions
Die hier aufgefuhrten Hinweise dienen Ihrer Sicher- The instructions here are designed to ensure your
heit und verhelfen Ihnen zu einem sicheren Umgang safety and to promote safe handling of the
mit dem Turbolader und mit seinen Betriebsmitteln. turbocharger and its operating materials.
Befolgen Sie unbedingt diese Sicherheitshinweise These safety instructions must be observed when
beim Betrieb mit und bei Arbeiten am Turbolader. working on or operating the turbocharger.
Nur in physisch und psychisch stabiler Verfas- Work on a turbocharger only in a stable physical
sung am Turbolader tatig werden. and mental condition.
Schutzkieidung (Helm, Gehorschutz, Schutzbril- Wear protective clothing (helmet, ear protection,
le, Schutzanzug, Handschuhe, Sicherheitsschuhe) protective glasses, protective suit, gloves,
tragen. protective shoes).
Einzelteile und grossere Baugruppen sorgfaltig an Attach individual parts and large component modules
geeigneten und technisch einwandfreien Hebe- carefully to suitable lifting devices which are in
zeugen/ Lastaufnahmemittein mit ausreichender technically perfect condition and which possess
Tragkraft befestigen. adequate load-bearing capacity.
Sich nicht unter schwebenden Lasten aufhalten. Do not stand under suspended loads.
Bei Montagearbeiten uber KOrperhohe die dafur For overhead assembly work use the steps and
vorgesehenen Aufstiegshiifen und Arbeitsbuhnen work platforms provided for this purpose.
verwenden.
Do not use machine parts as steps.
Maschinenteile nicht als Aufstiegshiifen benutzen.
If welding work is to be carried out above the
Bei Schweissarbeiten oberhalb des Turboladers turbocharger, the air filter must be covered to
unbedingt den Luftfilter abdecken, damit die Filter- prevent damage to the filter mat.
matte nicht beschadigt wird.
2.1
Sicherheit beim Anschliessen 2.1
Safety when connecting
Nur die Anschlusse fertigstellen, fur die Sie aus-
gebildet sind. Work only on those connections for which you
are qualified.
A IMI 10307
2.2 2.2
Sicherheit beim inbetriebnehmen Safety when commissioning and
und beim Betrieb during operation
Vor Arbeitsbeginn Sichtprufung der Arbeitsumge- Before starting to work make a visual inspection
bung machen. of the working area.
Hindernisse und herumliegende Gegenstande der Remove obstacles and any other objects lying
Arbeitsumgebung beseitigen. around from the work area.
Vor dem Inbetriebnehmen den Turbolader auf Be- Before commissioning check the turbocharger for
schadigungen und Leeks kontrollieren. damage or leaks.
Jede Arbeitsweise unterlassen, die die Sicherheit Refrain from any activity which could impair safety
am Turbolader beeintrachtigen konnte. at the turbocharger.
Turbolader ca. alle 12 Betriebsstunden bzw. min- Inspect the turbocharger approx, every 12 hours
destens einmal pro Tag auf aussere erkennbare or at least once a day for visible external damage
Schaden und MSngel prOfen. and defects.
Schaden und Veranderungen des BetriebsverhaP Report immediately any damage or changes in
tens sofort derzustendigen Person/ Stelle melden. operation performance to the person/department
responsible.
Im Schadensfall Turbolader sofort stillsetzen und
gegen unbeabsichtigtes und unbefugtes Benutzen In the event of damage, shut down the turbo
sichern. charger immediately and secure it against
unintended or unauthorized interference.
2.3 2.3
Reinigen cleaning
Vor dem Reinigen den Boden gegen unbeabsich- Before cleaning, protect the floor against
tigt eindringendes Ol und Betriebsmittel abdich- unintended leaks of oil and operating materials.
ten.
Wear protective clothing (oil- and petrol resistant
Schutzkieidung (6I- und benzinfeste Handschuhe, gloves, protective suit, eye protection, knee
Schutzanzug, Augenschutz, Knieschutz, Fuss- protection, foot protection).
schutz) tragen.
Handle operation materials and detergents with
Mit Betriebs- und Reinigungsmittein ausserst vor- utmost caution.
sichtig umgehen.
When handling solvents, protective clothing must
Beim Umgang mit Losungsmitteln unbedingt be worn. Avoid contact with the skin, inhalation
Schutzkieidung tragen. Hautkontakt, Einatmen und and penetration of clothes.
Durch-nassen der Kleidung vermeiden.
Ater cleaning, check electric cables for signs of
Nach der Reinigung Elektrokabel auf Scheuerst- wear or damage.
ellen und Beschadigungen uberprufen.
10307 il li»
Sicherheits- und Gefahrenhinweise Kap. I Chap. 1 Instructions on safety and hazards
2.4 2.4
Sicherheit bei Safety when
Demontage und Montage disassembling and assembling
Bedienpersonal vor Beginn uber Sender- und In- Inform operating personnel accordingly before
standsetzungsarbeiten informieren. starting any special or maintenance work.
Vorsorglich unter dem Turbolader Auffangwannen As a precaution, place a receptacle for leaking oil
fur Leckbl aufstellen. under the turbocharger.
Rotor vor Beginn der Arbeiten gegen Verdrehen Before starting work secure the rotor against
sichem. turning.
Absorbentien bereitstellen zum Aufnehmen ver- Ensure that absorbent material is available to soak
sehentlich auslaufender Betriebsmittel. up any spilled fluids.
Fur sicheres und umweltschonendes Ablassen, Ensure that operation and process materials are
Auffangen und Entsorgen von Betriebs- und Hilfs- drained, collected and disposed of in a safe and
stoffen sorgen. environmentally compatible manner.
Vorgeschriebene Einstell-, Wartungs- und Ensure that the prescribed, adjustment, mainte
Inspektionsarbeiten und -intervalle einhaiten. nance and inspection work is carried out at the
appropriate intervals.
Angaben zum Teileaustausch beachten.
Observe instructions for replacement of parts.
Abgebaute SIcherheitseinrichtungen mussen unmit-
telbar nach Abschluss der Wartungs- und Repara- Dismantled safety devices must be reassembled
turarbeiten wieder montiert und auf Funktions- and subjected to a function test immediately after
fahigkeit geprtifl werden. conclusion of maintenance and repair work.
Gelbste Schraubenverbindungen wieder nach Vor- Retighten screwed connections in accordance with
schrlft anziehen. the respective regulations.
2.5 2.5
Sicherheit beim Stillsetzen Safety when shutting down
Rotor gegen Drehen sichern. Secure the rotor against turning.
Turbolader vor dem Konservieren reinigen. Clean the turbocharger before mothballing.
Beim Konservieren des Turboladers Schutzklei- Wear protective clothing during mothballing the
dung tragen. turbocharger.
Arbeitsumgebung sauber halten und von Ol und Keep the work area clean and free of oil and
Betriebsmitteln reinigen. operating materials.
Am Boden liegende Hindernisse entfernen. Remove any obstacles laying around on the floor.
A IMi 10307
Sicherheits- und Gefahrenhinweise Kap. I Chap. 1 Instructions on safety and hazards
3 3
Gefahrenhinweise Hazards and
und Gefahrenschutz hazard protection
Beim Betrieb mit und bei Arbeiten am Turbolader Hazards may arise during operation of, and work
konnen Gefahren ausgehen: on, the turbocharger:
vom Turbolader und seinem Zubehdr from the turbocharger and its accessories
von den dabei verwendeten Betriebsmittein from the operating materials used
vom ungenugenden Beachten von Sicherheitshin- from failure to observe safety instructions
weisen
from inadequate maintenance and inspection
vom ungenugenden Ausfuhren von Wartungs- und work.
Prufarbeiten.
3.1 3.1
Mechanische Einfliisse Mechanical influences
Korperschaden Physical injury
Warnung ! Bewusstlosigkeit und Verletzungen durch: Warning ! Unconsciousness and injury due to:
Quetschen, Scheren, Schneiden, Wik- crushing, shearing, cutting, winding,

keln, Zertrummem fragmentation
Einziehen, Stossen, Stechen, Reiben drawing in, knocking, stabbing, rubbing
Herausspritzen von Flussigkeiten unter loss of liquids under high pressure and
Hochdruck und hoher Temperatur high temperature
Rutschen, Stolpern, Sturzen. slipping, tripping, falling
Ursachen Causes
scharfe Kanten, spitze Teile sharp edges, pointed parts

Quetsch-, Scher- und Wickelbereiche crush, shear and winding areas
Heraus- / Wegschleudem von Werkteilen fragmentation of parts
Bruch Oder Bersten von Teilen wegen Qberbean- fracture or rupture of parts due to overload
spruchung.
elastic elements (e.g. springs), liquids and gases
elastische Elemente (Federn), Flussigkeiten und under pressure or in a vacuum
Gase unter Druck Oder im Vakuum
slippery, oily work area, obstacles on the floor
rutschige, olverschmierte Arbeitsumgebung,
Bodenhindernisse.
ABB Turbo Systems Ltd 10307 ii im

Sicherheits- und Gefahrenhinweise Kap. / Chap. 1 instructions on safety and hazards
Schutzmoglichkeiten Protective measures
Leder-Schutzhandschuhe tragen. Wear leather protective gloves
Eng anliegende Schutzkieidung tragen. Wear close-fitting protective clothing
Langere Bart- und Kopfhaare zusammenbinden, Tie up long hair and beards, wear hair protection
Haarschutz tragen.
Wear face and eye protection
Gesichts- und Augenschutz tragen.
Wear protective shoes
Sicherheitsschuhe tragen.
Keep floor, equipment and the turbocharger clean
Boden, Gerate und Turbolader sauberhalten.
Ensure the availability of oilabsorbing materials
Clabsorbentien bereithalten und Olauffangwannen and have oil collector basins ready or in position
bereitstellen Oder aufstellen.
Eliminate leaks
Leckagen beseitigen.
Do not stay neither close nor radially to the
Aufenthalt nahe Oder radial neben dem Turbo turbocharger while engine is running at > 85%
lader bei Betrieb > 85% Motorlast ist zu vermei- rated output.
den.
3.2 3.2
Werk- und Arbeitsstoffe Operation and process materials
Das Sind chemische Substanzen wie Ole, Fette, Kiihl- This Includes all substances such as oil, grease,
flussigkeit, Reinigungs- und Ldsungsmittel, Sauren coolant, detergents and solvents, acids and other
und andere Gefahrenstoffe. hazardous substances.
Korper- und Sachschaden Physical injury and damage to property
Warnung ! Allergien, Hautschaden, Bewusstlosig- Warning ! Allergies, skin disease, unconscious

keit, Vergiftung Oder Benommenheit ness, poisoning or nausea after inha
nach Einatmen. lation
Verletzungen durch Verbruhen und Ver- Injury by scalding and burning of the
brennen der Haut. skin
Veratzungen durch Dampfe Oder Sau- Burning by vapours or contact with acids
re- und Laugenkontakt. or alkalis
Vorsicht! Umweitverschmutzung und Schadigung Caution ! Environmental pollution due to leakage

durch Auslaufen und Eindringen von of operation and process materials and
Werk- und Arbeitsstoffen in Boden und penetration into soil and water.
Gewasser.
10307
Ursachen Causes
Einatmen von schSdlichen Gasen, Nebein und Inhalation of toxic gases, smoke and vapours
Dampfen
Skin contact with aggressive fluids
Hautkontakt mit schSdlichen Flussigkeiten
Clothing wet or soaked with hazardous substances
Mit Gefahrenstoffen benetzte Oder durchtrankte
Arbeitskleidung Spilling and tipping over of vessels with operation
materials
Auslaufen und Umkippen von Behaitern mit
Arbeits-stoffen Leakages
Auslaufen durch Leckagen Tanks and collectors which are not gas-tight and
which do not comply with the regulations on
Nicht gasdichte und nicht der Gefahrenstoffverord- hazardous substances
nung entsprechende Behaiter und Sammelcon-
tainer Burning cigarettes or naked flame in the proximity
of operation materials
Brennende Zigaretten Oder offenes Feuer beim
Umgang mit Arbeitsstoffen.
Protection measures
Schutzmoglichkeiten Utmost caution when handling operation and

process materials.
Hochste Vorsicht beim Umgang mit Arbeits- und
Werkstoffen. Protective clothing must be worn (oil-proof, sol
vent-proof and acid-proof gloves, impermeable
Unbedingt Schutzkieidung tragen (olfeste, protective clothing, respiratory protection).
losungs-mittelfeste und saurefeste Handschuhe,
dichte Schutzanzuge, Atemschutz). Avoid skin contact and inhalation.
Hautkontakt und Einatmen unbedingt vermeiden. Ensure that the workroom is properly ventilated.
Fur ausreichende Be- und Entluftung des Arbeits- Observe the hazard indications on the containers
raumes sorgen. for operation and process materials.
Gefahrenhinweise auf den Behaltern der Werks- Immediately after use, sea! the hazardous
und Arbeitsstoffe beachten. substance container tight.
Gefahrenstoffbehalter nach Gebrauch sofort dicht Used operation materials must be collected safely
verschliessen. in accordance with the legal provisions, stored
separately in suitable containers as prescribed,
Alt-Betriebsmittel entsprechend den gesetzlichen and disposed of as special waste in an environ
Vorschriften sicher auffangen, in geeigneten, vor- mentally compatible manner.
geschriebenen Behaltern getrennnt aufbewahren
und als Sondermull umweitgerecht entsorgen. Ensure that containers with new / used operation
materials are sealed tight.
Behalter mit Neu- / Alt-Betriebsmittein sicher und
dicht verschliessen. In the event of leaks or spills immediately apply a
suitable absorbent material and dispose of this in
Bei Leckagen Oder nach Verschutten sofort ge- an environmentally compatible manner as special
eignete Absorbentien ausstreuen und diese um waste.
weitgerecht als Sondermull entsorgen.
10307 Jl IMI
Seite/Page 10 Turbocharger
Sicherheits-und Gefahrenhinweise Kap. / Chap. 1 instructions on safety and hazards
3.3 3.3
Larm Noise
Korperschaden Physical injury
Warnung ! Horverlust, Taubheit, SchwerhSrigkeit Warning ! Loss of hearing, deafness
Gesundheitsstdrungen wie Verlust des Impairments of health such as loss of

Gleichgewichts. des Bewusstseins und balance or of consciousness, cardiac
Herz-/Kreislaufstdrungen. and circulatory disturbances.
Ursachen Causes
Maschinengerauschpegel uber 90 dB (A). Machine noise level In excess of 90 dB (A)
Schutzmoglichkeiten Protective measures
Gehorschutz tragen. Wear ear protection
ik IMI 10307
Inbetriebnehmen
Putting into operation 2
Inbetriebnehmen Kap. / Chap. 2 Putting into operation
2 2
Inbetriebnehmen Putting into operation
1 1
Olversorgung 3 Oil supply 3
1.1 1.1
Olfiltrierung 3 Oil filtration 3
1.2 1.2
Oldruck / Oltemperatur 3 Oil pressure / Oil temperature 3
1.3 1.3
T urboladeraustausch 4 Turbocharger replacement 4
2 2
Prufarbeiten bei Inspection during
Inbetriebnahme 5 putting into operation 5
2.1 2.1
Obersicht Prufarbeiten 5 Outline of inspection work 5
2.2 2.2
Prufen vor Inspection before
2.3 2.3
Prufen nach Inspection after
2.4 2.4
100 Betriebsstunden 9 100 service hours 9
3 3
Inbetriebnahme Putting into operation
nach Stillegung 9 after out of service period 9
Volume: 9 pages
Edition: 04/2000
HZTL 10414 A III!

ABB Turbo Systems Ltd -B-
Selte/Page 2 Turbocharger TPL
Inbetriebnehmen Kap. I Chap. 2 Putting into operation
A lili 10414
-B- ABB Turbo Systems Ltd
1 1
Olversorgung Oil supply

Eine bei alien vorkommenden Betriebszustanden A carefully designed oil supply, which functions under
funktionierende und sorgfaltig ausgefuhrte Olver all operating conditions, is an important precondition
sorgung ist eine wichtige Voraussetzung fur einen for interference-free operation of the turbocharger.
stdrungsfreien Betrieb der Turbolader. Lubrication of the TPL turbocharger is normally done
Die Schmierung des TPL-Turboladers erfolgt in der with oil from the engine oil circuit.
Regel mit Ol aus dem Motorolkreislauf.
Note The engine manaufacturer's recommen

Hinweis Beachten Sie die Vorschriften des Moto- dation regarding oil selection, and oil
renherstellers zur Schmierdlauswahl und change intervals are to be observed.
Olwechsel-lntervallen.
1.1 1.1
Olfiltrierung Oil filtration
TPL 61 TPL 69 TPL 61 TPL 69

Fur TPL Turbolader der Grossen TPL 61 TPL 69 For TPL turbochargers, sizes TPL 61 to TPL 69, a
ist eine Schmierolfiltrierung mit einer Fiitermaschen- lubrication oil filter system wish a mesh size
weite < 0.034 mm erforderlich. < 0.034 mm is required.
TPL 73 ^ TPL 85 TPL 73^ TPL 85
Eine Schmierolfiltrierung mit einer Filtermaschenweite A lubrication oil filter system with a mesh sizes
<0.050 mm ist fur TPL 73 TPL 85 Turbolader < 0.050 mm is adequate for the TPL 73 to TPL 85
ausreichend. Bei einer feineren Filtrierung (Empfeh- turbochargers. However, if a finer filter is used
lung; Partikel grosser 0.034 mm abscheiden), kann (recommendation: filter out particles larger than
mit einer Erhohung der Lagerlebensdauer gerechnet 0.034 mm), this is likely to extend the life time of the
werden. bearings.
Diese Filtrierung kann durch den Einsatz eines zu- This filter system can also be achieved by using an
satzlichen, sich selbstreinigenden Feinfilters erreicht additional self-cleaning filter.
werden.
Note Observe the engine manufacturer's

Hinweis Beachten Sie die Vorschriften des Moto- recommendations.
renherstellers.
1.2
Oldruck / Oltemperatur 1.2
Oil pressure / Oil temperature
Der Oldruck vor den Lagern (Messstelle im
Blindanschluss) muss fur einen storungsfreien Be The oil pressure before the bearings (measunng point
trieb genau eingehalten werden. in blind connection) must be exactly maintained to
ensure fault-free operation.
Hinweis Beachten Sie die Vorschriften des Moto-

renherstellers. Observe the engine manufacturer’s
recommendations.
10414 Al IMI
Inbetriebnehmen Kap. I Chap. 2 Putting into operation
1.3 1.3
T urboladeraustausch Torbocharger replacement
A
Vorsicht! Austauschlader Oder Rotorbldcke werden
immer mit dem kleinstmdglichen Ol-
blendendurchmesser ausgeliefert.
A
Caution ! Replacement turbochargers or cartridge
groups are always supplied with the
smallest possible oil diaphragm dia
Deshalb mussen bei einem Ladertausch meter. The diaphragms of turbocharger
die Blenden des zu ersetzenden Laders to be replaced must therefore always
in den neuen Lader ubemommen wer be transferred to the new turbocharger.
den.
Observe the engine manufacturer’s

Hinweis Beachten Sie die Vorschriften des Moto- recommendations.
renherstellers.
Jk III! 10414
tnbetriebnehmen Kap. / Chap. 2 Putting into operation
2 2
Prufarbeiten bei Inspection during

Inbetriebnahme putting into operation
Diese Prufarbeiten sind vorbeugende Sichtkontrollen, Inspection work includes preventive visual controls,
Uberwachungs- und Messarbeiten, die die Funkti- as well as monitoring and measurement to ensure
onsfahigkeit des Turbotaders sicherstellen. Sie hel- the correct functioning of the turbocharger. These
fen, Abweichungen vor und bei Inbetriebnahme zu serve as an aid for the recognition of deviations
erkennen und dadurch Maschinenschaden fruhzeitig before and during putting into operation in order to
zu verhindern. prevent damage to the machine.
In den unten angegebenen ZeitabstSnden sind Control and measurement checks must be carried
an den aufgelisteten Prufstellen Kontroll- und out at the listed inspection points at the intervals
Messarbeiten durchzufuhren. quoted below.
Vor und bei alien Prufarbeiten sind die Sicher- Before and during inspection work, the safety
heitshinweise in Kap. 1 zu beachten. instructions cited in chap. 1 must be observed.
2.1 2.1
Ubersicht Prufarbeiten Outline of inspection work
Prufsymbole und -zeiten Inspection symbols and intervals
Prufort © Inspection location
Prufstelle Inspection point

(in Ubersicht sichtbar) (visible in the outline)

(in Ubersicht verdeckt) (not visible in the outline)
Prufen Inspection
Messwerte erfassen Recording of measurement values
Kurzbezeichnung der Prufzeitpunkte Abbreviations for the inspection times
vor Inbetr. vor Inbetriebnahme Before before putting into operation
nach Inbetr. nach Inbetriebnahme After after putting Into operation
10414 A »ll
vor Inbetr.
Before
nach Inbetr.
After
Fig. 2-1
Ubersicht Priifarbeiten
Outline of inspection work
10414
Ubersicht Priifarbeiten Outline of inspection work
Intervall Priif-, Mess-, Einstell-

Pos. Prtifs telle siehe
Priifzelt arbeiten
vor Handbuch
© Inbetriebnahme
Manometer Olleitung - Oldruck prufen
Motorenbauer
© Luftfiltermatte - auf Beschadigung prufen Kap. 3
nach
© Inbetriebnahme
Gas-, Luft- und Olleitungen - Dichtigkeit prufen Abschn. 2.3
© Laderdrehzahl - messen Kap. 3
© Ladedruck - messen Kap. 3
- vor/nach Turbine. Verdichter und

© Temperaturen Olzufuhr bei verschiedenen Motor- Kap. 3
leistungen messen_____________
Interval Inspection, measurement

Item Inspection point see
inspection time and adjustment
before
© putting into Oil pipe pressure gauge - Check oil pressure engine manual
operation
Air filter matting - check for damage chap.3
after
© putting into Gas. air and oil lines - check for leaks sec. 2.3
operation
© Charger speed - measure chap. 3
Charger pressure - measure chap. 3
- measure before and after turbine and

© Temperatures compressor and oil supply at various chap. 3
engine speeds
10414
2.2 2.2
Priifen vor Inspection before
Vorsicht! Vor der ersten Inbetriebnahme sowie

nach jeder Revision des Schmier-
systems wird dringend empfohlen, mit
A
Caution ! It is urgently recommended, before
putting into operation for the first time
and every time after lubricating system
Bypassleitung das komplette Schmier- overhaul, that the entire lubrication
system mitwarmem Ol grundlich durch- system be scavenged thoroughly with
zuspQlen. warm oil, with a bypass pipe.
Beim Einfahren des Motors sowie nach It is urgently recommended, before
jeder Revision des Schmiersystems putting into operation of the engine and
empfehlen wir dringend einen Einfahr- every time after lubricating system
filter zu benutzen. overhaul, that a starting filter be used.
Die Olfilter mussen vor Inbetriebnahme auf Sau- Before putting into operation check the oil filters
berkeit uberpruft werden. for cleanliness.
Oberprufen des Oldruckes in den Olzufuhr- Check the oil pressure of the oil feeding lines.
leitungen.
Check that the monitoring devices are functioning
Die Uberwachungseinrichtungen sind auf Funkti- (see chap. 3).
on zu prufen (s. Kap. 3).
2.3 2.3
Nach dem Aniassen des Motors alle Gas-, Luft- After the engine has been started up, check all
und Olleitungen auf Dichtheit prufen. gas, air and ol! lines for leaks.
Drehzahl, Oldruck, Ladedruck und Temperaturen Measure the speed, oil pressure, charging
vor und nach Turbine und Verdichter bei verschie- pressure and temperatures before and after the
denen Motorleistungen messen. turbine and the compressor at various engine
speeds.
Messwerte mit den Werten des Abnahme-
protokolls vergleichen und dabei unterschiedliche Compare the measured values with those of the
Betriebsbedingungen berucksichtigen. inspection report, taking into account the different
operation conditions.
Vorsicht! Vor dem Abstellen, Motor ca. 3 Minuten

im Leerlauf weiterlaufen lassen, damit Caution ! Before stopping the engine let it idle for
die Warme in den Lagern vom weiter- appr. 3 minutes to allow the heat in the
zirkulierenden Schmierol abgefuhrt wer bearings to dissipate by the circulating
den kann. oil.
Al IIII 10414
tnbetriebnehmen Kap. I Chap. 2 Putting into operation
2.4 2.4
100 Betriebsstunden 100 service hours
Nach den ersten 100 Betriebsstunden Schmlerdlfilter- After the first 100 service hours clean or change the
einsatz reinigen oderwechseln (s. Kap. 3). oil filter insert (see chap. 3).
3 3
Inbetriebnahme Putting into operation after
nach Stillegung out of service period
Falls vorhanden. Blindflansch zwischen Luftaus- If applicable, remove the blind flange between
trittsgehause und Ladeluftleitung entfernen. the air outlet casing and the charge-air line.
Motorenseitige Olzirkulation in Betrieb nehmen. Start up the engine end oil circulation system.
10414 A IMI
Betrieb und Unterhalt
Operation and maintenance 3
Betrieb und Unterhalt Kap. I Chap. 3 Operation and maintenance
3 3
Betrieb und Operation and
Unterhalt maintenance
1 1
Prijfarbeiten 3 Inspection 3
1.1 1.1
Obersicht PrCifarbeiten 3 Outline of inspection work 3
1.2 1.2
Priiten alle Inspection every
25 bis 50 Stunden 6 25 to 50 hours 6
1.3 1.3
Prufen nach Angaben des Inspection according to data from
Motorenbauers 6 engine manufacturer 6
1.4 1.4
Prufen alle Inspection every
S’OOO-12*000 Stunden 6 8*000- 12*000 hours 6
1.5 1.5
Eintrage in das Entries in the
Maschinentagebuch 7 machine logbook 7
2 2
Uberwachung 9 Monitoring 9
2.1 2.1
Drehzahimessung 9 Speed measurement 9
2.2 2.2
Pumpen des Turboladers 10 Surging of turbocharger 10
2.3 2.3
Streifen der rotierenden Teile 11 Contact with rotating parts 11
Volume: 32 pages
Edition: 05/2000
HZTL 10412 ik III!

ABB Turbo Systems Ltd -G-
Betrieb und Unterhalt Kap. / Chap. 3 Operation and maintenance
Inhait Seite Contents Page
3 3
Pfiegearbeiten 12 Cleaning work 12
3.1 3.1
Slcherheitshinweise 12 Safety instructions 12
3.2 3.2
Obersicht Pfiegearbeiten 13 Outline of cleaning work 13
3.3 3.3
Schalldampfer reinigen TPL 61 h- 69 17 Cleaning the silencer TPL 61 69 17
3.3 3.3
SchalldSmpfer reinigen TPL 73 ^ 85 19 Cleaning the silencer TPL 73 -s- 85 19
3.4
3.4 Cleaning the compressor in operation 20
Reinigen des Verdichters im Betrieb 20
3.5
3.5 Cleaning turbine blades and nozzle ring
Reinigung der Turbinenschaufein und in operation 26
des Dusenringes im Betrieb 26
4
4 Maintenance work 29
Unterhaltsarbeiten 29
4.1
4.1 Outline of maintenance work 29
Obersicht Unterhaltsarbeiten 29
4.2
4.2 Intervals for replacing the bearings 32
Lagenvechselzeit 32
4.3
4.3 Intervals for replacing the compressor wheel 32
Verdichterradwechselzeit 32
4.4
4.4 Intervals for replacing the bladad shaft 32
Turbinenwechselzeit 32
10412
r\mtw -G- ABB Turbo Systems Ltd
1 1
Priifarbeiten Inspection
Diese Prufarbeiten wahrend des Betriebes sind Sicht- Inspection work during operation includes visual
kontrollen, Oberwachungs- und Messarbeiten, die die checks, as well as monitoring and measuring in order
Funktionsfahigkeit des Turboladers erhalten. Sie hel- to ensure correct functioning of the turbocharger.
fen, Abweichungen wahrend des Betriebes zu er- This serves as an aid for the recognition of deviations
kennen und dadurch Maschinenschaden zu verhin- during operation In order to prevent damage to the
dern. machine.
In den unten angegebenen Zeitabstanden sind Control and measurement checks must be carried
an den aufgelisteten Prufstellen Kontroll- und out on the listed inspection points at the intervals
Messarbeiten durchzufuhren quoted below.
Bei alien Prufarbeiten sind die Sicherheitshinweise The safety instructions cited in the corresponding
in den entsprechenden Kapiteln zu beachten. chapters must be observed in the course of all
inspection work.
1.1 1.1
Ubersicht Prufarbeiten Outline of inspection work
Prufsymbole und -intervalle Inspection symbols and intervals
© Prufort © Inspection location


(in Obersicht verdeckt) (not visible in the outline)
Prufen Inspection
Messwerte erfassen Recording of measurement values
Kurzbezeichnung der Prufintervalle Abbreviations for inspection intervals
25 • 50 [h] alle 25-50 Betriebsstunden 25 - 50 [h] every 25-50 service hours
n. Ang. nach Angabe des see eng. see engine

Mot. herst. Motorherstellers manuf. manufacturer
L. schild or nach Leistungsschild Oder r. plate or see rating plate or

8*000 -12*000 [h] alle 8’000 -12'000 Betriebsstunden 8*000 -12*000 [h] every 8*000 - 12*000 service hours
10412 ik III!
Priifarbeiten Inspection work
25 - 50 [h]
n. Ang. Mot. herst.

see eng. manuf.
L. schild Oder
S'OOO -12'000 [h]
r. plate or
8*000-12’000 [h]
f;
1 '■ I ^
Fig. 3-1
Ubersicht Prufarbeiten
Outline of inspection work
10412
r\m9 -G- ABB Turbo Systems Ltd
Ubersicht Priifarbeiten Outline of inspection work
PrCifintervalle Priif-, Mess-, Einstell-

Pos. Prufstelle
nach Betriebsstunden arbeiten siehe
- erfassen Abschn. 1.2

Alle 25 bis 50 [h] Betriebsdaten - in das Maschlnentagebuch eintragen
- bei grob abweichenden Werten Ursachen klaren Kap. 4
Nach Angabe des Olfilter - bei Motorstillstand Otfiiter reinigen Oder

Motorherstellers austauschen Abschn. 1.3
- Turbolader zerlegen und reinigen

- Spielmessung
- Kontrolle und Beurteilung der Welle und der
Nach Leistungsschild Oder Lagerteile
Turbolader Abschn. 1.4
alle 8'000- 12'000 [h]
- Turbinen- und Verdichtergehause reinigen
und auf Risse und Erosion / Korrosion
kontrollieren
- Diisenring reinigen und auf Risse und Erosion

kontrollieren
Inspection intervals Inspection Inspection measurement,

Item acc. to service hours points see
adjustment
- check sec. 1.2

Every 25 to 50 [h] Operation data - enter In the log book
- establish the cause of deviations chap. 4
See engine manufacturer Oil filter - clean or replace oil filter with engine at a standstill sec. 1.3
- dismount and clean the turbocharger
- check tolerances
- inspection and assessement of the shaft and

(D See rating plate or
every S’OOO - 12’000 [h] Turbocharger the bearing parts
sec. 1,4
- clean turbine and compressor casing arxl check
for any cracks and erosion / corrosion
- clean nozzle ring and check for any cracks

and erosion
10412 ii nil
ABB Turbo Systems Ltd -G- r\wn
1.2 1.2
Priifen alle Inspection every
25 bis 50 Stunden 25 to 50 hours
Regelmassig alle 25 bis 50 Stunden sind die Be- The operating data of the exhaust gas turbo
triebsdaten des Abgasturboladers zu erfassen und charger must be recorded regularly every 25 to
in das Maschinentagebuch einzutragen (s. 50 hours and entered in the machine logbook
Abschn. 1.5). (see sec. 1.5).
Weichen die Betriebsdaten von den Oaten des If the operation data deviates significantly from
Abnahmeprotokolls grob ab, sind die Ursachen the data in the inspection report the causes must
nach Kap. 4 zu klaren. be established in accordance with chap. 4.
Rufen Sie eine autorisierte ABB Service-Stelle an Call an authorized ABB service station (see
(s. Kap. 8), wenn Sie die Ursache der Norm- chap. 8) if the reasons for the deviation cannot
abweichung nicht klSren kOnnen. be established.
1.3 1.3
Priifen nach Angaben Inspection according to data from
des Motorenbauers engine manufacturer
Bei Motorstillstand den Olfiltereinsatz reinigen Oder With the engine at standstill clean or replace the
austauschen. oil filter Insert.
1.4 1.4
Priifen alle Inspection every
8'000-12'000 Stunden S'OOO -12’000 hours
Die Standzeit der Gleitlager ist abhangig von der The operation life of the plain bearings depends on
Feinheit des Schmierolfilters. the quality of the oil filtration.
A
Vorsicht! Die erste Kontrolle und Beurteilung der
Lagerteile erfolgt nach den Angaben auf
dem Leistungsschild Oder nach 12'000
Caution ! The first inspection and assessement
of the bearing parts has to be carried
out acc. to the rating plate or after 12'000
Stunden. service hours.
Turbolader zerlegen und reinigen. Dismount and clean the turbocharger.

Prufen des Axialspieles und Beurteilung der Inspection of the axial clearance and assesse
Lagerteile, s. Kap. 5. ment of the bearing parts, see chap. 5.
Welle und Lagerstellen auf Beschadigungen kon- Check the shaft and bearing sites for any
trollieren. damages.
Turbinen- und Verdichterrad auf Beschadigungen Check the turbine and compressor wheels for any
kontrollieren. damages.
Turbinen- und Verdichtergehause auf Risse und Check turbine- and compressor casing for any
auf Erosion / Korrosion kontrollieren. cracks and for erosion / corrosion.
Dusenring auf Erosion kontrollieren. Check the nozzle ring for erosion.
10412
-G- ABB Turbo Systems Ltd
Vorsicht! Beschadigte Teile sind durch Original- Caution ! Damaged parts are to be replaced by
teile der ABB zu ersetzen. original ABB parts.
Reparatur- und Austauscharbelten an der It is recommended that an approved

Turbine Oder am Verdichter mussen in ABB turbocharger service station
einer ABB Turbolader-Servicestelle execute all works of repair and replace
durchgefuhrt werden. ment on the turbine and the compressor.
1.5 1.5
Eintrage in das Maschinentagebuch Entries in the machine logbook
Das Oberwachen der Maschinenanlage erlaubt Ruck- Monitoring of the machine plant provides Information
schlusse auf das Verhalten des Turboladers. about the performance of the turbocharger.
Folgende Betriebsdaten und Messwerte sind regel- The following operation data and measurement
maBig in das Maschinentagebuch des Motorenhers- values must be entered regularly in the machine
tellers einzutragen: logbook of the engine manufacturer:
Leistung und Drehzahl des Dieselmotors Output and speed of the diesel engine
Luftansaugtemperatur Air intake temperature
Druckverlust im Luftfiiter Pressure loss in the air filter
Druck der Ladeluft Pressure of the charge-air
Druckverlust im Ladeluftkuhler Pressure drop in the cooler
Abgastemperatur vor Turbine Exaust gas temperature before the turbine
Schmierdldruck, Schmierdltemperatur Lub oil pressure, lube oiltemperature
Falls vorhanden: If provided:

Lufttemperaturnach Verdichter und Luftkuhler Air temperature after compressor and after the
Drehzahl des Turboladers charge-air cooler
Temperatur der Zwischenwand Speed of the turbocharger
Temperature of the partition wall
Bei grob von der Norm abweichenden Messwerten,
Ursachen klaren (s. Angaben des Motorenherstelters In the event of measurement values which deviate
und Kap. 4). significantly from the norm (see the specifications of the
Nach einer Generaluberholung des Turboladers sind engine manufacturer and chap. 4), establish the cause.
folgende Daten zu erfassen und an ABB Turbo Sy Following a general overhaul of the turbocharger,
stems weiterzuleiten (Monteurbericht): the following data must be recorded and passed on
to ABB Turbo Systems (service report):
Zustand des Luftfilters
Art der Verschmutzung condition of the air filter
Lagerwechsel / -austausch type of contamination
verwendete Ersatzteile bearing change / replacement
nachbestellte Ersatzteile und Werkzeuge spare parts used
Betriebsstunden reorders of spare parts and tools
service hours
10412
Lagergehause
Bearing casing
Axiallager
0 Axial bearing
Fuhrung im Axiallager
Guide in axial bearing
Dichtring
Gasket ring
Verschlussschraube
Screw plug
Anschlusskabel
Connecting cable
Anbauvariante
Alternative fitting
Drehzahlgeber ^
Speed transmitter
Leitungsverstarker (Option)
Line amplifier (option)
Fig. 3-2
Anbau der Drehzahimessung
Fitting of speed measurement
10412
Betrieb und Unterhait Kap. / Chap. 3 Operation and maintenance
2 2
Uberwachung Monitoring
2.1 2.1
Drehzahimessung Speed measurement
TPL-Turbolader werden, mit der Ausnahme des TPL turbochargers, with the exception of TPL61, are
TPL61, serienmassig mit einem Drehzahlgebersystem fitted as standard with a speed transmitter system
zur Messung der Turboladerdrehzahl ausgerustet. for measuring the turbocharger speed. This system
Beim TPL61 ist das Drehzahlgebersystem als Option is available as an option with the TPL61. This speed
erhaltlich. Dieses Drehzahlgebersystem eimdglicht in transmitter system, in conjunction with the corres
Verbindung mit den entsprechenden Messgeraten ponding measuring units or monitoring systems (not
bzw. Oberwachungssystemen (gehoren nichtzum Lie- part of the delivery), permits continuous remote moni
ferumfang) eine standige Fernuberwachung der toring of the turbocharger speed. With continuous
Turboladerdrehzahl. Bei dauernder Obenwachung der monitoring of the engine installation, the turbocharger
Maschinenanlage bietet sich die Turboladerdrehzahl speed can be used as a suitable control parameter.
als geeigneter Kontrollwert an. The line amplifier can be procured as an additional
Als zusatzliche Option zum beschriebenen Dreh- option to the described of the speed measuring
zahlmesssystems kann der Leitungsverstarker er- system.
worben werden.
In the event of retrofitting of speed

Hinweis Bei einer ev. Nachriistung der Drehzahi measurement the gasket ring from the
messung darf bei der Montage des screw plug must not be used when fitting
Drehzahlgebers der Dichtring von der the speed transmitter.
Verschlussschraube nicht verwendet
werden.
Das Absinken der Drehzahl eines Laders kann A reduction in speed of a charger can signify:
bedeuten: - Damaged turbine or bearing
- Beschadigte Turbine Oder Lagerung. - Defects on the cylinder connected during bursts
- Defekte an den angechlossenen Zylinder bei - Severe contamination of turbine with 2-stroke
Stossbetrieb. applications.
- Starke Verschmutzung der Turbine bei 2-Takt
Anwendungen.
With 4-stroke applications severe con

tamination of the turbine can be a cause
Hinweis Bei 4-Takt Anwendungen kann die Star of an increase in turbocharger speed.
ke Verschmutzung der Turbine eine Ur-
sache fur das Zunehmen der Turbo
laderdrehzahl sein.
10412 ik M
ABB Turbo Systems Ltd -G- II
Mogliche Griinde fiir den Ausfall des Gebersy- Possible reasons for the breakdown of the speed
stemes; indicator:
- Defekte am Drehzahlgeber, am Anschlusskabel - Defect in speed transmitter, connecting cable and
und -stecker zum Messgerat, am Messgerat Oder plug to measuring unit, measuring unit or in power
an der Speisung. supply.
Turboladerhavarie. Turbocharger damage.
Hinweis Bei einem Ausfall der Drehzahlanzeige If the speed indication fails, it is recom
wird empfohlen die Motorleistung bis mended that the engine output be
zum Leerlauf zu reduzieren und den Mo reduced to idling speed and the engine
tor zu stoppen. Anschliessend soli die stopped. The cause of the failure should
Ursache fur den Ausfall gesucht war then be determined.
den.
2.2 2.2
Pumpen des Turboladers Surging of turbocharger
Bel gewissen BetriebszustSnden auf dem Motor, wie Surging of the turbocharger can occur with certain
schnelles Entlasten Oder beim Manovrieren, kann es engine operating states, such as rapid load removal
zum Pumpen des Turboladers kommen. Dabei wird or while manoeuvering, particularly with high engine
kurzzeitig die Strdmungsrichtung im Verdichter um- loads. The general direction of flow in the compressor
gekehrt. Solche sporadischen Pumpstosse beein- is then temporarily reversed. Although surging leads
trachtigen den sicheren Betrieb des Turboladers je- to increased load of individual turbocharger
doch nicht. components, sporadic pulses do not generally affect
safe operation of the turbocharger.
A
Vorsicht! Bei andauerndem Oder pehodisch wie-
derkehrendem Pumpen konnen folgen-
de Bauteile beschadigt werden;
A
Caution ! The following components can be
damaged by continuous or periodically
- Verdichterrad (Schwingungsbruche recurring surging;
etc.) - compressor wheel (vibration fractures,
- Turbinenbeschaufelung (Risse) etc.)
- Lagerung (Ueberhitzung) - turbine blades (cracks)- bearings
- Filterschalldampfer (overheating)
- filter silencer
Hinweis Zu treffende Massnahmen:

Bei andauerndem Oder periodisch wie- Action to be taken:
derkehrendem Pumpen ist die Betriebs- The operating safety of the turbocharger
sicherheit des Turboladers nicht mehr is no longer ensured with continuous or
gewahrieistet. Der Betreiber muss zu- periodically recurring surging. The
sammen mit der nachsten ABB Service- operator, together with the next ABB
Stelle (siehe Kap. 8) umgehend Mass service station (see chap. 8), must take
nahmen zur Beseitigung des Pumpens immediate action to eliminate the
einteiten. surging.
Die oben genannten Bauteile sind auf The above mentioned components
Beschadigung zu untersuchen, im Zwei- should be examined for damage and
feisfall zu ersetzen. replaced in case of doubt.
A III! 10412
2.3 2.3
Streifen von rotierenden Teilen Contact with rotating parts
Eine minime und glelchm^ssige Abnutzung am Urn- Mild, uniform wear around the circumference of rotor
fang der Rotorkomponenten, hervorgerufen durch components, caused by slight local grazing against
leichtes, ortliches Streifen an den angrenzenden Bau- adjacent components, is non-hazardous and
teilen ist ungefahrlich und zulSssig. Dabei werden permissible. This slightly reduces the length of the
die Verdichter- bzw. die Turbinenschaufeln etwas ver- blades in the compressor or turbine. Certain
kurzt. Urn keinen wesentiichen Wirkungsgradverlust tolerances must be observed to avoid a significant
zu verursachen, mussen bestimmte Toleranzen ein- loss in efficiency.
gehalten werden.
Note The check on dimensions must be

Hinweis Die Masskontrolle muss durch eine offi- carried out by an official Service Station
zielle Service-Stelle der ABB Turbo Sy of ABB Turbo Systems Ltd.
stems AG durchgefuhren werden.
10412 ik III!
ABB Turbo Systems Ltd -G- MIPIP
3 3
Pfiegearbeiten Cleaning work
Pflegearbeiten sind regelmassige Sichtkontrollen und Cleaning work includes regular visual checks and
Reinigungsarbeiten, die die stdrungsfreie Funktion washing to ensure the correct functioning of the
des Turboladers und seiner Anbauten sicherstellen turbocharger and its auxiliary appliances.
sollen.
The external condition and the degree of
Der Sussere Zustand und der Verschmutzungs- contamination of the cleaning points listed below
grad der unten aufgelisteten Pflegestellen ist durch must be established by visual checks at the
Sichtkontrollen in den angegebenen ZeitabstSnden intervals quoted.
festzustellen. During all cleaning work the safety instructions in
Bei alien Pflegearbeiten sind die Sicherheitshin- the respective chapters must be observed.
weise in den entsprechenden Kapitein zu beach-
ten.
3.1 3.1
Sicherheitshinweise Safety instructions
Beachten Sie beim Umgang mit Reinigungs- und L6- When handling detergents, solvents, acids and alkalis
sungsmitteln, mit Sauren und Laugen unbedingt die be sure to observe the respective safety directions
entsprechenden Sicherheitshinweise auf den Etiket- on the manufacturer’s label and in the operation
ten der Herstellerfirmen dieser Mittel und im Betriebs- manual. Observe also the instructions for the
handbuch. Befolgen Sie die Hinweise zum umwelt- environmentally compatible collection, storage and
gerechten Einsammein, Lagern und Entsorgen die disposal of these substances (see chap. 1).
ser Flussigkeiten (s. Kap. 1).
Warning ! Cleaning work should be carried out

Wamung ! Wegen Explosionsgefahr, Reinigungsar outdoors due to explosion hazards. If
beiten im Freien durchfuhren. this is not possible, ensure that there is
Ist das nicht moglich, unbedingt fur adequate ventilation.
ausreichende Frischluftzufuhr und Luft-
umwaizung sorgen. Before beginning cleaning work in
confined spaces, extinguish naked flame
Offenes Feuer (auch Zigaretten!) in ge- (including cigarettes!) due to the danger
schlossenen Raumen wegen Explo- of explosion.
sionsgefahr vor Beginn der Reinigungs
arbeiten loschen. Always wear protective clothing (solvent
and acid resistant gloves, body protec
Unbedingt Schutzkieidung tragen (L6- tion and eye protection). When using
sungsmittel- und saurefeste Handschu- chemical cleaning agents the instruc
he, Kdrperschutz und Augenschutz). tions and warnings of the manufacture
Beim Verwenden chemischer Reini- must be observed.
gungsmittel sind die Vorschriften und
Warnhinweise der Hersteller dieser Mit
tel zu beachten.
ii nil 10412
3.2 3.2
Ubersicht Pfiegearbeiten Outline of cleaning work
Pfiegesymbole Cleaning symbols
© Pflegeort
© Cleaning location
Pfiegesstelle Cleaning point

(in Gbersicht sichtbar) (visible in the outline)
Pfiegestelle Cleaning point

(in Obersicht verdeckt) (hidden in the outline)
Sichtkontrolle Visual check
Reinigen Cleaning
Kurzbezeichnung der Pfiegeintervalle Abbreviations for cleaning intervals
nach Bedarf nach Bedarf as reqd. as required
nach Ang. nach Angabe des see eng. see engine

Mot.herst. Motorenherstellers manuf. manufacturer
10412 ik nil
ABB Turbo Systems Ltd -G- /MPli
nach Ang. Motherst.

see eng. manuf.
0
nach Bedarf 00
as reqd.
(D
©
|o"
1
1
Fig. 3-3
Ubersicht der Pftegearbeiten
Outline of cleaning work
10412
^\IP»
Pfiegeintervall
Pos. Pfiegesteile Pflegeart nach Vorbedingungen Reinigungsmittei siehe

nach
Angabe
Bedarf
Motherst
- Schalldampfer
demontieren
- Schalldampfer - reinigen X Abschn. 3.3
- Dammmaterial -trocken reinigen
- betriebswarmer Motor
- Verdichter - nass X - reines Wasser Abschn. 3.4
reinigen
- hohe Verdichterdrehzahl
- Motorleisturg
nicht reduzieren
- nass X - reines Wasser
reinigen
- Gastemperatur vor Turbine
- Turbine 430-500X (703-773 K) Abschn. 3.5
- Naturkem-
- Gaseintrittstemperatur vor
- trocken granuiat
X Turbine nicht uber
reinigen - Aktivkohle-
580-590“C (653-663 K)
partikel
Cleaning intervals
Cleaning
Item Cleaning point as see Preliminaries Cieaning agent see
measures
requi engine
red manuf.
- Dismantle
silerrcer
- Silencer - cleaning X sec. 3.3
- Insulating material - dry clean
- engine at normal
- wet operation
- Compressor X - pure water sec. 3.4
cleaning
- high compressor speed
- no reduction in speed
- wet X - max. gas temperaure - pure water
cleaning before turbine
- Turbine 430-500“C (703-773 K) sec. 3.5
- Natural core-
- Gas inlet temperature befor
- dry granuiat
X turbine not over
cleaning - Activated charcoal-
580-590“C (653-663 K)
particles
10412 A IIII
ABB Turbo Systems Ltd -G- rxtwtw
TPL 61 - 69
81005 81006 81271

81137
<
81136 <;.•
' i .
V . *
o'
ilift. .........
flip
>*,V>,
.V
..•.*.
il#
vV
j'r.. V/
81265
81270
81138
81135
Fig. 3-4
Schalldampfer
Silencer
A IIII
#Mfli
10412
-G-
3.3 3.3
Schalldampfer reinigen Cleaning the silencer
TPL 61 - 69 TPL 61 - 69
Zur Reinigung den SchalldSmpfer zerlegen. For cleaning, dismantle the silencer.
Filterring (81265) entfernen und Spannbander Remove the filter ring (81265) and loosen the
(81270) losen (s. Fig. 3-4). tension bands (81270) (see fig. 3-4).
Mantelbleche (81137 & 81138) herausziehen, auf- Withdraw the cover sheet-metals (81137 &
biegen und Filzsegmente (81136) herausnehmen. 81138), bend them and remove the felt segments
(81136).
Vorsicht! Beim Reinigen darauf achten, dass der

Filterring und die Filzsegmente nicht
nass werden. Caution ! During cleaning take care that the filter
ring and the felt segments does not
Schmutz mit Putzlappen, weicher Burste Oder mit become wet.
Pressluft entfernen.
Remove dirt with a soft brush or dry compressed
Stark verschmutzte Filzsegmente und Filterring air.
durch eine unserer Service-Stellen ersetzen les
sen (s. Kap. 8). Heavily soiled felt segments and filter ring should
be replaced by one of our Service Stations (see
- J- chap. 8).
- J-
Hinweis Veriangerte Mantelbleche (81138) uber Mount the extended cover sheet-metal
die drei Rippen (A) montieren. (81138) over the ribs (A).
Vorsicht! Beschadigte Spannbander mussen

durch neue ersetzt werden. Caution 1 Damaged tension bands must be
replaced by new ones.

10412 tin ^
-G-
r\i
TPL 73 - 85
r7.v.v.v.v.v»\yA,v<
<7»V.V.'.V.V.V.V.
........
81266
ws>
81271
__ Mwsmsf,
VXV
81270
Option
81265
Fig. 3-5
Schalldampfer
Silencer
Ali I 10412
G ABB Turbo Systems Ltd
3.3 3.3
Schalldampfer reinigen TPL 73^ 85 Cleaning the silencer TPL 73^ 85
Fails vorhanden: If provided:

+ Filterring (81265) reinigen: + Cleaning the filter ring (81265):
Der Filterring kann ersetzt Oder durch waschen The filter ring can be replaced or cleaned by was
gereinigt werden. hing.
Hinweis Urn w^hrend des Waschens ein ein- Note To ensure satisfactory operation during
wandfreien Betrieb zu garantieren ist es the washing, it is advisable to fit a new
ratsam den Filterring durch einen Zwei- filter (twin-pack filter ring available).
ten zu ersetzen (Filterring im Zweierpack
erhaltlich).
A
Vorsicht! Der Filterring alle 500 Betriebsstunden
A
Caution ! Wash or replace the filter ring every 500
operating hours. The filter ring must not
be washed more than five times.
waschen Oder ersetzen. Der Filterring
ist nicht mehr als funfmal zu waschen. + Washing the filter ring:
Rinse with water (up to 40°C) using fine washing
+ Waschen des Filterringes: powder or, if very dirty, soak it. Squeeze it out
Mit Wasser (bis 40®C) mit Zugabe von Feinwasch- carefully. Rinse in cold water. Avoid high
mittel ausspulen Oder bei starker Verschmutzung mechanical stress (wringing out, powerful water
einweichen und dabei sorgfaitig durchdrOcken. In jet).
kaltem Wasser ausspulen. Hohe mechanische Be-
anspruchung (wringen, scharfer Wasserstrahl) + Dry thoroughly before fitting.
vermeiden.
For cleaning, dismantle the silencer:
+ Vor Montage vollstandig trocknen. - Loosen the tension bands (81270) and remove
the cover grid (81266) (see fig. 3-5).
Zur Reinigung den Schalldampfer zerlegen:
- Spannbander (81270) Ibsen und Abdeckgitter Withdraw the cover sheet-metals (81137), bend
(81266) entfernen (s. Fig. 3-5). them and remove the felt segments (81136).
Mantelbleche (81137) herausziehen, aufbiegen

und Filzsegmente (81136) herausnehmen.
Caution ! During cleaning take care that the felt
A
Vorsicht! Beim Reinigen darauf achten, dass die
Filzsegmente nicht nass werden.
segments does not become wet.
Remove dirt with a soft brush or dry compressed

air.
Schmutz mit Putzlappen, weicher Burste Oder mit Heavily soiled felt segments should be replaced
Pressluft entfemen. by one of our Service Stations (see chap. 8).
Stark verschmutzte Filzsegmente durch eine un- - J-

serer Service-Stellen ersetzen lassen (s. Kap. 8).
- J-
Caution ! Damaged tension bands must be

replaced by new ones.
Vorsicht! Beschadigte Spannbander mussen

durch neue ersetzt werden.
10412
ABB Turbo Systems Ltd -G- /MiW
3.4 3.4
Reinigen des Verdichters im Be Cleaning the compressor in
trieb operation
Einleitung Introduction
Die Verschmutzung der Verdichterstufe (Verdichter- The dirt in the compressor stage (compressor wheel
rad und Diffusor) hSngt vom Reinheitsgrad der an- and diffuser) depends on the cleanness of the air
gesaugten Luft und des Betriebspunktes ab. drawn in and the operating point.
Eine Schmutzablagerung in den Strdmungskanalen A deposit of dirt in the flow ducts occurs particularly
kommt vor allem vor, wenn Ol- oder Saiznebel, feste when oil or saline mist, solid combustion residues
VerbrennungsruckstSnde und Staube verschiedener and dusts of various kinds are drawn in.
Arten, mitangesaugt werden. Soiling of the compressor stage has a negative
Das Verschmutzen der Verdichterstufe hat, vor al influence on the compressor efficiency and turbo
lem bei kleineren Turboiader, einen negativen charger pressure, particularly for smaller turbo
Einfluss auf den Verdichterwirkungsgrad und auf den chargers.
Ladedruck. This results in higher exhaust gas temperatures and
Motorseitig bewirkt dies hohere Abgastemperaturen increased fuel consumption by the motor.
und einen erhbhten Brennstoffverbrauch. Contamination of the compressor also increases the
Die Verschmutzung des Verdichters erhoht auch die rotor unbalance.
Unwucht des Rotors. Periodic cleaning of the compressor in operation
Die periodische Reinigung des Verdichters im Be prevents or delays severe increase of soiling, but
trieb verhindert Oder verzdgert eine starke Zunahme this in no way replaces normal overhauls, during
der Verschmutzung. sie ersetzt aber keinesfalls die which the turbocharger is completely dismantled.
ubiichen Revisionen, bei denen der Turboiader voll-
standig zerlegt wird.
Principle of cleaning during

operation
Prinzip der Reinigung im Betrieb
Water is fed or injected before the compressor wheel
Um die Verdichterstufe im Betrieb zu reinigen, wird
via injection pipes fitted in the filter silencer and
mit einem eingebauten Einspritzrbhrchen im Filter-
suction branch in order to clean the compressor stage
schalldampfer Oder im Saugstutzen Wasser vor das
in operation.
Verdichterrad eingespritzt. The water does not act as a solvent in the process,
Das Wasser wirkt dabei nicht als Lbsungsmittel, viel-
but the coating is removed by the mechanical impact
mehr wird der Belag durch die mechanische Arbeit
of the falling drops. The process is ideal, provided
der aufprallenden Trdpfchen abgetragen. Das Ver-
the soiling is not too advanced.
fahren ist gut geeignet, solange die Verschmutzung Cleaning is most effective when the engine is fully
noch nicht zu weit fortgeschritten ist.
loaded.
Die Reinigung ist bei voll beiastetem Motor am wirk-
The cleaning installation can be provided in principle
samsten. in three different ways:
Die Reinigungsinstallation kann grundsatzlich auf drei
a. Cleaning with the low pressure cleaning device
verschiedene Arten realisiert werden: on the turbocharger.
a. Reinigung mit der Unterdruck-Reinigungsvor-
b. Cleaning with externally attached pressure water
richtung am Tubolader.
vessel.
b. Reinigung mit dem extern montierten Druck-Was-
c. Cleaning with automatic fluid control.
serbehalter.
c. Reinigung mit einer automatischen Fluidsteuerung.
10412
#\IPIP
Allgemeine Vorschriften General instructions
Bei sehr starkem, verhartetem Belag kann der Ver- If the coating is very thick and hard, the compressor
dichter nur noch in ausgebautem Zustand gereinigt can only be cleaned when dismantled. For exposed
werden. Daher wird fur exponierte Aniagen empfoh- systems periodical cleaning of the compressor after
len, den Verdichter nach der Inbethebnahme regel- commissioning is recommended.
massig zu reinigen.
A
Vorsicht! Es dart aus Griinden der Korrosionsgefahr
nur reines Wasser, keinenfalls Salzwas-
ACaution ! Due to the danger of corrosion, only
fresh water must be used and on no
account salt water. The water should
ser verwendet werden. Das Wasser soil not contain any cooling additives which
auch keine Kuhlwasser-Aufbereitungs- could form deposits in the flow ducts.
mittel enthaiten, die sich als Belag in den
StromungskanSlen niederschlagen kbn- The injection pipe must on no account be connected
nen. directly via a cock to a water pipe, a larger dosing or
water vessel than available from ABB Turbo Systems.
Auf keinen Fall darf das Einspritzrbhrchen uber ei- This prevents uncontrolled volumes of water entering
nen Hahn direkt an eine Wasserleitung, ein grbsseres the turbocharger and engine, which can lead to
Dosiergefass Oder einen grosseren Wasserbehalter, serious damage.
als von ABB Turbo Systems erhaltlich, angeschlos- The interval between periodic cleanings largely
sen werden. Dies um zu vermeiden, dass unkontrol- depends on the operating conditions. Cleaning should
lierte Wassermengen in den Lader und in den Motor normally be performed every 25 to 100 operating
gelangen, was zu grossen Schaden fuhren kann. hours.
Die Zeitspanne zwischen den periodischen Reinigun-
gen hangt stark von den Bethebsbedingungen ab. In
der Regel soil alle 25 bis 100 Betriebsstunden gerei
nigt werden. Installation
The ABB filter silencers and suction branches of the

TPL turbochargers are fitted as standard with inte
Installation gral water injection tubes. The filter silencer is
provided with an injection pipe, and the suction branch
Die ABB-Filterschalldampfer und -Saugstutzen der with three injection pipes set at 120° to each other,
TPL-Turbolader sind serienmassig mit integrierten for connection as required.
Wassereinspritzrohrchen ausgerustet. Der Filterschall-
dampfer ist mit einem Einspritzrbhrchen und der Saug
stutzen mit drei um 120° versetzten Einspritzrbhrchen
zum wahlweisen Anschluss, ausgerustet.

10412 ik nil
-G- /MflP
Inhalt Dosiergefass Wassereinspritzzeft

Turbolader Typ Turboladerdrehzahl
Volume of dosing vessel Water injection time
Turbocharger type Turbocharger speed ldr&] Us]
TPL 61 0.5 8 ... 10
TPL 65 0.5 8... 10
TPL 69 0.5 8 ... 10
Moglichst
TPL 73 As nearly as possible 1 16 ... 20
TPL 77 ^\max 1 16 ... 20
TPL 80 2.5 40 ... 50
TPL 85 2.5 40 ... 50
Fig. 3-6
Reinigung des Verdichters mit der Reinigungsvorrichtung
Cleaning the compressor with the cleaning device
10412
Vorgehen beim Reinigen Procedure for cleaning
Das Reinigen der Verdichterstufe muss bei betriebs- Cleaning of the compressor stage must be performed
warmen und mdglichst voll belastetem Motor durchge- with the engine warm from running and as fully loaded
fuhrt werden, das heisst bei hoherTurboladerdrehzahl. as possible, i.e. at high turbocharger speed.
Der Erfolg der Reinigung kann am Lade- Oder The success of the cleaning can be seen from the
Spuhidruck Oder auch an den Abgastemperaturen charger or flushing pressure or from the exhaust
erkannt werden. gas temperatures.
1st die Reinigung erfolglos, muss diese fruhestens If cleaning is unsuccessful, it should only be repeated
nach 5 Minuten wiederholt werden. Sollte die Reini after 5 minutes. If cleaning is unsuccessful after three
gung nach drei Vorgangen erfolglos bleiben, emp- operations, we recommend that the turbocharger is
fehlen wir, den Turbolader durch eine konzessionier- inspected and cleaned by a licensed ABB service
te ABB-Servicestelle kontrollieren und reinigen zu las- department.
sen. After cleaning the compressor stage the engine
Nach der Reinigung der Verdichterstufe soil der Mo should be run under load for at least another 5
tor noch mindestens wahrend 5 Minuten unter Belas- minutes.
tung laufen.
Note These guidelines apply exclusively to

Hinweis Diese Richtlinien gelten ausschliesslich fur turbocharger cleaning with water,
die Reinigung des Laders mit Wasser und assuming that the engine manufacturer
unter der Voraussetzung, dass der Motor- permits the procedure.
herstelier das Verfahren zulasst.
Bedienung der Unterdruck- Operating the low pressure

Reinigungsvorrichtung cleaning device
1. Deckel (1) des Dosiergefasses (4) offnen 1. Open cover (1) of dosing vessel (4).
2. Dosiergefass bis ca.1 cm von seinem oberen 2. Fill dosing vessel with pure water up to approx.
Rand mit reinem Wasser ftillen. 1 cm below its upper rim.
3. Absperrventil (3) solange offnen bis das Wasser 3. Open shut-off valve (3) until the water has been
vollstandig eingespritzt wurde. Um das Absperr fully injected. The shut-off valve is opened by
ventil zu offnen, muss an der Kette (2) gezogen pulling the chain (2).
werden. Die approximative Wassereinspritzzeit ist The approximate water injection time is specified
in der Tabelle angegeben. in the table.
Vorsicht! Die Wassermenge versteht sich pro

Turbolader.
A
Caution ! The water volume is specified for each
turbocharger.
4. Deckel schliessen. Die Reinigung ist abgeschlos- 4. Close cover. This completes cleaning.
sen.
10412 ill )9
ABB Turbo Systems Ltd -G- r\i
Inhatt Wasserbehatter Wassereinspritzzert

Turbolader Typ Turboladerdrehzahl
Volume of water vessel Water injection time
Turbocharger type Turbocharger speed Idmn %ls]
TPL 61 0,4
TPL 65 0,4
TPL 69 0,4
Moglichst
TPL 73 As nearly as possible 1 4 ... 10
^\max
TPL 77 1
TPL 80 2,0
TPL 85 2.0
Fig. 3-7
Reinigung des Verdichters mit dem Wasserbehalter
Cleaning the compressor with the water vessel
A IIU 10412
/MPIP
Bedienung des Druck-Wasserbe- Operating the pressure water

halters vessel
1. Verschlussstopfen (A) ausschrauben. 1. Remove the screw plug (A).

2. Behalter mit reinem Wasser fOllen. 2. Fill the vessel with pure water.
3. Verschlussstopfen (A) einschrauben. 3. After filling tighten the screw plug (A).
4. Ventilgriff (B) gegen die Feder schieben und ca. 4. Actuate the valve lever (B) towards the spring
10 Sekunden halten, bis die gesamte Wasser- and hold it for about 10 seconds until all the water
menge eingespritzt ist. has been injected.
Reinigung mit einer automatischen Cleaning with an automatic fluid

Fluidsteuerung controller
Hinweis Beachten sie die Vorschriften des Pay attention to the specifications of the
Motorenherstellers. engine manufacturer.
10412
rwnw
3.5 3.5
Reinigung der Turbinenschaufein Cleaning turbine blades and nozzle
und des Dusenringes im Betrieb ring in operation
Die Verbrennung von Schwerol in Dieselmotoren be- Combustion of heavy oil in diesel engines causes
wirkt eine Verschmutzung der Turbinenschaufein und contamination of the turbine blades and nozzle rings
Dusenringe der Turbolader. of the turbochargers.
Die Verschmutzung nimmt mit der Zeit zu, \weshalb Contamination increases with time, so that regular
eine regelmassige und richtig durchgefuhrte Reini and properly performed cleaning is important to
gung wichtig ist, urn die entstandenen Ablagerungen remove the deposits produced.
zu entfemen. The frequency of cleaning depends on the degree of
Die Haufigkeit der Reinigung hangt vom Ausmass contamination of the turbine during a specific period
der Verschmutzung der Turbine uber eine bestimm- of operation.
te Betriebsdauer ab. With register supercharging it must be ensured that
Bei Registeraufladung muss speziell nach Betriebs- both turbochargers are cleaned regularly, especially
perioden im unteren Leistungsbereich darauf geachtet following periods of operation in the lower perfor
werden, beide Turbolader regelmassig zu reinigen. mance range.
Ein abnormal hoher Schmierolverbrauch kann die Men- An abnormally high consumption of lubricating oil
ge der Asche und der Schlacke ebenfalls erhdhen. can similarly Increase the volume of ash and slag.
Durch verschmutzte Turbinenkomponenten kann der The charging pressure can rise slightly owing to the
Ladedruck infolge der Verengung des Turbinen- narrowing of the turbine cross-section due to
querschnittes etv\/as ansteigen. Zudem fuhrt die Ver contaminated turbine components. Contamination of
schmutzung der Turbine zu Rotor-Unwucht. Sehr the turbine also results in rotor unbalance. Severe
Starke Verschmutzung kann bis zu unzuiassig hoher contamination can lead to impermissibly high rotor
Unwucht des Rotors fuhren. unbalance.
Ein schlechter Turbinenwirkungsgrad, erhohte Ab- The results are low turbine efficiency, increased
gastemperaturen, hohere Lade- und Zunddrucke und exhaust gas temperatures, higher charging and
eine geringere Motorleistung sind die Folge. ignition pressures and reduced engine performance.
Betriebserfahrungen zeigen, dass trotz periodischer Experience in operation has shown that despite
Reinigung im Betrieb nicht auf die Oberholungen, periodic cleaning during operation, it is impossible to
bei denen Turbine und Dusenring mechanisch gerei- dispense with overhauls in which the turbine and
nigt werden, verzichtet werden kann. Bei richtiger nozzle ring are mechanically cleaned. If cleaning is
Anwendung der Reinigung und bei richtig dimensio- performed correctly and the cleaning system is
niertem Reinigungssystem konnen die Abstande zwi- properly dimensioned, however, the Intervals between
schen den Uberholungen aber veriangert werden. overhauls can be extended.
Prinzip der Reinigung im Betrieb Principle of cleaning in operation
Urn die Turbinenkomponenten im Betrieb zu reinigen Two different processes are used for cleaning the
werden zwei verschiedene Verfahren angewendet: turbine components during operation:
- Nassreinigung von Turbine und Dusenring - Wet cleaning of turbine and nozzle ring
(Abschnitt 3.5.1) (section 3.5.1)
- Trockenreinigung von Turbine und Dusenring - Dry cleaning of turbine and nozzle ring
{Abschnitt 3.5.2) (section 3.5.2)
Hinweis Aufgrund von Betriebserfahrungen emp- From experience In operation we

fehlen wird die Nassreinigung anzuwen- recommend the use of wet cleaning.
den.
li III! 10412
r\wt9
3.5.1 3.5.1
Nassreinigung Wet cleaning
Die folgenden allgemeinen Vorschriften sind in Ober- The following general instructions must be observed
einstimmung mit der ..Betriebsanleitung des Diesel- together with the “Operating instructions for the diesel
motors" einzuhaiten. engine”;
- Die maximale Abgastemperatur vor der Turbine - The maximum exhaust gas temperature before
darf vor der Reinigung 430 °C nicht ubersteigen. the turbine must not exceed 430®C before
Wahrend der Reinigung darf die Turbineneintritts- cleaning. The turbine inlet temperature may rise
temperatur auf 500 °C ansteigen. to 500®C during cleaning.
A
Vorsicht! Der vorgeschriebene Wassereinspritz-
druck und die Wassereinspritzdauer sind
unbedingt einzuhaiten.
Caution ! The prescribed water Injection pressure
and the duration of water injection must
be observed without fail.
Kleinere Wassermengen konnen zu un- Smaller volumes of water can lead to
genugender Reinigungswirkung fCihren. an inadequate cleaning effect. Larger
Grossere Wassermengen fiihren zu un- volumes of water result in impermissible
zulassigen WSrmespannungsbean- thermal stresses and possible turbine
spruchungen und einem mdglichen touching.
Turbinenstreifen. Clean fresh water free from cleaning
Es muss sauberes Susswasser ohne agents and solvents must be used.
Reinigungs- Oder Losungsmittel verwen-
det werden.Vorgehen belm Reinigen Thermal-shock cleaning:
- The temperature before the turbine must lie
Thermoschockreinigung: between 430°C and 500®C to achieve the required
- Dm die gewunschte Thermoschockwirkung bei der thermal-shock effect for wet cleaning.
Nassreinigung zu erreichen, muss die Tempera-
tur vor der Turbine zwischen 430 °C und 500 '’C
liegen.
Caution ! For reasons of material strength we
A
Vorsicht! Aus Materialfestigkeitsgriinden empfeh-
len wir beim Reinigungsvorgang die
Temperatur vor der Turbine 500 °C nicht
recommend that the temperature before
the turbine 500®C should not be
exceeded.
If the exhaust gas temperature can be
reduced for cleaning, we recommend
zu uberschreiten. this should be done as far as possible,
Kann die Abgastemperatur fur die Rei to reduce stress on the material, but the
nigung reduziert werden, so empfehlen exhaust gas temperature must not be
wir aus Griinden der Materialschonung, reduced below 430®C.
dies soweit als mdglich zu tun, jedoch
darf die Abgastemperatur nicht unter
430 °C abgesenkt werden.
Procedure for cleaning
Vorgehen beim Reinigen

Pay attention to the specifications of the
engine manufacturer.
Hinweis Beachten sie die Vorschriften des

Motorenherstellers.

10412 ti III!
-G-
3.5.2 3.5.2
Trockenreinigung Dry cleaning
Trockene Festkdrper in Granulatform werden mit Dry solid matter in granular form is blown by
Druckluft in die Abgasleitungen vor dem Gaseintritts- compressed air into the exhaust pipes before the
gehause eingeblasen. Die Festkorper wirken mecha- gas inlet casing. The solid matter has a mechanical
nisch reinigend, wodurch Ablagerungen auf Turbine cleaning effect and removes deposits on the turbine
und Dusenring abgetragen werden. Diese Reinigung- and nozzle ring. This method of cleaning should be
smethode ist atle 24 - 48 Vollast-Betriebsstunden performed every 24-48 operating hours on full load.
anzuwenden. Dabei hSngtder Abstandzwischen den The interval between cleaning operations depends
Reinigungen vom Ausmass der Verschmutzung und on the degree of contamination and on the increase
von der Erhdhung der Abgastemperatur nach der of exhaust gas temperature following the turbine.
Turbine ab. Die Reinigung muss wiederholt werden, Cleaning must be repeated if the gas temperature
wenn die Gastemperatur nach der Turbine bei Voll- following the turbine rises to 20°C (20 K) above the
ast auf 20 °C (20 K) oberhalb der mittleren Tempe- mean temperature on full load. The gas inlets should
ratur ansteigt. FQr Turbolader mit mehr als einem be cleaned in turn on turbochargers with more than
Gaseintritt ist ein Gaseintritt nach dem anderen zu one gas inlet. In engines with several turbochargers
reinigen. Bei Motoren mit mehreren Turboladern the turbochargers should be cleaned in turn.
muss ein Turbolader nach dem anderen gereinigt To prevent excessive combustion of the dry cleaning
werden. agent before the turbine, the gas inlet temperature
Urn einen hohen Abbrand des Trockenreinigungs- before the turbine must not exceed 580-590°C.
mediums vor der Turbine zu verhindem, darf die Gas- Since it is not possible to remove thick coatings with
eintrittstemperatur vor der Turbine 580 - 590 °C nicht relatively small amounts of solid matter, this method
ubersteigen. must be used more frequently.
Da es nicht mbglich ist, dicke Beiage mit relativ klei- Injection of the granulated dry cleaning agent in the
nen Mengen von FestkOrpem abzutragen, muss die turbine is best performed at high turbocharger speed
se Methode hSufiger angewendet werden. to ensure efficient mechanical cleaning.
Die Einspritzung des granulierten Trockenreinigungs-
mediums in die Turbine erfolgt am besten bei hoher
Turbolader-Drehzahl, um eine effiziente mechanische
Reinigung sicherzustellen. General instructions
- The gas inlet temperature before the turbine must

not exceed 580-590®C.
Allgemeine Vorschriften - Care should be taken, since incompletely burnt
soot particles can be emitted with the exhaust
Die Gaseintrittstemperatur vor der Turbine darf gas fumes.
580- 590 °C nicht ubersteigen.
Es ist Vorsicht walten zu lassen, da mit dem Ab-
gasrauch unvdlstandig verbrannte Russteilchen aus-
treten kdnnen. Procedure for cleaning
Vorgehen beim Reinigen Pay attention to the specifications of the

eng
Hinweis Beachten sie die Vorschriften des

Motorenherstellers.
tl III! 10412
Betrleb und Unterhalt Kap. / Chap. 3 Operation and maintenance
4 4
Unterhaltsarbeiten Maintenance work
Unterhaltsarbeiten sind Pruf- und Funktionskontrollen Maintenance work includes inspection and function
von Verschleissteilen ohne Oder mit Austausch von checks of wearing parts with or without changing
Bethebsmitteln, Teilen Oder Baugruppen. Sie sind process materials, parts or modules. U must be
entsprechend den in der Obersicht Unterhattsarbeiten carried out in accordance with the intervals as set
angegebenen Zeitintervallen durchzufuhren. out in the Outline of Maintenance work.
Warnung ! Das Nichteinhalten von Unterhalts Warning ! Failure to carry out the maintenance
arbeiten in den angegebenen Zeit- work within the prescribed intervals can
abstanden kann zu Beschadigung und lead to damage and inoperation of the
Nutzungsausfall des Turboladers fuhren. turbocharger.
Bei alien Unterhaltsarbeiten sind die The safety instructions in the respective
Sicherheitshinweise in den entsprechen- chapters must be observed for all main
den Kapitein zu beachten. tenance work.
Beschadigte Teile, die die Funktion be- Damaged parts which could impair
eintrachtigen kbnnen, sind grundsatzlich correct function must be replaced.
auszutauschen. Screw fastenings must be tightened with
Befestigungen sind mit einem Dreh- a torque wrench (see chap. 5).
momentschlussel nachzuziehen (s. If retightening is no longer possible,
Kap. 5). replace the screw fastenings.
1st Nachziehen nicht mehr mbglich, Keep lubrication and process materials
Schraubbfestigungen gegen neue aus- ready.
tauschen.
Schmier- und Hilfsmittel bereithalten.
4.1 4.1
Ubersicht Unterhaltsarbeiten Outline of maintenance work
Unterhaltssymbole Maintenance symbols

© Unterhaltsort (T) Maintenance location
Unterhaltsstelle Maintenance point

Unterhaltsstelle Maintenance point

(in Ubersicht verdeckt) (not visible in the outline)
Austauschen Replace
Kurzbezeichnung der Unterhaltsintervalle Abbreviations for maintenance work
n. Ang. nach Angaben see

L. schild des Leistungsschilds r. plate rating plate
u/o Serv. stelle und/oder der Servicestelle a/o serv. station and/or Service station
10412 ik IIII
ABB Turbo Systems Ltd -G- #\IPIP
Unterhaltsarbeiten Maintenance work
n. Ang. L. schiid
u/o Serv. stelle
see r. plate
a/o serv. station
Fig. 3-8
Ubersicht Unterhaltsarbeiten
Outline of maintenance work
10412
Ubersicht Unterhaltsarbeiten Outline of maintenance work
nach Angaben
Unterhattstelle Unterhaltsart des Leistungsschilds
und /Oder der siehe
Servicestelle
© Lager - komplett wechsein X Abschn. 4.2
Verdichterrad - wechsein X Abschn. 4.3
Turbine - wechsein X Abschn. 4.4
see
Maintenance point Maintenance measure rating plate see
and /or service station
© Bearings - replace complete X sec. 4.2
Compressor wheel - replace X sec. 4.3
Turbine - replace X sec. 4.4
Hinweis Die Obersicht der Reserveteile befindet Note For the list of spare parts please refer
sich im Kap. 5. to chap. 5.
10412
ABB Turbo Systems Ltd -G- r\wn
4.2 4.2
Lagerwechselzeit Intervals for replacing the bearings
Die Lager sind bei Beschadigung Oder laut den An- The bearings must be replaced if damaged or at the
gaben der Servicestelle zu wechseln. latest in accordance to the instructions of the service
Die Standzeit der Lager ist abhSngig von der Fein- station.
heit des SchmierOlfilters und den Einsatzbedin- The operation period of the bearings depends on the
gungen. quality of the oil filtration and the operation conditions.
Wird das Axialspiel uberschritten, so sind die Lager-
teile zu ersetzen.
Aus- und Einbau der Lager siehe Kap. 5.
The bearings have to be replaced if the axial
clearance is exceeding.
See chap. 5 for removing and installation of the
I
bearings.
4.3
Verdichterradwechselzeit 4.3
Intervals for replacing the
Der Verdichter ist bei Beschadigung Oder spatestens compressor wheel
laut den Angaben auf dem Leistungsschild und/oder
der Servicestelle zu wechseln (s. Kap. 0).
The compressor must be replaced If damaged or at
Aus- und Einbau des Verdichters siehe Kap. 5.
the latest in accordance to the instructions of the
rating plate and/or the service station (see chap. 0).
4.4 compressor wheel.
T urbinenwechselzeit
Die Turbine ist bei Beschadigung Oder spStestens 4.4

laut den Angaben auf dem Leistungsschild und/oder Intervals for replacing the bladed
der Servicestelle zu wechseln (s. Kap. 0).
shaft
Aus- und Einbau der Turbine siehe Kap. 5.
The bladed shaft must be replaced If damaged or at

the latest in accordance to the instructions of the
rating plate and/or the service station (see chap. 0)
bladed shaft.
il III! 10412
Beheben von Storungen
Troubleshooting 4
c.
4
o C
/
Beheben von Storungen Kap. / Chap. 4 Troubleshooting
4 4
Beheben von Troubleshooting
Storungen
1 1
Storungen Troubles
Ursachen, Abhilfe 3 causes, remedies 5
Volume: 6 pages
Edition: 04/2000
HZTL 10403 III!

ABB Turbo Systems Ltd -A-
Beheben von Storungen Kap. I Chap. 4 Troubleshooting
10403
-A- ABB Turbo Systems Ltd
1
Storungen,
Ursachen, Abhilfe
Storung Ort Ursachen Abhitfe siehe
Motor - Storungen im Elnspritesystem - reparieren Oder nnit Motoren-

hersteller Kontakt aufnehmen
Turbo lader - Luftmangei, z.B. Luftfitter - reimgen Kap. 3

durch Schmutz verstopft
“ Verdichter / Turbine verschmutzt - reinigen Kap. 3

Abgastemperatur ‘ Abgasgegendnjck zu hoch - Boiler Oder Abgasschalldampfer
zu hoch, dabei reinigen Oder reparieren
Motorieistung und
-drehzahl - Turbine beschadigt Oder erodiert - Rotor ersetzen Kap. 3
unverandert
Ladeluft' - Kuhier verschmutzt - reinigen
kuhier
- Kuhlwassermenge zu gering - auffullen
- Kuhlwassereintrittstemperaturzu hoch - Kuhlsystem kontrollieren/

reinigen
- Entluftung nicht ausreicherxj - besser entluften
Motor - Luftreceiver undicht - repaneren

- Gasleitung zwischen Motor und - repaneren
Turbine undicht
- Einspritzung versteitt - richtig einstellen

Ladeluftdruck Turbolader - Manometeranzeige tehlerhaft - Manometer ersetzen
zu niedrig, dabei
Motoiieistung und - Zuleitung zum Manometer undicht - Leek reparieren
•drehzahl
- Luftfllter verschmutzt, deshalb - reinigen Kap. 3
unverandert; Druckabfall zu gross
Ansaugbedingung
normal - Verdichter / Turbine verschmutzt - reinigen Kap. 3
- Verdichter / Turbine beschadigt - Rotor ersetzen Kap. 5
- Abgasgegendruck zu gross - Boiler Oder Abgasschalldampfer

reinigen
10403 ik »l»
Storung Ort Ursachen Abhilfe siehe
Motor - Stormgen im Einspritzsystem - richtig einstellen

Ladeluftdruck zu
hoch, dabei - Motorteistung hbher als vermulet - Motorleistung kontrollieren
Motoiieistung und >
Drehzahl - Einspritzung verstellt - richtig eir^tellen
unverander^
Ansaugbedingung
normal Turbolader - Manometeranzeige fehlerhaft - Manometer ersetzen
Turboiader - Rotonjnwucht wegen starker - demontieren und reinigen Kap. 5

Verdichter/Turbinenverschmutzung Service-Stelle annjfen
Vibrationen - Turbine oder Verdichter beschadigt - Rotor erseteen Kap. 5
- Lager defekt - Lager ersetzen, evtl. Ursache Kap. 5

suchen
Turbolader - Lager beschadigt - Lager ersetzen Kap. 5
Auslaufgerausche - Rotor streift - Service-Stelle anrufen Kap. 8

Auslaufzeit
zu kurz - Turbolader verschmutzt - reinigen Kap. 3
Aniauf zogemd
- Fremdkbrper im Turbolader - Service-Stelle anrufen, Kap. 8
beschadigte Teile auswechsein
Turbolader - Otfitter stark verschmutzt - reinigen
- Olpumpe im Schmiersystem defekt - kontrollieren
Schmierdidruck
zu tief - Axialspiel des Rotors - Lager ersetzen Kap. 5
I zu gross
- Manometer zeigt falsch an - Marxjmeter ersetzen
Notoltank - Undichtheit - Notditank ausser Betrieb Kap. 2

Leckage nehmen
Standiges Pumpen Turbolader - Durchfluliwiderstand erhoht, weil:
des Turboladers
- Ladeluftkuhler Oder - reinigen Kap. 3
Schalldampfer verschmutzt
- Starke Schmutzablagerung in der - reinigen Kap. 3

Turbine
Motor - Abgasdmck nach Turbine erhoht, - reinigen

weil Boiler Oder Abgasschalldampfer
verschmutzt
- Fanggitter verschmutzt - reinigen
Servicestelle anrufen, wenn die Ursache des Pumpens nicht gefunden wird
1) nurTPL73-B..-85-B..
ik III! 10403
-A- ABB Turbo Systems Ltd
1
Troubles
causes, remedies
Trouble Location Cause Remedy see
Engine - faults in injection system - repair or consult engine

manufacturer
Turbo - lack of air, e.g. fitter blocked by dirt - clean chap. 3
charger by dirt
- compressor / turbine corrtamlnated - clean chap. 3

Exhaust gas
- Exhaust gas back pressure too high - clean or repair boiler or
temperature too exhaust gas silencer
high, engine
performance - turbine damaged or eroded - replace the rotor chap. 5
and speed Charge-air - dirt in the cooler - clean
unaltered
cooler
- insufficient cooling water - top up
- cooling water inlet temperature - check / clean coolirtg system

to high
- insufficient ventilation - improve ventilation
Engine - leak in the air receiver - repair

- leak In the gas duct between engine - repair
and turbine
- injection irrcorrectty adjusted - adjust correctly

Charge air pres
sure too low, Turbo - manometer indication defective - replace manometer
engine perfor charger
- leaks in the line to the manometer - repair leak
mance and
speed unaltered; - dirt in the air fitter causing, - clean chap. 3
air intake normal excessive pressure loss
- dirt in the compressor / turbine - clean chap. 3
- turbine / compressor damaged - replace the rotor chap. 5
- exhaust gas back pressure too high - clean boiler or exhaust gas
silencer
10403 A III!
Trouble Location Cause Remedy see
Engine - fautts in the injection system - adjust correctly
Charge air - engine performance higher than - check engine performance

pressure too high, assumed
engine
performance and - injection system incorrectly adjusted - adjust con'ectty
speed unaltered
Turbo
charger - manometer indication incorrect - replace manometer
Turbo - rotor unbalance due to heavy - remove arxl clean, chap. 5

charger contamination of compressor / turbine call service station
- turbine or compressor damaged - replace rotor chap. 5

Vibrations
- bearing defect - replace bearing, seek possible chap. 5
cause
Turbo - bearing damaged - replace bearing chap. 5

charger
Noises on running - rotor rubbing - call service station chap. 8 *
down,
time too short, - dirt in turbocharger - clean chap. 3
reluctant starting
- foreign bodies in the turbocharger - call service station, replace chap. 8 *
damaged parts
Turbo - oil filter choked with dirt - clean
charger
Pressure of - damaged pump for oil circulation - check
lubrication oil
too low - axial play of the rotor to large - replace bearings chap. 5
I Emergency
- manometer indication incomect
- leaky
- replace manometer
- Putting out of operation the chap. 2
Leakage oil tank emergency oil tank
Constant Turbo - ir>creased flow resistarxê due to:

surging of the charger
turbocharger - dirt in the charge air cooler - dean chap. 3
or silencer
- heavy deposits of dirt in the - clean chap. 3

compressor / turbine
Engine - exhaust gas pressure irx^reased after - clean

the turbine, because the boiler or
the exhaust gas silencer are dirty
- grid dirty - clean
Call the service station if the cause of the surging cannot be detected.
I 1) TPL 73-B..-85-B.. only
ik III! 10403
p\mw -A- ABB Turbo Systems Ltd
Demontage und Montage
Disassembly and assembly 5
Demontage und Montage Kap. / Chap. 5 Disassembly and assembly
5 5
Demontage und Montage Disassembly and assembly
1 1
Gewichte 3 Weights 3
1.1 1,1
Turbolader 3 Turbocharger 3
1.2 1.2
Baugruppen 5 Assemblies 5
2 2
Turbolader abbauen und anbauen 7 Removing and installing the turbocharger 7
3 3
Turbolader demontieren Disassembling and assembling the
und montieren 9 turbocharger 9
3.1 3.1
Axialspiel 9 Axial clearance 9
3.2 3.2
Rotorblock ausbauen 11 Removing the cartridge group 11
3.3 3.3
Rotorblock einbauen 21 Installing the cartridge group 21
4 4
Rotorblock demontieren Disassembling and assembling
und montieren 25 the cartridge group 25
4.1 4.1
Verdichterrad und Welle Removing the compressor wheel
ausbauen 25 and the shaft 25
4.2 4.2
Kontrolle und Beurteilung Inspection and assessment of
der Lager 33 bearing condition 33
43 4.3
Turbine ersetzen und Replacing turbine and
Verdichterrad ersetzen 35 compressor wheel 35
4.4 4.4
Rotorblock zusammenbauen 37 Assembling the cartridge group 37
Volume: pages 47
Edition: 04/2000
HZTL 10411 il III!

ABB Turbo Systems Ltd ^MilP
-F-
Seite / Page 2 T urbocharger TPL
5 5
Reserveteile 44 Spare parts 44
6 6
Tabelle der Anziehmomente 47 Table of tightening torques 47
A III! 10411
/MPIP -F- ABB Turbo Systems Ltd
Demontage und Montage Kap. I Chap. 5 Disassembly and assembly
1 1
Gewichte Weights
Warnung ! Einzelteile und grossere Baugruppen Warning ! Attach individual parts and large com
sorgfSitig an geeigneten und technisch ponent modules carefully to suitable
einwandfreien Hebezeugen / Lastauf- lifting devices which are in technically
nahmemitteln mit ausreichender Trag- perfect condition and which possess
kraft befestigen. adequate loading-bearing capacity.
Sich nicht unter schwebenden Lasten Do not stand under suspended loads
aufhalten (s, Kap. 1). (see chap. 1).
1.1 1.1
Turbolader Turbocharger
Turbolader komplett:
(ohne Schalldampfer/Luftsaugstutzen)
TPL
Turbocharger complete:
(without silencer/air suction branch)
[kg]
69 1'415
73 2'080
77 3‘200
80 4'920
85 8'380
ABB Turbo Systems Ltd 10411 A III!

-F-
Fig. 5-1
Gewichte der Baugruppen
Weights of assemblies
A l»l» 10411
-F- ABB Turbo Systems Ltd
1.2 1.2
Baugruppen Assemblies
Gewicht/Weight
[kgl
Bezeichnung
Pos. TPL TPL TPL
Designation TPL TPL
69 73 77 80 85
1 Luftsaugstutzen radial / Air suction branch radial 80 140 155 242 290
2 Luftsaugstutzen axial / Air suction branch axial
3 Schalldampfer / Silencer 140 230 380 570 950
4 Verdichtergehause Innenteil / Compressor casing internal part 83 120 220 344 538
5 Einsatzwand / Wall insert 85 134 276 431 675
6 Diffusor/ Diffuser 36 57 80 125 195
7 Verdichtergehause Aussenteil / Compressor casing external part 180 240 395 617 963
8 Rotorblock / Cartridge group 356 546 868 1'356 2'118
9 Verdichterrad / Compressor wheel 20 32 51 80 125
10 Zwischenwand / Partition wall 27 41 59 92 140
11 Lagerteile / Bearing parts 16 27 42 81 180
12 Lagerbuchse / Bearing bush 22 33 58 91 140
13 Lagergehause mit Haube / Bearing casing with hood 226 337 543 848 1’325
14 Dichtungsdeckel / Sealing cover 8 14 22.5 35 51
15 Welle / Shaft 37 58 92 144 225
16 Turbinendiffusor/Turbine diffuser 46 72 96 150 460
17 Dusenring / Nozzle rir>g 17 25 40.5 63 95
18 Gasaustrittsgehause / Gas outlet casing 342 467 707 1105 1725
19 Gaseintrittsgehause axial / Gas inlet casing axial 120 202 316 495
20 Gaseintrittsgehause radial / Gas inlet casing radial 147 213 320 520
21 Fuss / Foot 104 183 298 466 860
ABB Turbo Systems Ltd 10411 Ik mi

-F-
Neue Ausfuhrung
New design
Alte Ausfuhrung
Fig. 5-2 Old design
Turbolader ab- und anbauen
Removing and installing the turbocharger
ik llll 10411
2
2
Turbolader abbauen Removing and installing
und anbauen the turbocharger
Samtiiche Gas- Luft- und Olleitungen nach den Disconnect all gas air and oil lines in accordance
Angaben des Motorenbauers trennen. with the manufacturer’s instructions.
Isolationsschale vom Lagergehause entfernen. Remove the insulating dish of the bearing casing
Hebegeschirr kontrollieren. Check the lifting equipment.
Hebegeschirr an den Aufhangeosen des Lager- Fix lifting equipment to suspension lugs of bearing
gehauses befestigen (s. Fig. 5-2/1). casing (see fig. 5-2/1).
Vorsicht 1 Gewichte des Turboladers fur die Seil- Caution 1 Take into account the weight of turbo
wahl berucksichtigen. charger when selecting rope
Gesamter Turbolader am Lagerge Suspend the complete turbocharger on
hause, an den zwei dafur vorgesehe- bearing casing, using the two ribs
nen Rippen aufhangen. provided for this purpose.
Bei Lagergehausen ohne verstarkte For bearing casings without reinforced
Aufhangeosen muss der gesamte La- suspension eyelets the complete
der am Luftaustritts- und Gaseintritts- turbocharger must be secured at the air
gehause befestigt werden (s. Fig. 5-2/2). outlet and gas inlet casing (see fig.
1st der Schalldampfer eventuell mit ei- 5-2/2).
nem Poller (A) versehen, darf dieser If the silencer is provided with a post
beim Anheben des gesamten Turbo (A), this must not be used when lifting
laders nicht benutzt werden. the complete turbocharger.
Befestigungsschrauben am Fuss Ibsen. Release fixing screws on foot.
Turbolader vom Motor abheben und deponieren Lift the turbocharger from the engine and put it by
side.
Vorsicht I Kippgefahr:
Turbolader an geeigneter Stelle abstCit- Caution 1 Beware of tilting.
zen. Support turbocharger at suitable place
Olanschlusse abdecken. Cover oil connectors.
- J- - J-
Turbolader in sinngemass umgekehrter Reihenfolge To install the turbocharger follow these instructions
anbauen. in the reverse order.
- Inbetriebnahme gem. Kap. 2. - Putting into operation as in chap. 2.
10411 A III!
ABB Turbo Systems Ltd -F-
90235
I
Fig. 5-3
Schalldampfer transportieren
Transport silencer
74027 74028
Fig. 5-4
Axiatspiele
Axial clearances
Spiel / Clearance
[mm]
TPL 69 TPL 73 TPL 77 TPL 80 TPL 85

A min. 0,37 0,40 0,43 0,47 0,52
A max. 0,47 0,51 0,55 0,59 0,66
il IMI 10411
psMwn -F- ABB Turbo Systems Ltd
3 3
Turbolader demontieren Disassembling and
und montieren assembling turbocharger
A
Vorsicht I Gewichte derTurboladerteile ftirdie Seil-
wahl berticksichtigen.
Hebegeschirr kontrollieren und ord-
A
Caution 1 Take account of the weight of the
turbocharger parts when selecting a
suitable rope.
nungsgemass befestigen. Check lifting equipment and secure
properly.
Samtiiche Luftleitungen nach den Angaben des
Motorenbauers trennen. Disconnect all air lines in accordance with the
motor manufacturer's instructions.
Isolationsschalen entfernen.
Remove the insulating dishes.
Muttern (74027) mit Verbus-Ripp-Scheiben
(74028) losen (s. Fig. 5-4) und Luftsaugstutzen Release nuts (74027) with verbus-discs (74028)
entfernen. and remove air suction branch (see fig. 5-4).
TPL 69 TPL 69
+ Hebezeug an den ruckseitigen Osen mit Schakel + Fix lifting gear to eyes at rear with shackle and
befestigen und um den Poller schlingen. loop round post.
TPL 73 - 85 TPL 73 - 85
+ Ringschraube (90235) am SchalldSmpfer montie + Fit lifting eye bolt (90235) on silencer. Fix lifting
ren. Hebezeug an den ruckseitigen Osen und in gear on eyes at rear and in lifting eye bolt with
der Ringschraube mit Schake! befestigen (s. Fig. shackle (s. Fig. 5-3).
5-3).
Release nuts (74027) with verbus-discs (74028)
Muttern (74027) mit Verbus-Ripp-Scheiben and remove the silencer (see fig. 5-4).
(74028) losen und Schalldampfer entfernen (s.
Fig. 5-4).
3.1 3.1
Axialspiel Axial clearance
Vordem weiteren Demontieren ist das Axialspiel "A' Before removing the axial clearance "A" of the rotor
des Rotors zu messen. has to be measured.
Vorsicht 1 Axialspiel messen und notieren (s. Fig.

5-4).
Ist das Spiel ausserhalb der Toleranz,
A
Caution 1 Measure and note the axial clearance
(see fig. 5-4).
If the clearance is out of tolerance,
Lager demontieren, ausgebaute Lager- disassemble and check the beanng parts
teile kontrollieren und defekte Teile er- and replace defective ones (see sec 4).
setzen (s. Abschn. 4). If the clearance cannot be obtained, an
Kann das Spiel nichterreichtwerden, ist authorized ABB Turbo Systems Ltd
eine autorisierte Service-Stelle der ABB service station should be contacted
Turbo Systems AG zu kontaktieren.
10411 A II l»
-F-
Selte/Page 10 Turbocharger TPL
74026
90320
76040
76000
74027
90190 90195
90025
90900
90190
0 2
\o
76000
0 0 3
10
.0'
Fig. 5-5 0
Rotorblock ausbauen
Removing the cartridge group
10411
3.2 3.2
Rotorblock ausbauen Removing the cartridge group
Olleitungen nach Angaben des Motorenbauers Disconnect the oil lines with the motor manu
trennen. facture's instructions.
Im oberen Bereich sechs Stiftschrauben (74026) Remove six studs (74026) in upper section and
entfernen und vier Fuhrungsbolzen (90320) mon- and fit four guide bolts (90320) (see fig. 5-5/1).
tieren (s. Fig. 5-5/1).
Leave 2 holes free for fitting the lifting

Hinweis Zwei Ldcher fur die Hebevorrichtung device (90190).
(90190) freihalten.
Push back internal part of compressor casing
Verdichtergehause-Innenteil (76000) mit Abdruck- (76000) with puller screws (90900) until the lifting
schrauben (90900) soweit abdrucken, bis die He device (90190/90195) can be fitted.
bevorrichtung (90190/90195) angebracht werden
kann. Withdraw internal part of compressor casing with
wall insert and diffuser.
Verdichtergehause-Innenteil mit Einsatzwand und
Diffusor herausziehen. Fit support angle (90025).
Abstutzwinkel (90025) anbringen. Place internal part of compressor casing with wall
insert and diffuser on support angle and shim.
Diffusor auf Abstutzwinkel und Unterlage abstel- Loop lifting device round rear of flange (see fig.
len. 5-5/2).
Turn internal part of compressor casing with wall

Hebevorrichtung auf die Ruckseite des Flansches
insert and diffuser carefully over support angle
umhangen (s. Fig 5-5/2).
(90025) and place on shims.
Diffusor vorsichtig uber den Abstutzwinkel (90025)
drehen und auf Unterlagen legen.
Caution ! Ensure that the shims do not slide away
Remove 0-ring gasket (76040).

Vorsicht I Darauf achten, das die Unterlagen nicht
wegrutschen.
0-Ring (76040) entfernen.
10411 ik im
90235 76002
TPL 77 - 85
79000
90230
77000
77006
77005
Fig. 5-5
Rotorblock ausbauen
il IMI 10411
TPL 69 & 73 TPL 69 & 73

+ Schrauben (76002) und Diffusor (79000) entfer- + Remove screws (76002) and diffuser (79000)
nen (s. Fig. 5-5/3). (see fig. 5-5/3).
TPL 77 - 85 TPL 77 - 85
+ Schrauben (76002) entfernen (s. Fig. 5-5/3). + Remove screws (76002) (see fig. 5-5/3)
+ Diffusor (79000) mittels Ringschrauben (90235) + Remove diffuser (79000) by means of ring bolts
entfernen. (90235).
Einsatzwand (77000) mittels Ringschrauben Withdraw wall insert (77000) by means of ring
(90230) herausziehen und 0-Ringe (77005 & bolts (90230) and remove O-ring gasKets (77005
77006) entfernen (s. Fig. 5-5/4). & 77006) (see fig. 5-5/4).
ABB Turbo Systems Ltd 10411

-F-
74000
25005
90020
90480
90460
max. Loslosemement
max. releasing torque 260 410 140 220 400
[Nm]
Fig. 5-6
Rotorblock ausbauen
A l»l» 10411
p\mn -F- ABB Turbo Systems Ltd
Verschlussschraube (25005) demontieren (s. Fig. Remove screw plug (25005) (see fig. 5-6/1).
5-6/1).
Fit assembly-disassembly device (90020) to
Montage-Demontage-Vorrichtung (90020) am external part of compressor casing (74000).
Verdichtergehause-Aussenteil (74000) befestigen.
Do not yet tighten screws fully.

Hinweis Die Schrauben noch nicht anziehen.
Place lock (90480) in compressor wheel through
Arretierung (90480) durch Montage-Demontage- assembly-disassembly device. Turn rotor slightly
Vorrichtung in Verdichterrad schieben. Dabei Ro until the hexagon of the lock engages with that of
tor lelcht drehen, bis der Sechskant der Arretie the compressor wheel.
rung mit dem des Verdichterrades greift.
Place box spanner (90470) on shaft through lock.
Steckschlussel (90470) durch Arretierung auf Wel Turn spanner slightly until the hexagon of the
le schieben. Dabei Steckschlussel leicht drehen, spanner engages with that of the shaft (see fig.
bis der Sechskant des Steckschlussels mit dem 5-6/2).
der Welle greift (s. Fig. 5-6/2).
Vorsicht! Steckschlussel muss ganz hinten auf

dem Sechskant sein (Mass L kontrollie-
A
Caution 1 Box spanner must be right back on the
hexagon (check dimension L).
ren).
TPL TPL TPL TPL TPL

69 73 77 80 85
L
54 56 75 80 70
[mm]
Schrauben der Montage-Demontage-Vorrichtung Tighten screws of assembly-disassembly device.

anziehen. Kraftvervielfaltiger (90460) anbringen Fit torque multiplier (90460) and release compres
und Verdichterrad ca. 1 bis 2 Umdrehung Idsen sor wheel about 1 to 2 turns (see fig. 5-6/3).
(s. Fig. 5-6/3).
Vorsicht I Drehrichtung auf der Montage-Demon-

tagevorrichtung beachten.
Caution I Note sense of rotation on assembly-
disassembly device.
Do not exceed max. releasing torque
I
Max. Losidsemoment nicht uberschrei- (see table)! If the compressor wheel
ten (siehe Tabelle)! Kann das Verdich cannot be released, an authorised ABB
terrad nicht geldst warden, ist eine au- Turbo Systems service station should
torisierte Service-Stelle der ABB Turbo be contacted.
Systems AG zu kontaktieren.
Remove torque multiplier (90460).

Kraftvervielfaltiger (90460) entfernen
Remove box spanner, lock and assembly-
Steckschlussel, Arretierung und Montage-Demon disassembly device.
tage-Vorrichtung entfernen.
10411 A IIII
ABB Turbo Systems Ltd -F- ^MPli
74000
90190/90195
0^
r
'•s.
61037
61037
61036
90921
42001
90900
61035
86505 / 86506
86515
Fig. 5-7
Rotorblock ausbauen
90450 Removing the cartridge group
At III! 10411
P\WMW -F- ABB Turbo Systems Ltd
Hebevorrichtung (90190/90195) am Verdichter- Secure lifting device (90190/90195) to external

gehause-Aussenteil (74000) befestigen und am part of compressor casing (74000) and fix to crane
Kran sichern (s. Fig. 5-7/1). (see fig. 5-7/1).
Muttern (61037) Ibsen, Verdichtergehause-Aus- Loosen nuts (61037), press off external part of
senteil mit den drei Abdruck-Muttern (61037) compressor casing evenly with the three press-
gleichmassig abdrucken und entfernen. off nuts (61037) and remove.
Kabel (86515) ausstecken und Drehzahlmess- Withdraw cable (86515) and unscrew speed
geber (86505) mit O-Ring (86506) ausschrauben measuring transmitter (86505) with 0-ring (86506)
(s. Fig. 5-7/2). (see fig. 5-7/2).
Falls vorhanden; If present:

+ Kabel am Leitungsverstarker (86525) ausstecken + Disconect cable to line amplifier (86525).
Drei Schrauben (61035) entfernen, Hebegeschirr Release screws (61035), check lifting equipment
kontrollieren und am Lagergehause (42001) be and fix to bearing casing (42001).
festigen.
A
Vorsicht! Gewicht des Rotorblocks fur die Seil-
wahl berucksichtigen.
A
Caution I Take account of weight of cartridge
group when selecting the rope.
Press cartridge group down evenly with jack

Rotorblock mit den Abpressschrauben (90900) in screws (90900) into the holes provided.
den daftir vorgesehenen Lbchern gleichmassig
abdrucken
A
Vorsicht! Durch Drehen am Rotor prufen, dass
A
Caution I By turning the rotor, check that the shaft
does not touch the turbine diffuser.
die Welle nicht am Turbinendiffusor Extract cartridge group, fit supports (90450) and
streift. lay it down (see fig. 5-7/2).
Rotorblock ausfahren und die Abstiitzungen Cover oil connectors.

(90450) anbringen (s. Fig. 5-7/2).
Olanschlusse abdecken. Place clamp (90921) over stud (61036) until it

lies against the inner radius of the gas outlet
casing. Insert extension (A) of torque spanner (B)
Bride (90921) uber Stiftschraube (61036) stek- through clamp hole and release the torque of
ken bis Bride am Innenradius vom Gasaustritts- screws (61032) in succession. Do not yet remove
gehause aufliegt. Durch Bohrung der Bride die screws (61032) (see fig. 5-7/2).
Verlangerung (A) des Drehmomentschlussels (B)
fijhren und nacheinander das Anzugsmoment der
Schrauben (61032) Ibsen. Schrauben (61032)
noch nicht entfernen (siehe Fig.5-7/2).
ABB Turbo Systems Ltd 10411 ii III!

-F-
90320
61032 1
90178
90921
63000
90901
90490
56001
Fig. 5-8
Turbinendiffusor & Diisenring ausbauen
Removing the turbine diffusor & nozzle ring
A IMI 10411
Im oberen Bereich des Turbinendiffusors (63000) In upper section of turbine diffuser (63000) replace
zwei Schrauben (61032) durch zwei Fuhrungs- two screws (61032) with two guide studs (90320).
bolzen (90320) ersetzen. Die Fuhrungsbolzen wer- The guide studs are taken through the hole of
den vorne durch die Bohrung der Briden (90921) clamps (90921) at the front. To secure fit hexagon
gefuhrt. Zur Sicherung 6kt-Muttern (90178) mon- nuts (90178) (see fig. 5-8/1).
tieren (siehe Fig. 5-8/1).
Before dismantling the turbine diffuser, the nozzle
Vor der Demontage des Turbinendiffusors ist nach ring should be secured against falling if possible,
Mdglichkeit der Dusenring mit Spannset und Holz- with clamping set and wooden block (see fig,
stuck gegen herunterfallen zu sichern (s. Fig. 5-8/2).
5-8/2).
Release remaining screws (61032), push back
Restliche Schrauben (61032) losen, Turbinen- the turbine diffuser (63000) with press-off screws
diffusor (63000) mit den Abdruckschrauben (90901) and withdraw turbine diffuser (63000) as
(90901) losdrucken, bis zur 6kt-Mutter (90178) far as hex-headed nut, fix diffusor at lifting gear
herausziehen, am Hebezeug befestigen und ent- and remove.
fernen.
A
Vorsicht I Wenn Dusenring nicht gesichert:
Dusenring (56001) hangt lose an den
A
Caution I If nozzle ring not secured:
The nozzle ring (56001) hangs loosely
from the positioning pins and can drop
Positionierungstiften und kann herunter down.
fallen.
Fix holder (90490) on gas outlet casing (see fig
5-8/3).
Halter (90490) am Gasaustrittsgehause befesti
gen (s. Fig. 5-8/3). Draw nozzle ring (56001) forward, fix nozzle ring
at lifting gear and remove (see fig. 5-8/4).
Dusenring (56001) nach vorne ziehen, am Hebe
zeug befestigen und entfernen (s. Fig. 5-8/4).
ABB Turbo Systems Ltd 10411 a im

-F-
90460
Drehmoment / Torque
TPL TPL TPL TPL TPL

69 73 77 80 85
Anzugsmoment am Schlussel
Tightening torque at the key 130 205 70 110 200
[Nm]
Kraftvervielfaltiger
5:1 5:1 25:1 25:1 25:1
Torque multiplier
Resultierendes Moment
Resulting torque 660 1030 1730 2700 4960
[Nm]
Fig. 5-9
Montage vom Verdichterrad
Installing compressor wheel
A IIII 10411
3.3 3.3
Rotorblock einbauen Installing the cartridge group
Die Montage erfoigt in sinngemass umgekehrter Rei- Assembly is performed in the reverse sequence to
henfolge wie im Kap. 3.2, Rotorblock ausbauen be- dismantling of the cartridge block described in
schrieben wird. chap. 3.2.
Folgende Hinweise mussen zusatzlich beachtet wer- The following points must also be noted:
den:
Montage Dusenring Assembling the nozzle ring
Hinweis Positionierungsstifte im Dusenring auf Note Align positioning pins in nozzle ring with
die Ldcher im Gaseintrittsgehause aus- the holes in the gas inlet casing.
richten. Smear all screws in and on the gas
Alie Schrauben im und am Gasaustritts- outlet casing with Anti Scuff Paste 868
gehause mit Anti Scuff Paste 868 von from SPANJAARD.
SPANJAARD einstreichen.
Montage Rotorblock Assembling the cartridge group
A
Vorsicht I Lagergehause gerade am Kran befesti-
gen und vorsichtig einfahren.
Schrauben (61035) gleichmassig anzie-
A
Caution ! Fix bearing casing straight on crane and
introduce carefully.
Tighten screws (61035) evenly and
hen und durch Drehen an der Welle pru- check by turning the shaft that they do
fen ob diese nicht am Turbinendiffusor not touch the turbine diffuser (see fig.
streift (s. Fig. 5-7/2). 5-7/2).
Montage Verdichtergehause-Aussenteil Assembling external part of compressor

casing
Hinweis Vor der Montage des Verdichtergehause-

Aussenteils. drei Abdruckmuttem (61037) Before fitting the external part of the
bis ans Gewindeende auf die daftir vor- compressor casing, screw three press-
gesehenen Stiftschrauben schrauben off nuts (61037) on the studs provided
(s. Fig. 5-7/1). for this purpose, to the end of the thread
(see fig. 5-7/1).
Montage des Verdichterrades
Assembling the compressor wheel
Hinweis Vor dem Arbeiten mit dem Kraft-

vervielfaltiger (90460) unbedingt die Be- Before working with the torque multiplier
dienungsanleitung von diesem Wekzeug (90460), read the operating instructions
durchlesen Die Bedienungsanleitung ist for this tool carefully without fail. These
der Werkzeugkiste beigefugt. are provided in the toolbox.
Verdichterrad mittels Kraftvervielfaltiger mit dem Tighten compressor wheel using the torque
in der Tabelle angegebenen Drehmoment fest- multiplier to the torque M^ specified in the table
ziehen (s. Fig 5-9). (see fig. 5-9).
Drehrichtung auf der Montage-Demontage- Note direction of rotation on the assembly-
vorrichtung beachten. disassembly device.
ABB Turbo Systems Ltd 10411 ik IIII

-F- ^MPIP
90235 -
TPL 77 - 85
72002
79000
90230
77000
77006
77005
Fig. 5-10
Ensatzwand und Diffusort montleren
Mounting of the wall insert and diffuser
ik IIII 10411
p\§wn -F- ABB Turbo Systems Ltd
Hinweis Die Montage-Demontage-Vorrichtung Note The assembly-disassembly device can

kann sich wahrend dem Anziehen durch bend under pressure \while tightening.
den Druck verbiegen. Aus diesem Grund For this reason the torque multiplier
ist vor dem endgultigen Anziehen der should be briefly released before final
Kraftvervielfaltiger kurz zu entlasten. tightening.
A
TPL 77-85
Warnung I Dm den Kraftverfielfaltiger zu entspan-
TPL 77 - 85
Warning! To release or remove the torque
nen Oder zu entfernen, Rucklauf- multiplier, move return travel lock to
sicherung auf "Free" schieben und den “Free” and turn the torque spanner
Drehmomentschlussel langsam mit der slowly by hand counter-clockwise, until
Hand gegen den Uhrzeiger drehen, bis the torque multiplier is loosened.
sich der Kraftvervielfaltiger lockert.
Montage Verdichtergehause-Innenteil Assembling internal part of compressor

casing
a) Einsatzwand
a) Wall Insert
- 0-Ringe (77005 & 77006) montieren (s. Fig. 5-10).
- Fit 0-ring gaskets (77005 & 77006) (see fig 5-10).
Ringschrauben (90230) montieren und Einsatz
wand (77000) montieren. Fit ring bolts (90230) and wall insert (77000)
Hinweis Die Verlangerung an den Ringschrauben The extension of the ring bolts (90230)
(90230) dienen als Fuhrung bei der Mon serves as a guide when fitting the wall
tage der Einsatzwand (77000). insert (77000).
b) Diffusor b) Diffuser
- Diffusor (79000) montieren, bei TPL77-85 mit - Fit diffuser (79000), at TPL77-85 with ring bolts
Ringschrauben (90235). (90235).
Schraube (72002) bis zum Anschlag anziehen und Tighten screw (72002) to stop and then release
dann %-Umdrehung Ibsen. Die Schraube muss Va turn. The screw must be loose and the diffuser
lose und der Diffusor beweglich sein. movable.
c) Montage Verdichtergehause-Innenteil c) Assembling internal part of compressor

casing
- Verdichtergehause-lnnenteii in umgekehrter Rei-
henfolge von Kap. 3.2 montieren. - Fit internal part of compressor casing in the
reverse sequence to point 3.2.
Vorsicht I Abstutzwinkel anbringen.

Verdichtergehause-Innenteil mit Einsatz
wand und Diffusor vorsichtig uber Ab
stutzwinkel aufrichten und montieren.
A
Caution ! Attach supporting bracket.
Place internal part of compressor casing
with wall insert and diffuser carefully over
supporting bracket and fit.
Nach der Montage des Verdichtergehause-Innen
teil das Axialspiel messen (s. Abschn. 3.1). The axial clearance should be measured after
assembling the internal part of the compressor
casing (see point 3.1).
ABB Turbo Systems Ltd 10411 A ll»

-F-
TPL 73 -
90190/90195
0 •
\o\
25000
90500
90020
25000
90920
90300 90174
2
90235
TPL 77 - 85
43001
43005
32104
90174
Fig. 5-11
90300 Rotorblock demontieren
Dismantling the cartridge group
A ll» 10411
4 4
Rotorblock demontieren und mon- Disassembling and assembling the
tieren cartridge group
4.1 4.1
Verdichterrad und Welle ausbauen Removing the compressor wheel
and the shaft
Rotorblock ausbauen (s. Abschn. 3.2).
Dismantle the cartridge group (see sec. 3.2).

TPL 69:
+ Verdichterrad (25000) von Hand entfernen (s. Fig.
TPL 69:
5-11/1).
+ Remove compressor wheel (25000) by hand (see
fig. 5-11/1).
Warnung I Das Verdichterrad hat scharfe Kanten

die zu Verletzungen fuhren konnen.
Warning I The compressor wheel has sharp edges
which can cause injury.
TPL 73 -85:
+ Hebevorrichtung (90190/90195) an der Montage-
TPL 73-85:
Demontage-Vorrichtung (90020) anschrauben und
+ Screw lifting device (90190/90195) to assembly-
am Hebezeug befestigen.
disassembly device (90020) and fix to lifting gear.
+ Haltevorrichtung (90500) einschrauben.

+ Fit locking device (90500). I
+ Verdichterrad Ibsen und horizontal ausfahren.
+ Release compressor wheel and withdraw hori
zontally.
Warnung I Die Montage-Demontage-Vorrichtung

kann sich beim beim Abstellen auf den
Warning I The assembly-disassembly device can
Boden ruckartig verdrehen.
twist suddenly when placed on the floor.
Verlangerung (90174) und Fuhrungsrohr (90300) Fit extension piece (90174) and guide tube (90300)
zum Schutz des Gewindes montieren. Abdruck- as thread protection. Fit press-off tool (90920) (see
werkzeug (90920) montieren (s. Fig. 5-11/2). fig. 5-11/2).
TPL 69 & 73 TPL69 & 73

+ Zwischenwand (43001) abdrucken und mit + Press off partition wall (43001) and withdraw with
Fuhrungsrohr (90300) herausziehen. Zwischen guide tube (90300). Remove partition wall with
wand mittels Hebezeug entfernen lifting gear.
TPL 77 - 85 TPL77-85
+ Zwischenwand (43001) abdrucken. + Press off partition wall (43001).
+ Zwischenwand 90° drehen, Ringschraube (90235) + Turn partition wall 90°, fit lifting eye bolt (90235)
montieren und am Hebezeug befestigen. and secure to lifting gear.
+ Zwischenwand (43001) mit Fuhrungsrohr (90300) Withdraw and remove partition wall (43001) with
herausziehen und entfernen. guide tube (90300).
- Verlangerung (90174) entfernen (s. Fig. 5-11/2). Remove extension piece (90174) (see fig. 5-11/2).
- Beruhrungsdichtung (32114) und Hilfslager (32104) Remove contact seal (32114) and auxiliary bearing
entfernen. (32104).
ABB Turbo Systems Ltd 10411 A IIII

-F- ^ÎPli
32107 32101
42050 42050
32112
Fig. 5-12
Rotorblock demontieren
32001 Disassembling the cartridge group
il IIII 10411
Veriangerung (90174) wieder montleren. Refit extension piece (90174).
Vorsicht I Urn eine Lagerbeschadigung beim her- Caution I To prevent damage to the bearings
ausziehen zu verhindern, mussen die \when withdraNwing, the holes of the
Locher der Verlangerung in horizontaler extension piece must be in the horizon
Lage sein. tal position.
Schrauben (32112) entfernen (s. Fig. 5-12/1). Remove screws (32112) (see fig. 5-12/1).
Axiallager (32106) mitden Schrauben (32112) in Press axial bearing (32106) with screws (32112)
den dafur vorgesehenen Ldchern abdrucken und in the holes provided and remove.
entfernen.
Caution ! Floating disc (32105) can stick to the

Vorsicht I Schwimmscheibe (32105) kann am axial bearing and drop down.
Axiallager haften und herunterfallen.
Remove floating disc (32105).
Schwimmscheibe (32105) entfernen.
Remove extension piece (90174).
Verlangerung (90174) entfernen
With radial bearing change:

Bei Radiallagertausch: + Remove screws (32110) and dismantle radial
+ Schrauben (32110) entfernen und Radiallager bearing (32101) (see fig. 5-12/2).
(32101) ausbauen (s. Fig. 5-12/2).
Note When fitting, new, original fixing screws

Hinweis Bei der Montage mussen neue, originale
Befestigungsschrauben (32110) (mit
(32110) (with Precot coat) must be used.
I
Precot-Anstrich) venA/endet werden.
Release screws (42050) until the threads are still
effective for at least 10 mm (see fig. 5-12/3).
Schrauben (42050) soweit Ibsen, dass die Gewin-
de noch mindestens 10 mm im Einsatz sind. Press thrust bearing (32001) and bearing bush
(s. Fig. 5-12/3). (32107) with the screws (32112) into the holes
provided.
Kammlager (32001) und Lagerbuchse (32107) mit
den Schrauben (32112) in den dafiir vorgesehe
nen Lbchern abdrucken. In order to prevent any damage to the
shaft, press the bearing bush only as
far as necessary to remove the thrust
Hinweis Dm die Welle vor Beschadigung zu bearing.
schuteen, Lagerbuchse nur soweit ab-
pressen bis das Kammlager entfernt Remove thrust bearing (32001)
werden kann.
To remove the shaft, re-tighten screws (42050)
Kammlager (32001) entfernen. provisionally.
Zum entfernen der Welle, Schrauben (42050) pro-

visorisch wieder anziehen.
10411 ik III!
-F-
1 0
90600
90174
90170 21000
32112
43006
42012
43007
90600
90174
Disassembling the cartridge group
A IMI 10411
/%IPIP -F- ABB Turbo Systems Ltd
Verlangerung (90174) (mitden kleinen Ldchern ge- Fit extension piece (90174) (with small holes
gen die Lagerbuchse) montieren (s. Fig. 5-13/1). towards bearing bush) (see fig. 5-13/1).
Hinweis Verlangerung leicht einolen Oil extension piece lightly.
Fuhrungsplatte (90170 mit Schrauben (32112) Fit guide plate (90170) with screws (32112).
montieren.
Fix lifting gear (90600) to shaft.
Hebewerkzeug (90600) an Welle befestigen
Drive out shaft (21000) slightly. Loop lifting rope
Welle (21000) wenig ausfahren, Hebeseil hinter round shaft behind turbine disc and drive out shaft
Turbinenscheibe um Welle schlingen und Welle horizontally (see fig. 5-13/2).
horizontal ausfahren (s. Fig.5-13/2).
Caution 1 Loop second lifting rope round crane

Vorsicht 1 Zur Sicherung der Welle gegen Abrut- hook and secure to lifting gear (90600)
schen vom Hebeseil, zweites Hebeseil to prevent the shaft slipping off the lifting
um den Kranhaken schlingen und am cable.
Hebewerkzeug (90600) befestigen.
The shaft should be placed axially on

Hinweis Welle ist axial auf der Turbinenscheibe the turbine disc (see fig. 5-13/4).
zu lagern (s. Fig.5-13/4). For this purpose the shaft should be
Dazu ist die Welle horizontal auf zwei placed on two suitable wooden supports
geeignete Hoizunterlagen abzustellen and secured with wedges (see fig. 5-
und mit Keilen zu sichern (s. Fig.5- 13/3). Release lifting rope behind turbine
13/3). Hebeseil hinter Turbinenscheibe disc and fix to bore of extension piece
Idsen und an der Bohrung der Verlan (90174). The shaft should be turned
gerung (90174) zu befestigen. Mitzwei- vertically with the second crane hook.
tem Kranhaken ist Welle vertikal zu dre- Remove lifting gear (90600). Place shaft
hen. Hebewerkzeug (90600) entfernen. turbine end on suitable wooden
Welle Turbinenseitig auf geeignete Hoiz supports.
unterlagen abstellen.
0-Ring (42012) entfernen. Remove 0-ring gasket (42012).
0-Ringe (43006/43007) entfernen Remove 0-rings (43006/43007).
10411 Al IMI
ABB Turbo Systems Ltd fMPIP
-F-
32107
90320
90170
32102
42002
90901
90320
42016
42015
42002
Fig. 5-14
Disassembling the cartridge group
10411
Fuhrungsplatte (90170 entfernen (s. Fig. 5-14/1). Remove guide plate (90170) (see fig. 5-14/1).
Schrauben (42050) entfernen. Remove screws (42050)
Drei Fuhrungsbolzen (90320) montieren Fit three guide bolts (90320).
Vorsicht 1 Zur Sicherung gegen das Heraus- Caution 1 Place a cross-pin in the top guide bolt
rutschen der Lagerbuchse, im obersten to prevent the bearing bush slipping out.
Fuhrungsbolzen ein Querstift anbringen.
Withdraw bearing bush (32107) over guide bolts
Lagerbuchse (32107) uber Fuhrungsbolzen her- and remove with lifting gear.
ausziehen und mittels Hebezeug entfernen.
Fit one guide bolt (90320) in bearing

Hinweis Ein Fuhrungsbolzen (90320) in Lager bush. Withdraw bearing bush with
buchse montieren. Mit wippenden Be- rocking motions.
wegungen Lagerbuchse herausziehen.
Warnung 1 Beim herausfahren der Lagerbuchse aus

dem Fuhrungssitz kippt die Lager
A
Warning 1 The bearing bush tilts when withdrawing
the bearing bush from the guide seat.
This drives the guide bolt upwards.
buchse. Dadurch schlagtder Fuhrungs
bolzen nach oben.
With radial bearing change:
+ Remove screws (32111) and dismantle radial
Bei Radiallagertausch: bearing (32102) (see fig. 5-14/2).
+ Schrauben (32111) entfernen und Radiallager
(32102) ausbauen (s. Fig. 5-14/2).
When fitting, new, original fixing screws

I
Precot-Anstrich) verwendet warden.
A
Caution I Secure hood (42002) with clamping set
round bearing casing (see fig. 5-14/3).
Vorsicht! Haube (42002) mit Spannset urn Lager- Remove screws (42016) (see fig. 5-14/4)
gehause sichern (s. Fig. 5-14/3).
Fit guide bolt (90320) on the top.
Schrauben (42016) entfernen (s. Fig. 5-14/4).
Press of and remove sealing cover (42015) with
Fuhrungsbolzen (90320) montieren. puller screws (90901).
Dichtungsdeckel (42015) mit den Abdruckschrau- Remove 0-ring gasket (42011) and remove guide
ben (90901) abpressen und entfernen. bolt.
0-Ring (42011) entfernen und Fuhrungsbolzen Release clamping set and remove hood (42002).
entfernen.
Spannset losen und Haube (42002) entfernen
ABB Turbo Systems Ltd 10411 A IMI

-F-
Vorsicht I Ausgebaute Teile vor Verschmutzung Caution 1 Protect removed parts from dirt.
schutzen. Damaged turbine blades, damping wires
Beschadigte Turbinenschaufeln, Dampfer- and compressor may only be replaced
drahte und Verdichter nur von einer auto- by an authorized ABB Turbo Systems
risierten Service-Stelle der ABB Turbo Sy Ltd. service station.
stems AG ersetzen lassen. The changing times of the turbine and
Die Wechselzeiten der Turbine und des compressor must be observed (changing
Verdichters sind einzuhalten (Wechselin- interval according to rating plate, see
tervall gemass Leistungsschild, s. Kap 0). chap. 0).
Notizen Notes
A ll» 10411
4.2 4.2
Kontrolle und Beurteilung der La Inspection and assessment of
ger bearing conditions
4.2.1 4.2.1
Visuelle Beurteilung Visual assessment
Bezeichnung Befund Massnahme

Ausgebrochene Teile des Lagermaterial Neues Lager einbauen
Risse im Lagermaterial Neues Lager einbauen
Vereinzelte leichte Kratzspuren von
Radial- und Axial- Kratzspuren in den Gleitflachen Fremdkbrpem Sind bedeutungslos. Keinesfalls
gleitflachen der diirfen diese durch Nacharbeit entfernt warden.
Lager Abnutzung der Gleitflachen bei guter Sofem das Axialspiel zulassig ist, ist das Lager
Oberflachenbeschaffenheit waiter verwendbar
Anfressung Oder starke Abnutzung der
Gleitfiachen, was hauptsachlich bei Neues Lager einbauen
langerem Olmangel zu erwarten ist
Designation Finding Measure

Parts of bearing material broken away Install new bearing
Cracks in bearing material Install new bearing
Single minor scratches can be left as they are.
Scored bearing surfaces Never attempt to remove them by touching up
Radial and axial the bearing.
bearing surfaces As long as axial clearance is within the
Contact surfaces are worn but in good
permissible values, the bearing can still be
condition
used
Pitting or excessive wear of bearing
surfaces, especially after prolonged oil Install new bearing
starvation
4.2.2 4.2.2
Radiallager Radial bearing
Visuelle Prufung der Oberflachen innen auf Ab- Visual inspection of the surface inside for wear
nutzung und Kratzspuren. and scratches.
Vorsicht 1 Die Radiallager sind periodisch zu kon-

trollieren (Kontrollintervall gemass
Leistungsschild, s. Kap 0).
A
Caution I The radial bearings should be checked
periodically (interval according to rating
plate, see chap. 0).
ABB Turbo Systems Ltd 10411 ii IIII

-F- iPMPli
Fig. 5-15
Schwimmscheibe
Floating disc
10411
4.2.3 4.2.3
Hilfsiager Auxiliary bearing
Visuelle Prufung der Gleitflachen. Leichte Verfar- Visual inspection of sliding surfaces. Minor dis
bungen sind ungefahrlich. colouring is harmless.
4.2.4 4.2.4
Schwimmscheibe Floating disc
A
Vorsicht! Die Auflageflachen sind periodisch zu
kontrollieren (Kontrollintervall gemass
Leistungsschild, s. Kap. 0).
A
Caution ! The contact surfaces should be
periodically (interval according
plate) (see chap. 0).
checked
to rating
Bei erreichen Oder unterschreiten des If the marked angle is reached or fallen
markierten Winkels, muss die Schwimm below, the floating disc must be replaced
scheibe ersetzt werden (s. Fig. 5-15). (see fig. 5-15).
Visuelle Prufung der Gleitflachen. Visual inspection of sliding surfaces.
Hinweis Werden am Innendurchmesser (Radial- If bright metallic areas are found on the
fuhrung) der Schwimmscheibe metal- internal diameter (radial guide) of the
lisch blanke Stellen festgestellt, muss floating disc, the disc must be replaced.
die Schwimmscheibe ersetzt werden.
4.3 4.3
Turbine und Verdichterrad ersetzen Replacing turbine and
compressor wheel
A
Vorsicht! Die Wechselzeiten der Turbine und des
Verdichterrades ist einzuhalten (Wech-
selintervall gemass Leistungsschild, s.
A
Caution 1 The changing intervals for the turbine
and compressor wheel must be observed
Kap. 0).
(changing interval according to rating
Beschadigte Turbinenschaufein bedin-
plate, see chap. 0).
gen den Einbau einer Ersatzwelle.
Damaged blades require the installation
of a replacement shaft.
Hinweis Siehe auch Kapitel 3. "Streifen von ro-

tierenden Teilen".
See also chapter 3, "Contact with
rotating parts".
Visuelle Kontrolle der Lagerstellen. Geringe Kratz-
spuren konnen mit Poliertuch egalisiert werden.
Visual inspection of bearing positions Minor
scratches can be smoothed with a polishing cloth.
ABB Turbo Systems Ltd 10411 A II l»

- F-
0 0 0
1
0,
s«'
42002
90320
42016
42015
90305
32102
32107 Fig. 5-16

Rotorblock montieren
Assembling the cartridge group
A III! 10411
4.4 4.4
Rotorblock zusammenbauen Assembling the cartridge group
A
Vorsicht! Nur Ohginalteile von autorisierten Ser-
vice-Stellen der ABB Turbo Systems ver-
wenden.
A
Caution 1 Use only original components from
authorised ABB Turbo Systems service
station.
Haube (42002) aufstecken und mit Spannset urn Fit hood (42002) and secure with clamping set
Lagergehause sichern (s. Fig. 5-16/1). round bearing casing (see fig. 5-16/1).
Dichtungsdeckel (42015) und 0-Ring (42011) mit- Insert sealing cover (42015) and 0-Ring gasket
tels Fuhrungsbolzen (90320) einschieben (s. Fig. (42011) with guide bolt (90320) (see fig. 5-16/2).
5-16/2).
Observe graduation scaling

Hinweis Auf die Lochteilung achten.
Remove guide bolt (90320) and secure sealing
Fuhrungsbolzen (90320) entfemen und Dichtungs cover with screws (42016).
deckel mit den Schrauben (42016) befestigen.
Lubricate threads of the screws (42016)

Hinweis Gewinde der Schrauben (42016) mit with Antiscuff (or similar high tempera
Antiscuff (Oder ahniicher Hochtempe- ture lubricating paste).
ratur - Schmierpaste schmieren.
Remove clamping set.
Spannset entfernen.
Fit radial bearing (32102) in bearing bush (32107)
Radiallager (32102) in die Lagerbuchse (32107) and fix with radial bearing pins (90305) (see fig.
einbauen und mit den Radiallagerstiften (90305) 5-16/3).
fixieren (s. Fig. 5-16/3).
Observe marks (dot and arrow at top)

Hinweis Auf die Markierungen (Punkt und Pfeil and hole division.
oben) und die Lochteilung achten. The radial bearing must always remain
Das Radiallager muss immer ein wenig slightly movable.
beweglich bleiben.
Screw in screw (32111), remove radial bearing
Schraube (32111) eindrehen, Radiallgerstifte ent pins (90305) and screw in remaining screws
fernen und restliche Schrauben (32111) eindre (32111).
hen.
When fitting, new, original fixing screws

Precot-Anstrich) verwendet werden.
Tighten fixing screw (32111) with torque
given in section 6.
I
Befestigungsschraube (32111) mit dem
in Abschnitt 6 angegebenen Drehmo-
ment anziehen.
10411 ik mi
1 32107
.9’
t>
90174
90320
90320
42050
2
90600
O'
42012
21000
90174
90170
32112
32001
Fig. 5-17
a 32105
Rotorblock montieren 90240
Assembling the cartridge group 90380
10411
Drei Fuhrungsbolzen (90320) montleren und Fit three guide bolt (90320) and insert bearing
Lagerbtichse (32107) (Markierung oben) mittels bush (32107) (marking on top) by a hoist into the
Hebezeug uber Fuhrungsbolzen ins Lagergehûse bearing casing over the guide bolt (see fig. 5-
einschieben (Fig. 5-17/1). 17/1).
Hinweis Bin Fuhrungsbolzen (90320) in Lager- Fit one guide bolt (90320) in bearing
buchse montieren. Mit leichten Bewe- bush. Insert bearing bush by moving
gungen Lagerbuchse einschieben. slightly.
Fuhrungsbolzen (90320) entfernen und Lager Remove guide bolt (90320) and fit bearing bush
buchse (32107) mit Schrauben (42050) im Lager- (32107) with screws (42050) in bearing casing.
gehause montieren.
Fit guide plate (90170) with screws (32112) (see
Fuhrungsplatte (90170) mit Schrauben (32112) fig. 5-17-2).
montieren (s. Fig. 5-17/2).
Fit extension piece (90174) on shaft (21000) (with
VerlSngerung (90174) (mit den kleinen Lbchern small holes towards turbine).
gegen die Turbine) auf die Welle (21000) montie-
ren. Fix lifting rope to extension piece, raise and fit
lifting gear (90600). Bring shaft to horizontal
Hebeseil an der Veriangerung befestigen, hoch- position and loop lifting rope round shaft behind
ziehen und Hebewerkzeug (90600) montieren. turbine disc.
Welle in horizontaler Lage bringen und Hebeseil
hinterder Turbinenscheibe urn Welle schlingen.
Caution I Loop second lifting rope round crane

hook and secure to lifting gear (90600)
Vorsicht I Zur Sicherung der Welle gegen Abrut- to prevent the shaft slipping off the lifting
schen vom Hebeseil, zweites Hebeseil rope
urn den Kranhaken schlingen und am
Hebewerkzeug (90600) befestigen.
Note Oil extension piece (90174) lightly.
Hinweis Verlangerung (90174) leicht einblen. - Insert shaft (21000) horizontally in bearing casing.
Welle (21000) horizontal in Lagergehause einfah- Remove guide plate (90170).

ren.
Remove extension piece (90174), fit 0-ring gasket
Fuhrungsplatte (90170) entfernen. (42012).
Verlangerung (90174) entfernen, 0-Ring (42012) The thrust bearing should be heated evenly to
montieren. 110°C max. for assembly.
Zur Montage ist das Kammlager gleichmassig auf Place thrust bearing (32001) with floating disk
max. 110 ®C zu enwarmen. (32105) on shaft and draw thrust bearing (32001)
up to stop with C-spanner (90240) and pressing-
Kammlager (32001) mit Schwimmscheibe (32105) on sleeve (90380) (see fig. 5-17/3).
auf die Welle schieben und mittels Hakenschltissel
(90240) und Aufziehhulse (90380) bis zum An-
schlag aufziehen (Fig. 5-17/3). Apply Molykote on the friction surface.
The thrust bearing must cool completely
before further assembly stages.
Hinweis Reibungsflache mit Molykote bestreichen.
Vor den weiteren Montageschritten muss
das Kammlager vollstandig erkalten.
10411 il IIII
90305
1
32110
32106
2
32101 Q
90320
90174
32106
43006
32104 43007
Fig. 5-18
90174 Rotorblock montieren
10411
Radiallager (32101) in das Axiallager (32106) ein- Fit radial bearing (32101) in axial bearing (32106)
bauen und mit den Radiallagerstiften (90305) fi- and fix with radial bearing pins (90305) (see fig.
xieren (s. Fig. 5-18/1). 5-18/1).
Hinweis Auf die Markierung (Pfeil oben) und die Observe the mark (arrow at top) and
Lochteilung achten. hole division.
Das Radiallager muss immer ein wenig The radial bearing must always remain
beweglich bleiben. slightly movable.
Schraube (32110) eindrehen, Radiallgerstifte ent- Screw in screw (32110), remove radial bearing
fernen und restliche Schrauben (32110) eindre pins (90305) and screw in remaining screws
hen. (32110).
Hinweis Bei der Montage mussen neue, origina- When fitting, new, original fixing screws
le Befestigungsschrauben (32110) (mit
Precot-Anstrich) verwendet werden.
Befestigungsschraube (32110) mit dem
Tighten fixing screw (32110) with torque
given in section 6.
I
in Abschnitt 6 angegebenen Drehmo-
ment anziehen.
Fit extension piece (90174) (see fig. 5-18/2).
Verlangerung (90174) montieren (s. Fig. 5-18/2).
Caution I The holes in the extension piece must

be in the horizontal position to prevent
Vorsicht! Urn eine Lagerbeschadigung beim hin- damage to the bearing when inserting.
einschieben zu verhindern, mussen die
Ldcher der Verlangerung in horizontale Fit guide bolt (90320) and fit axial bearing (32106)
Lage sein. (marking on top) with screws (32112).
Fuhrungsbolzen (90320) montieren und Axiallager

(32106) (Markierung oben) mit Schrauben (32112)
montieren. Insert the screws manually, then tighten
the screws for only half a turn each time,
until the axial bearing reaches its final
position.
Hinweis Die Schrauben von Hand einschrauben
und dann abwechslungsweise jeweils eine Fit auxiliary bearing (32104) and contact seal
halbe Umdrehung anziehen, bis das Axial (32114) (for this purpose remove and refit
lager die endgultige Position erreicht hat. extension piece (90174) (see fig. 5-18/3).
Hilfsiager (32104) und Beruhrungsdichtung (32114)

montieren (Dazu Verlangerung (90174) entfemen
und wieder montieren) (s. Fig. 5-18/3). Observe correct fitting position of
auxiliary bearing. When fitting, new, ori
ginal gasket (32114) must be used.
Hinweis Auf die richtige Einbaulage des Hilfs Fit 0-ring gaskets (43006/43007),
iager achten. Bei der Montage muss
eine neue, originale Beruhrungsdichtung
(32114) verwendet werden.
0-Ringe (43006/43007) montieren.
10411 ik li»
-F-
90235
TPL 77-85
90174
43001
90300
43005
90190/90195 TPL 73 - 85
2 Q %
TPL 69
ioh
25000
90020
90500
25000
Fig. 5-19
Rotorblock montieren
10411
TPL69 & 73 TPL 69 & 73

+ Zwischenwand (43001) mittels Fuhrungsrohr + Fit partition wall (43001) by using the guide tube
(90300) montieren (s. Fig. 5-19/1). (90300) (see fig. 5-19/1).
TPL77-85 TPL77-85
+ Zwischenwand (43001) mittels Fuhrungsrohr + Move partition wall (43001) to rear with guide tube
(90300) und Hebezeug nach hinten schieben. (90300) and lifting gear.
+ Hebezeug entfernen, Zwischewand 90“ drehen + Remove lifting gear, turn partition wall 90“ and
und in endgultige Lage schieben. set to final position.
A
Vorsicht 1 Nur am Fuhrungsrohr schieben, da
sonst die Zwischenwand auf die Ver-
langerung fallen kann.
A
Caution I Push only on guide tube, since otherwise
the partition wall can fall on the extension
piece.
Die Markierungen am Lagergehause The marks on the bearing casing and
und an der Zwischenwand mussen oben partition wall must coincide at the top.
ubereinstimmen.
Remove guide tube (90300) and extension piece
Fuhrungsrohr (90300) und Verlangerung (90174) (90174).
entfernen.
Fit the 0-ring (43005).
0-Ring (43005) montieren.
Oil shaft end and thread slightly. Wipe thread so
Wellenende und Gewinde leicht eindlen. Gewin- that a thin film of oil remains.
de abwischen, so dass ein leichter Olfilm bleibt.
A
Vorsicht I Kein Molykote Oder andere Fette ver-
wenden.
A
Caution I
TPL 69:
Do not use Molykote or other grease.
I
+ Tighten compressor wheel (25000) to stop (see
TPL 69: fig. 5-15/19/2).
+ Verdichterrad (25000) bis zum Anschlag anzie- A
hen (s. Fig. 5-19/2).
A
Warning 1 The compressor wheel has sharp edges
which can cause injury.
Warnung I Das Verdichterrad hat scharfe Kanten
die zu Verletzungen fuhren kdnnen. TPL 73-85:
+ Screw lifting device (90190/90195) to assembly-
TPL 73 -85: disassembly device and fix to lifting gear (see fig.
+ Hebevorrichtung (90190/90195) an der Montage- 5-19/2).
Demontage-Vorrichtung (90020) anschrauben und
am Hebezeug befestigen (s. Fig. 5-19/2).
10411 A IM»
+ Verdichterrad (25000) mit der Haltevorrichtung + Fix compressor wheel (25000) with locking device
(90500) befestigen (s. Fig. 5-19/2). (90500) (see fig. 5-19/2).
Warnung I Die Montage-Demontage-Vorrichtung Warning I The assembly-disassembly device can

kann sich beim beim Anheben ruckartig twist suddenly when lift.
verdrehen.
+ Tighten compressor wheel to stop.
+ Verdichterrad bis zum Anschlag anziehen
- J-
- J-
Der weitere Zusammenbau erfoigt gemass Abschn. Further assembly is performed according to point
3,3 3.3.
5 5
Reserveteile Spare parts
Die zusammen mit dem Turbolader bestellten Re The set of spare parts ordered with the turbocharger
serveteile sind vollstandig und gebrauchsfahig zu hal- must be complete and in a useable condition.
ten.
For this reason:
Deshalb sind:
replaced or missing parts must be substituted
ausgetauschte und fehlende Teile sofort zu er- immediately
setzen
parts affected by rust must be cleaned carefully
angerostete Teile sorgfaitig zu reinigen und einzu- and greased.
fetten.
A
Vorsicht I Lagerteile mit Rostansatz sind unbrauch-
bar und deshalb auszutauschen.
A
Caution ! Bearing parts affected by rust are un-
useable and must be replaced.
For this reason:

Deshalb sind:
Bearing parts must be stored in tins to resist
Lagerteile tropensicher in einer Blechdose zu ver- tropical conditions
packen.
Do not open the tin until Immediately before use
Dose erst unmittelbar vor dem Gebrauch zu off-
nen.
ik IM» 10411
jF\mw -F- ABB Turbo Systems Ltd
Verzeichnis der Reserveteile List of spare parts

Satz 1 Verdichter- und Turbinenrevlsion Kit1; Compressor and turbine check
Satz2 Lagerrevision Kit 2 Bearing check
Satz 3 Lagerwechsel Kit 3 Bearing changes
Menge Bezeichnung Teil-Nr Amount ignation Part no.

I
1 Reserveteil-Satz 1: 97070 1 Service kit 1: 97070
15 6kt-Schraube 42042 / 42046 / 15’) Hex.-headed screw 42042 / 42046 /
61009/61032/ 61009/61032/
61035 61035
2 2) 6kt-Schraube 42042 / 42046 2 2) Hex.-headed screw 42042 / 42046
15 2) 6kt-Schraube 61009/61032/ 15 2) Hex.-headed screw 61009/61032/
61035 61035
3 6kt-Mutter 61037 3 Hex.-headed nut 61037
1 Dichtung 42041 1 Gasket 42041
1 Dichtung 42045 1 Gasket 42045
2 0-Ring 42012/76040 2 O-ring gasket 42012/76040
2 O-Ring 77005 / 77006 2 O-ring gasket 77005 / 77006
1 O-Ring 86506 1 O-ring gasket 86506
1 Reserveteil-Satz 2: 97075 1 Service kit 2: 97075

6 6kt-Schraube 32110/32111 6 Hex.-headed screw 32110/32111
1 Beruhrungsdichtung 32114 1 Gasket 32114
1 O-Ring 42011 1 O-ring gasket 42011
2 O-Ring 43006 / 43007 2 O-ring gasket 43006 / 43007
1 O-Ring___________ 43005 1 O-ring gasket 43005
1 Reserveteil-Satz 3: 97080 1 Service kit 3; 97080

1 Radiallager 32101 1 Radial bearing 32101
1 Radiallager 32102 1 Radial bearing 32102
1 Kammlager 32001 1 Thrust bearing 32001
1 Hilfstager 32104 1 Auxiliary bearing 32104
1 Schwimmscheibe 32105 1 Floating disc 32105
1 Axiallager 32106 1 Axial bearing 32106
’) TPL 69/77/85
2) TPL 73/80
Hinweis Bei Ersatzteilbestellungen immer Turbo- When reordering spare parts always quote
lader - Typ und HT - Nummer angeben. the turbocharger type and the HT no.
10411
-F- ^MPIP
18
Fig. 5-20
Ubersicht der Anziehmomente
Summary of tightening torques
A III! 10411
p\mw -F- ABB Turbo Systems Ltd
6 6
Tabelle der Anziehmomente Table of tightening torques
Fur die in der unteren Tabelle angegebenen Schrau- For the screws in the table below the following
benverbindungen mussen folgende Anziehmomente tightening torques have to be applied;
eingehalten werden:
Anziehmomente
Pos. Teil-Nr. Tightening torques
Pos. Part no. [Nm]
TPL 69 TPL 73 TPL 77 TPL 80 TPL 85
M39x2 M45x3 M55x3 M62x4 M76x4

1 25005
35 35 35 35 35
Ml 6x1.5 Ml 6x1.5 Ml 6x1.5 Ml 6x1.5 Ml 6x1.5
2 82005
50 50 50 50 50
M12 M14 M16 M18 M20
3 76002 Kein Anziehmoment / no tightening torques
s. Abschn. 3.3/ see sec. 3.3
M16 M18 M20 M22 M24
4 61037
110 150 220 300 370
M16 M18 M20 M22 M24
5 61036
30 40 40 40 40
M12 M12 M16 M16 M20
6 32110/32111
50 50 120 120 120
M16 M18 M20 M22 M24
7 32112
160 220 315 350 365
M16 M18 M20 M22 M24
8 61035
160 220 315 350 365
M16 M18 M20 M22 M24
9 42050
160 220 315 350 365
M16 M18 M20 M22 M24
10 42016
160 220 315 350 365
M16 M18 M20 M22 M24
11 61009
160 220 315 350 365
M16 M18 M20 M22 M24
12 61032
160 220 315 350 365
M16 M18 M20 M22 M24
260 360 500 690 860
13 61006
M16 M18 M20 M22 M24
120 2) 180 2) 255 2) 350 2) 545 2)
M16 M16 M20 M20 M24
14 42042
120 120 240 240 240
s. Abschn. 3.3
15
see sec. 3.3
M16 M18 M20 M22 M24
16 74026
30 40 40 40 40
M16 M18 M20 M22 M24
17 74027
80 115 155 215 270
Ml 8x1.5 Ml 8x1.5 Ml 8x1.5 M22x1.5 M22x1.5
18 86505
60 60 60 150 150
6kt-Scraube mit Verbus-Ripp Scheibe / Hex.-headed screw with disc verbus

2* Dehnschraube (ohne Verbus-Ripp Scheibe) / Expansion screw (without disc verbus)
ABB Turbo Systems Ltd 10411 il II l»

-F-
Ausserbetriebnehmen
Taking out of operation 6
Ausserbetriebnehmen Kap. / Chap. 6 Taking out of operation
6 6
Ausserbetriebnehmen Taking out of operation
1 1
Turbolader stillsetzen 3 Shutting down the turbocharger 3
1.1 1.1
Abschlussdeckel anbringen 5 Fitting the blanking cover 5
1.2 1.2
Rotor blockieren 7 Blocking rotor 7
2 2
Turbolader konservieren 8 Mothballing the turbocharger 8
2.1 2.1
bis zu 12 Monaten 8 for up to 12 months 8
2.2 2.2
uber 12 Monate 9 for over 12 months 9
Volume: 9 pages
Edition: 03/99
HZTL 10416 ik llll

I *
•V
7y.\ '
Seite / Page 2 T. T urbocharger TPL
t
' AiJjMerbetrieimfhmen ^ Kap. / Chap. 6
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10416
-B-
L
Ausserbetriebnehmen Kap. I Chap. 6 Taking out of operation
1 1
Turbolader Shutting down
stillsetzen the turbocharger
Kann der Diesel- Oder Gasmotor, bei beschadigtem If, in the case of a damaged turbocharger, the diesel
Turbolader, fur eine Notreparatur nur kurzfristig ab- or gas engine can only be shut down for a short
gestellt warden, so ist wie foigt vorzugehen: period for an emergency repair, then proceed as
follows:
Schaden mit den vorhandenen Ersatzteilen be-
heben, eliminate damage with the available spare parts
Oder or
Abschlussvorrichtung anbringen (s. Abschn. 1.1). fit the blanking device (see sec. 1.1).
10416 ii nil
61037
Fig. 6-1
Abschlussdeckel
Blanking cover
Al IIII 10416
1.1 1.1
Abschlussdeckel anbringen Fitting the blanking cover
Rotorblock ausbauen (s. Kap. 5). Remove the cartridge group (see chap. 5).
Offnung im Gasaustrittsgehause mit dem Ab Close the opening in the gas outlet casing with
schlussdeckel schliessen (s. Fig. 6-1) the blanking cover (see fig. 6-1).
Hinweis Im Notfall kann der Abschlussdeckel an- In case of an emergency the blanking
hand der Tabelle in Kap. 7 selbst gefer- cover can be manufactured by yourself
tigt werden. according to the table in chap. 7.
Abschiussdeckel mit Distanzhulsen und Muttern Fix the blanking cover with spacer sleeve and
(61037) befestigen. nuts (61037).
Vorsicht! Ol- und Luftteitungen verschliessen. Caution ! Close the oil and air lines.
10416 ik »ll
ABB Turbo Systems Ltd - B- ^MPIP
90020
90480
Fig. 6-2
Rotor blockieren
Blocking rotor
n »» 10416
1.2 1.2
Rotor blockieren Blocking rotor
In Notfallen, bei denen ein Ausbau des Rotorblocks In case of an emergency and if the cartridge group
nicht moglich ist, kann es vorkommen, dass der Mo can not be removed, it may occur that the engine
tor ohne Aufladung betrieben werden muss. has to be operated without turbocharging.
In solchen Fallen wird der Rotor blockiert. In such cases the rotor has to be locked.
A
Vorsicht! Die Vorschriften des Motorenherstellers
Sind zu beachten.
A
Caution ! Be careful to observe the manufacturer’s
instructions.
Schalldampfer Oder Luftsaugstutzen und Ver- Remove silencer or air suction branche and
dichtergehause-lnnenteil mit Einsatzwand und Dif- internal part of compressor casing with wall insert
fusor entfernen (s. Kap. 5). (see chap. 5).
Verschlusschraube (25005) entfemen (s. Fig 6-2). Remove screw plug (25005) (see fig. 6-2)
Montage-Demontage-Vorrichtung (90020) montie- Fit assembly-disassembly device (90020).

ren.
Block the rotor with the lock (90480).
Rotor mit der Arretierung (90480) blockieren.
Note Cut a thread (M12 or 1/2") in the existing

Hinweis Zur Sicherung der Arretierung ins be- hole to secure the lock with a screw (A).
stehende Loch ein Gewinde (Ml2 Oder
1/2") schneiden und die Arretierung mit
einer Schraube (A) sichern.
Caution ! Shut off the lubricating oil circuit to the

turbocharger and close the air lines.
Vorsicht! Schmierdikreislauf zum Turbolader un- Reduce the power output in such a way
terbrechen und die Luftleitungen ver- that the admissible exhaust gas tempe
schliessen. rature after cylinder is not exceeding.
Die Leistung des Motors ist so zu be-
grenzen, dass die zulassigen Abgas-
temperaturen nach Zylinder nicht uber-
schritten werden.
10416 A IMI
2 2
Turbolader konservieren Mothballing the turbocharger
2.1 2.1
bis zu 12 Monaten for up to 12 months
Wird ein Turbolader fur bis zu 12 Monate stillgelegt, If a turbocharger has to be laid up for up to 12
so hangt eine eventuell notwendige spezielle Kon- months, the decision whether the turbocharger needs
servierung des Laders in erster Linie vom Zustand special protection or not depends mainly on the
des Schmieroles vor der Stillegung ab. condition of the lubricating oil before laying up.
1st die Neutralisationszahl kleiner als 2 mg KOH/g, If the neutralization factor is lower than 2 mg KOH/g
so mussen keine speziellen Massnahmen getroffen no special measures need to be taken. However, if
warden. 1st die Neutralisationszahl jedoch grosser, the factor is higher the turbocharger must be
muss der Lader nach der Stidegung demontiert, ge- dismantled after laying up, cleaned and protective oil
reinigt und die blanken Teile mussen mit Konservie- has to be applied on the bright parts.
rungsol eingedit warden. If the turbocharger is left on the engine, and the
engine oil replaced by a protective oil which is
Bleibt der Turbolader auf dem Motor angebaut und circulated with a prelubrication pump prior to laying
wird das Motordl vor der Stillegung durch ein Konser- up, no mesures need to be taken in respect of the
vierungsdl ersetzt und mit der Vorschmierpumpe um- turbocharger. The remains of the old engine oil will
gewalzt, so erubrigt sich jede Massnahme am Turbo be washed away and the sensitive bearing parts
lader. Reste von altem MotorenschmierdI werden da- extensively protected against corrosion.
durch weggespult und die empfindlichen Lagerpartien
weitgehend vor Korrosion geschutzt. If the rotor turns due to a draught from the flue, fit a
blind flange between the compressor casing and the
Dreht der Rotor wegen Kaminzuges. ist zwischen charge-air receiver.
dem Verdichtergehause und der Ladeluftleitung ein
Blindflansch einzubauen.
10416
2.2 2.2
liber 12 Monate for over 12 months
Wird der Turbolader vom Motor abgebaut und fCir If a charger has to be removed from the engine and
langere Zeit auf Lager gelegt, so ist wie folgt vorzu- stored for any length of time, proceed as follows:
gehen;
Dismantle the turbocharger (see chap. 5).
Turbolader zerlegen, (s. Kap. 5).
Clean the shaft and the bearing parts and treat
Lagerpartien der Welle und Lagerteile reinigen, with a protective oil
und mit Konservierungsmittel einstreichen.
Assemble the turbocharger and store it in the
Turbolader zusammenbauen und in montiertem assembled condition.
Zustand lagern.
Spray or brush the housing flanges with TECTYL
Gehauseanschlussflansche mit TECTYL 502 sprit- 502.
zen Oder streichen.
Seal all openings in the turbocharger with wooden
Alle Offnungen des Turboladers mit Hoizdeckein covers and paraffined paper.
und Paraffmpapier als Dichtung abschliessen.
Ensure that the room in which the turbocharger is
Als Lagerungsort eignen sich nur trockene Raume, going to be stored is dry and free of condensation.
in denen keine Kondenswasserbildung moglich ist.
Check mothballed turbochargers yearly

Hinweis Konservierter Turbolader jahrlich auf for corrosion.
Korrosion uberprufen.
In the event of rust, clean and renew
Bei Rostanfall Teile reinigen und Korro- the corrosion protection.
sionsschutz erneuern.
10416 ik IIII
ABB Turbo Systems Ltd -B- iPMPIP
Anhang
Appendix 7
Anhang Kap. / Chap. 7 Appendix
7 7
Anhang Appendix
Inhatt Seite Contents Page
1 1
Ersatzteile 3 Spare parts 3
1.1 1.1
Ersatzteile bestellen 3 Ordering spare parts 3
1.2 1.2
Numerierung der Numbering of
Bildseiten 4 illustrations 4
2 2
Verzeichnis der Teilenummern 7 Directory of part numbers 7
2.1 2.1
Turbolader 7 Turbocharger 7
2.2 2.2
Werkzeuge 35 Tools 35
2.3 2.3
Abschlussdeckel 39 Cover plate 39
Volume: pages 41
Edition: 04/2000
HZTL10415 A l» l»
ABB Turbo Systems Ltd ^MPIP
-E-
Al »» 10415
#ÎP» -E- ABB Turbo Systems Ltd
1 1
Ersatzteile Spare parts
1.1 1.1
Ersatzteile bestellen Ordering spare parts
Bei Ruckfragen und Ersatzteil-Bestellungen sind fol- In case of Inquiries and spare part order the following
gende Oaten zu nennen: data must be quoted:
benotigte Daten erhaltiich in data required see
Typ TPL ... Kap. 0 Oder Type TPL...

Chap. 0, or rating
Leistungsschild
plate on the
am
turbocharger
HT-Nummer Turbolader HT-Number
Bezeichnung Abschn. 2 Designation sec. 2
Stuckzahl Amount
Unsere Vertretungen und Service-Stellen (siehe Ser- Our representatives and service stations (see
vice-Stellen Liste im Kap. 8) nehmen Bestellungen Directory of Service Stations in chap. 8) will accept
fur Ersatzteile entgegen. Sie erteilen auch Auskunft, orders for spare parts. They also provide information
falls in der vorliegenden allgemeinen Vorschrift be- in the event that individual cases are not taken
sondere Faile nicht berucksichtigt sein sollten. account of in the general instructions.
Beispiele von Ersatzteil * Bestellungen Oder Ruck Example of spare part order or enquiry
fragen
Turbolader TPL Turbocharger TPL
Fabrikate-Nummer HT Serial number HT
1 Verdichterrad, Teil-Nr 25000 1 Compressor wheel, part no. 25000

(Bild TPL ..-02,0-,,.*) (Illustration TPL ..-02.0-...*)
*) Laufnummer (siehe Abschn. 2.0) *) Consecutive number (see sec. 2.0)
10415 A IM»
1.2 1.2
Numerierung der Bildseiten Numbering of illustrations
Die Bildnummer besteht aus The illustration number consists of
1. Turboladertyp und -grosse 1. Turbocharger type and size

2. Einordnungsnummer 2. Classification number
3. Laufnummer 3. Consecutive number
Beispiel; Example;
TPL - 02.0 - 1 TPL - 02.0 - 1
3. Laufnummer 3. Consecutive number
2. Einordnungsnummer 2. Classification number
1. Turboladertyp und -grdsse 1. Turbocharger type and size
ik IMi 10415
Notizen Notes
10415 ik IMi
Bild-Nr. / Illustration-No Mod.
TPL 69-i-85 - 02.0-001 B
I
IT
w
21000
25000
10415
Anhang Kap. I Chap. 7 Appendix
2 2
Veizeichnis der Teilenummem Directory of part numbers
Die folgenden Teilenummern und Bezeichnungen The follov/ing part numbers and designations must
Sind bei irgendwelchen Mitteilungen Oder Bestellun- be quoted in all correspondence or spare part orders
gen zu verwenden (siehe Beispiele von Ersatzteil- (see example for spare parts order, sec. 1.1).
Bestellungen unterAbschn. 1.1).
2.1 2.1
Turbolader Turbocharger
Teil-Nr. Bezeichnung Part no. Designation
21000 Welle beschaufelt 21000 Shaft bladed
25000 Verdichterrad 25000 Compressor wheel

25005 Verschlussschraube 25005 Screw plug
ABB Turbo Systems Ltd 10415 ik l»l»

-E- #\IPIP
TPL 69-5-85-02.1-001 A
27010
27000
TPL 69 TPL 73 - 85
ik IM» 10415
^%IPIP -E- ABB Turbo Systems Ltd
27010 Reinigungsvorrichtung 27010 Cleaning device
27000 Wasserbehaiter 27000 Water vessel
10415 A lill
-E-
Bi!d-Nr. / Illustration-No Mod.
TPL 69-s-85-03.0-001
32102 S
32107
32001 S
32105 S)
32106S
32101 (3
32104(3
Hinweis 13 = Nur im Reserveteilsatz erhaltlich (s. Kap. 5)

Note 3 = Available within the service kit only (see chap. 5)
10415
32001 SI Kammlager 32001 SI Thrust bearing
32101 SI Radiallager VS 32101 SJ Radial bearing CE

32102 SI Radiallager TS 32102 S) Radial bearing TE
32104 SI Hilfslager 32104 SI Auxiliary bearing
32105 SI Schwimmscheibe 32105 SI Floating disc
32106 SI Axiallager 32106 SI Axial bearing
32107 Lagerbuchse 32107 Bearing bush
32110S1 6kt-Schraube VS 32110S) Hex.-headed screw CE
32111 S) 6kt-Schraube TS 32111 SI Hex.-headed screw TE
32112 6kt-Schraube 32112 Hex.-headed screw
32114 SI Beriihrungsdichtung 32114 SI Contact seal
Hinweis SI = Nur im Reserveteilsatz erhaltlich (s. Kap. 5)

Note SI = Available within the service kit only (see chap. 5)
10415 a ii»
ABB Turbo Systems Ltd #\ipip
-E-
TPL 69 85 - 04.0-001 B
42000
42001
42016
43007 S)
42050
42002
atf43006 B
'^42047
42043
42049
42045 B
42044
42012S
42046 B
43001 42060
43005 B 42041 B
42040
42042 B
Hinweis B= Nur inn Reserveteilsatz erhaltlich (s. Kap. 5)

Note B = Available within the service kit only (see chap. 5)
10415
42000 Lagergehause komplett 42000 Bearing casing complete

42001 Lagergehause bearb. 42001 Bearing casing mach.
42002 Haube 42002 Hood
42011 ^ 0-Ring 42011 ® 0-Ring gasket
42012® 0-Ring 42012® 0-Ring gasket
42015 Dichtungsdeckel 42015 Sealing cover
42040 Olaustrittsflansch 42040 Oil outlet flange
42041 ® Dichtung 42041 ® Gasket
42042 ® 6kt-Schraube 42042 ® Hex.-headed screw
42043 Blende 42043 Diaphragm
42044 Flansch 42044 Flange
42045 ® Dichtung 42045® Gasket
42046 ® 6kt-Schraube 42046® Hex.-headed screw
42049 Sicherungsring 42049 Safety ring
42060 Abdeckung 42060 Cover
43001 Zwischenwand 43001 Partition wall

43005 ® 0-Ring 43005 ® O-Ring gasket
43006 ® 0-Ring 43006 ® O-Ring gasket
43007 ® O-Ring 43007 ® O-Ring gasket
Hinweis ® = Nur im Reserveteilsatz erhaltlich (s. Kap. 5)

Note ® = Available within the service kit only (see chap. 5)
10415 A III!
TPL 69 -s- 85 - 05.0-001 B
51000
Axial
51001
Mit Waste-Gate-Anschluss
With waste-gate~connection
o o
o.A
"A q
o
.0
0
.0
.0
56001
.0
.0)
.0 V^\/
o'
o'
sO
.0
10415
^MPIP
T urbocharger TPL Seite/Page 15
Gaseintrittsgehause Axial Gas inlet casing axial
51000 Gaseintrittsgehause komplett 51000 Gas inlet casing complete

51001 Gaseintrittsgehause bearb. 51001 Gas inlet casing mach.
56001 Dusenring (mit Bolzen) 56001 Nozzle ring (with pins)
10415 A IM»
-E- P\MWMW
TPL 69-i-85-05.0-002 C
51008
51000 51006
Radial
51007
51001
51007
51006
51008
51060
il IMI 10415
Gaseintrittsgehause Radial Gas inlet casing radial

51007 Dichtung 51007 Gasket
51060 Isolation (nur TPL 73 85) 51060 Insulation (TPL 73 85 only)
56001 Dusenring (mit Bolzen) 56001 Nozzle ring (with pins)
10415 Ik III!
TPL 69 85 - 05.0-003 A
51000
Axial
51012
51001
56001
10415
^\mn -E- ABB Turbo Systems Ltd
Gaseintrittsgehause axial (Mehreintrittig) Gas inlet casing axial (multiple entrance)

51012 Segment 51012 Segment
56001 Dusenring (mit Bolzen) 56001 Nozzle ring {with pins)
10415 A III!
-E -
TPL 69 85-06.0-001 A
61000
61060
61012
61013 61009 S)
61036
61037 0
61035 0
61032 0
61013
61011
61012
61001
63000
68000 61006
Hinweis 0 = Nur im Reserveteilsatz erhaitlich (s. Kap. 5)

Ai IMI 10415
61000 Gasaustrittsgehause kompl. 61000 Gas outlet casing complete

61001 Gasaustrittsgehause bearb. 61001 Gas outlet casing mach.
61009!^ 6kt-Schraube 61009 [H Hex.-headed screw
61011 Blindflansch 61011 Blind flange
61035^ 6kt-Schraube 61035 Hex.-headed screw
61036 Stiftschraube 61036 Stud
61037 m 6kt-Mutter 610371^ Hex.-headed nut
61060 Isolation 61060 Insulating
63000 Turbinendiffusor 63000 Turbine diffuser
68000 Fuss 68000 Foot
Hinweis = Nur im Reserveteilsatz erhaltlich (s. Kap. 5)

Note = Available within the service kit only (see chap. 5)
10415 ik IM»
-E-
Blld-Nr. / Illustration-No Mod. 76040 a
TPL 69^ 85-07.0-001
76000
0 (i*
77006 a /
77005 a
76002
v\
79000
/ 77000
W
i\
74026
74028
74027
74000
74060
Hinweis a = Nur im Reserveteilsatz erhaltlich (s. Kap. 5)

Note a = Available within the service kit only (see chap. 5)
A IMI 10415
74000 Verdichtergehause Aussenteil 74000 Compressor casing external part

74027 6kt-Mutter 74027 Hex.-headed nut
74028 Verbus-Ripp-Scheibe 74028 Verbus-disc
74060 Isolation 74060 Insulation
76000 Verdichtergehause Innenteil 76000 Compressor casing internal part

76040 ^ 0-Ring 76040 SI 0-ring gasket
77000 Einsatzwand 77000 Wall insert

77005 SI 0-Ring 77005 SI 0-ring gasket
77006 SI 0-Ring 77006 SI 0-ring gasket
79000 Diffusor 79000 Diffuser

Note SI = Available within the service kit only (see chap. 5)
10415 A IM»
Bild-Nr. / l!lustration-No Mod.
TPL 69 - 08.0-001 A
81000
81005 81006 81271
81270
A »li 10415
TPL 69 TPL 69
81000 Schalld^mpfer komplett 81000 Silencer complete

81135 Schalldampferkorper 81135 Silencer body
81136 Filzsegment 81136 Felt segment
81137 Mantelblech 81137 Cover sheet-metal
81265 Filterring 81265 Filter ring
81270 Spannband 81270 Tension band
81271 Verschluss 81271 Clamp
10415 A IMI
-E-
TPL 73 ^ 85 - 08.0-002 A 81136
81000 I7.V
81266
81005
81006
81271
rr.
IV.
'*'**“**Sv
L*J
'v.*.v.v.v.vmr\
••••••• •
VAVAV.
•••••••#•!
> ••• Am •A» Vi
isMm
VAVAVmA*
••afeVKSKV*
n«
&V.VA»»
AMI AV.V.V.V.V
81135 81266
81270
Option"
81265
1) Nur im 2-Pack erhaltlich / Only available in double pack
Ak ll» 10415
E ABB Turbo Systems Ltd
TPL 73 ^ TPL 85 TPL 73 - TPL 85
81000 Schalldampfer komplett 81000 Silencer complete

81135 Schalldampferkdrper 81135 Silencer body
81136 Filzsegment 81136 Felt segment
81265 Filterring (option) 81265 Filter ring (option)
81266 Abdeckgitter 81266 Cover grid
81270 Spannband 81270 Tension band
81271 Verschluss 81271 Clamp
1) Nur im 2-Pack erhSItlich / Only available in double pack
ABB Turbo Systems Ltd 10415 it IM»

-E - #MPIP
TPL 69 ^85-08.5-001
82000
Radial
82005
82006
82000
ik IMI 10415
82000 Luftsaugstutzen 82000 Air suction branch

10415 A IMI
-E- p\mw
Bild-Nr / Illustration-No Mod.
TPL 69- 85-08.5-002
82000
Axial
'82005
82006
82000
A IM» 10415
Luftsaugstutzen Axial Air suction branch axial
82000 Luftsaugstutzen 82000 Air suction branch

10415 Ai IIII
ABB Turbo Systems Ltd ^\mw
-E-
TPL 69-s-85-08.9-001 D
Option
86525
Alternative to 86515
86506 0 86505 86515

\ /
V
Standard
Hinweis 0 = Nur im Reserveteilsatz erhaltlich (s. Kap. 5)

10415
86505 Drehzahimessgeber (inkl.86506) 86505 Speed sensor (incl. 86506)

86506 (D 0-Ring 86506 SI 0-Ring gasket
86515 Kabelkupplung 86515 Cable clutch
86525 Leitungsverstarker (option) 86525 Power amplifier (option)

Note S) = Available within the service kit only (see chap. 5)
ABB Turbo Systems Ltd 10415 A »»

-E-
TPL 69 85 - 09.0-900 D
90000
90010
90174
90020 90025
90170
90178
(TPL 73 - 85)
90177
(TPL 73 - 85)
90175 0
(TPL 73 - 85) 90195
90240
90190
0
90230 90231 90235

(TPL 73 - 85) (TPL 77 - 85)
A III! 10415
2.2 2.2
Werkzeuge Tools
90000 Werkzeuge komplett 90000 Tools complete

90010 Kassette 90010 Box
90020 Montage-Demontage-Vonichtung 90020 Assembly-disassembly device

90025 Abstutzwinkel 90025 Support angle
90170 Fuhrungsplatte 90170 Guide plate
90174 Verlangerunq 90174 Extension piece
90175 Halter 90175 Holder
(TPL 73-85) (TPL 73 - 85)
(TPL 73 - 85) (TPL 73 - 85)
90178 6kt-Mutter 90178 Hex.-headed nut
(TPL 73 - 85) (TPL 73 - 85)
90190 Hebevorrichtung 90190 Lifting device
90195 Schakel 90195 Shackle
90230 Ringschraube 90230 Ring bolt
(TPL 73 - 85) (TPL 73 - 85)
(TPL 77-85) (TPL 77 - 85)
90240 Hakenschliissel 90240 C-spanner
10415
-E-
TPL 69-i-85 - 09.0-901 A
90305 90320
90300
90325
90450
90380
90490
90460 90470
90480
90600
90901
90920 90500
(TPL 77 - 85)
90900
90921
90950 90951 90952
(TPL 73 - 85) (TPL 73 - 85) (TPL 73 - 85)
ik II li 10415
/MPIP -E- ABB Turbo Systems Ltd
90300 Fuhrungsrohr 90300 Guide tube

90305 Radiallagerstift 90305 Radial bearing pin
90320 Ftihrungsbolzen 90320 Guide bolt
90325 Drehstift 90325 Pin
90380 Aufziehhuise 90380 Pressing-on bush
90450 Abstutzung 90450 Support
90460 Kraftvervielfaltiger 90460 Torque multiplier
90470 Steckschlussel 90470 Box spanner
90480 Arretiemng 90480 Lock
90490 Halter 90490 Holder
90500 Haltevorrichtung 90500 Locking device
{TPL 77 - 85) (TPL 77 - 85)
90600 Hebewerkzeug 90600 Lifting tool
90900 Abdruckschraube 90900 Puller screw
90901 Abdruckschraube 90901 Puller screw
90920 Abdruckwerkzeug 90920 Press-off tool
90921 Bride 90921 Clamp
(TPL 73 - 85) (TPL 73 - 85)
TPL 73 - 85) TPL 73 - 85)
(TPL 73 - 85) (TPL 73 - 85)
10415
-E-
TPL 69-^85-09.1-001 91000
A IIII 10415
2.3 2.3
Abschlussdeckel Cover plate
Die Fertigungszeichnung wird auf Wunsch kostenlos The drawing to the cover plate can be ordered
abgegeben. separately.
Tell-Nr. Bezeichnung Part. no. Designation
91000 Fertigungszeichnung Abschluss 91000 Drawing of cover plate

deckel
ABB Turbo Systems Ltd 10415 A »ll

-E-
TPL 6985-09.2-001
JJb5
t
CN
CD
CD
BA B6
B8
If)
Q
10415
2.3.1 2.3.1
Tabelle Abschlussdeckel Table cover plate
Hinweis Im Notfall kann der Abschlussdeckel In case of an emergency the cover plate
auch anhand untenstehender Tabelle can also be manufactured by yourself
selbst gefertigt werden. according to the table below.
Abschlussdeckel / Cover plate
Typ B1 B2 B3 B4 B5 B6 B7 B8 01 02 03 04 05 a2
a1 a3
Type [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm]
TPL 69 385 30 30 9 12 6 84 726 818 779 18 25
TPL 73 450 8 10 94 844 948 905 20 28
TPL 77 13 535 9 12 107 1003 1124 1075 22 30 4x90° 37,5° 24x15°

50 50 8
TPL 80 623 11 15 136 1164 1300 1248 24 32
TPL 85 774 14 18 167 1425 1578 1548 26 36
10415 ik IM»
ABB Turbo Systems Ltd -E- ^\nn
Service - Stellen Verzeichnis
Guide to service stations 8
rrrmi
Turbocharger
Power Turbine
Service Stations
2000/2001
HZTL 93750
2000-09

ABB Turbocharger / Power Turbine
Service Stations
Liste der von ABB Turbo Systems AG, Baden List of Service Stations acknowledged by ABB
anerkannten Service Stationen. Turbo Systems Ltd, Baden.
Sie bieten Gewahr fur fachgerechte Ausfuhrung They ensure the competent execution of your
Ihres Auftrages order
(Anderungen vorbehalten) (Subject to modifications)
Fur Anderungen in dieser Liste wenden Sie sich bitte an: For modifications in this list please contact:

Dept. ZTD
CH-5401 Baden
Switzerland
phone; +41 56 205 7295

fax: +41 56 205 6634
Neueintrage und Anderungen sind am Seitenrand mit New or modified addresses are marked with a black line
einem schwarzen Balkan markiert. at the page margin.
Die Telefon- und Faxnummern in dieser Liste sind The telephone and fax numbers in this list are presented
in der folgenden Form dargestellt: in the following form:
+ 41 56 205 7777
Zugangsziffer Anschluss-Nummer
Access code Subscriber’s number
Vorwahlnummer
Area code
Modifications processed through Sept 30. 2000

Printed in Switzerland
Turbocharger Technical Documentation Group Next Issue: March 2001
Alili
HZTL 93750 ABB Turbo Systems Ltd
2000-09
Turbocharger / Power Turbine Page 1 of 9
Service Stations
Country Address Phone Fax E-Mail
Argentina Asea Brown Boveri S.A. +54 11 4 229 5500 +54 11 4 229 5602
Division Turbocompresores +54 11 4 229 5651
Jos6 Ignacio Rucci 1051 +54 11 4 229 5524
1822 Valentin Alsina
Buenos Aires
Australia ABB Service 24 hrs: +61 2 9795 3100 +61 2 9773 8855
A Division of
ABB Industry PTY Ltd
20 Queen Street
Revesby
Sydney. N.S.W. 2212
- New Castle for service call
- Papua New Guinea ABB Service
- Port Kembla Revesby I Sydney
- South Pacific Islands
ABB Service 24 hrs: +61 8 9455 9455 +61 8 9455 1715
A Division of
109 Bannister Road
Canning Vale
Perth. WA 6155
- Albany for service call
- Bunburt ABB Service
- Dampier Canning Vale / Perth
- Espemce
- Fremantle
- Geraldton
- Port Headland
ABB Service 24 hrs: +61 3 9644 4100 +61 3 9644 4190
A Division of mobile: +61 4 1836 1893
2 Douglas Street
Port Melbourne
Melbourne, VIC 3207
-Adelaide for service call
- Geelong ABB Service
- Portland Victoria / Melbourne
-Tasmania
- Western Port
ABB Service 24 hrs: +61 7 3868 2722 +61 7 3868 2711
A Division of
1 Lavarack Avenue
Eagle Farm
Brisbane, QLD 4009
- Darwin for service call
- Gladstone ABB Service
- North Queensland Queensland / Brisbane
Bahrein for service call
ABB Industries (LLC)
Reg. Office Dubai
United Arab Emirates
Belgium ABB Service N.V. 24 hrs: +32 3 541 7140 +32 3 544 3239
Turbocharger Service
Noorderlaan 81
B-2030 Antwerpen
ABB Turbo Systems Ltd HZTL 93750

2000-09
Page 2 of 9 Turbocharger / Power Turbine
Service Stations
+55 13 232 8044 [

Brazil Asea Brown Boveri Ltda. +55 13 234 4568
Turbocharger Service +55 13 233 35391
Rua Dona Luiza Macuco 201
11015-060 Santos
Bulgaria ABB TC Workshop +359 52 665 7465 +359 52 60 1104 odessos@Qdessos-yard.bg
Odessos Ship Repair Yard aft hrs: +359 52 60 3462
Island Zone
BG-9015 Varna
Canada Asea Brown Boveri Canada +1 514 630 5504 +1 514 694 8040
123 Labrosse Street +1 514 630 5505
Pointe Claire aft hrs: +1 514 684 5158
Quebec H9R 1A3 +1 514 624 4361
ABB Canada Inc. +1 604 433 2226 +1 604 433 2666
Turbocharger Dept. +1 604 412 2803
North Fraser Way 600-3731 aft hrs: +1 604 592 0877
Burnaby / Vancouver
B.C. V5J 5J2
Abco Industries Ltd. +1 902 634 8821 +1 902 634 8583
81 Tannery Road aft hrs: +1 902 634 9101
P.O. Box 1120
Lunenburg. N.S. BOJ 2CO
Chile Asea Brown Boveri S.A. +56 41 42 6601 +56 41 42 6602
Autopista 5970
VIII Region Chile
Talcahuano
China ABB Engineering Co. Ltd. +86 20 8222 2088 +86 20 8222 0553
1/F West Block, A3 Buildg. 24 hrs: +86 13 9240 9901
Beiwei Ind. Area, Youth Rd.
Econ. & Techn. Devel. Distr.
510730 Guangzhou______
ABB Industrial and Building sw brd: +852 2929 3838 +852 2929 3501
Systems Ltd. +852 2929 3683
No. 3 Dai Hai Street +852 2929 3630
Tai Po Industrial Estate +852 9103 5163
24 hrs:
Tai Po / N.T, / Hong Kong
ABB Engineering Shanghai Ltd +86 21 5048 1163 +86 21 5048 0092 leo-yunping.lu@cn.abb.com
1/F, East Block, 251 Ri Ying emerg: +86 139 0195 3754
Nan Road, w-shop: +86 139 0198 1441
Waigaoqiao Free Trade
Zone. Shanghai.
200131 Shanghai________
ABB Engineering Co. Ltd. +86 22 6620 1001 +86 22 6620 2772
No. 6 The Fifth Avenue 24 hrs: +86 136 0208 6208
Teda
300457 Tianjin
- Qingdao for service call
ABB Engineering Co.
Ltd. Guangzhou
or
ABB Industrial and
Building Systems Ltd.
Tai Po. N.T./Hong
Kong______________
Croatia ABB d.o.o. +385 51 211 017 +385 51 211 039
Branch Office Rijeka +385 51 673 0291
Nikole Tesle 9 / 3 kat
HR-51000 Rijeka
+385 51 211 031 I
Cuba for service call
ABB Turbocharger Co.
North Brunswick
USA

2000-09
Service Stations
Country Address Phone Fax E~Mait
Denmark ABB Service A/S +45 43 26 6200 +45 43 26 6205

TurboladerTeknik +45 43 26 6211
Vallensbaekvej 47 aft hrs: +45 40 86 6211
DK-2605 Brendby
Copenhagen
- Aalborg for service call
- Aarhus ABB Service A/S
- Esbjerg Brendby / Copenhagen
- Odense
P/F Torshavnar Skipasmidja +298 31 1155 +298 31 1125
P.O. Box 65 aft hrs; +298 31 2955
FR-110Torshavn +298 31 3053
Faroe Islands
Egypt ABB Turbochargers S.A.E. +20 2 293 1359 +20 2 298 7533
7 Dr. Mohamed Kamel +20 2 296 8001+10
Hussien St. +20 12 211 4759
emerg:
P.O. Box 5040
aft hrs: +20 2 240 8748
El-Nozha El-Gedida
Cairo
Estonia for service call
ABB Industry Oy
Helsinki
Finland
Finland ABB Industry Oy sw brd: +358 10 22 2000 +358 10 22 26379
ABB Turbochargers +358 10 22 26474/57
P.O. Box 185 aft hrs: +358 10 22 26470
SF-00381 Helsinki
France ABB +33 47 205 4010 +33 47 849 4257

Division Turbocompr. ABB 24 hrs: +33 47 205 4040
15. Rue Sully
F-69150 Cedex / D6cines-
Charpieu____________
ABB 24 hrs: +33 44 202 2316 +33 44 202 2323
Dept. Turbocompr. ABB
Agence de Marseille
Z.A. de L’agavon
20. Avenue Lamartine
F-13170 Les Pennes
Mirabeau
ABB +33 25 176 0167 +33 25176 0168
Division Turbocompr. ABB aft hrs: +33 60 825 4564
Quai des Frigates
F-44600 Saint Nazaire
ARNO Dunkerque +33 32 866 4800 +33 32 866 5928
Route des Docks mobile: +33 60 729 7441 +33 32 821 0114
B.P. No. 2074 Cedex
F-59376 Dunkerque
ABB Automation +33 23 524 8270 +33 23 524 8271

Marine & Turbocharger mobile: +33 60 782 8112
do Siren
Route du M6le Central

F-76600 Le Havre
AS&S
2000-09
Service Stations
Germany ABB Turbolader Vertriebs- 24hrs: +49 40 317 8770 +49 40 3178 7719 turbolader@abb.de
und Service GmbH +49 40 3178 7741
Reiherdamm 44
D-20457 Hamburg______
ABB Turbolader Vertriebs- +49 231 997 2541 +49 231 997 2583 turbolader@abb.de
und Service GmbH 24hrs; +49 40 317 8770
Service Office West
Kanalstrasse 25
D-44147 Dortmund
ABB Turbolader Vertriebs- for service call turbolader@abb.de
und Service GmbH ABB Turbolader
Kallstadterstrasse 1 Vertriebs-
D-68309 Mannheim und Service GmbH
Dortmund
- all sea ports for service call
ABB Turbolader
Vertriebs-
und Service GmbH
Hamburg________
Greece Asea Brown Boveri SA +30 1 429 0071 +30 1 429 0188 ioannis.smymeos@gr.abb.c
Turbochargers +30 1 429 0075 +30 1 429 om
Marine Division +30 1 429 0240
99 Akti Miaouli Street aft hrs: +30 93 240 1648
GR-18538 Piraeus
emerg: +30 93 700 2504
Iceland Sturlaugur +354 551 4680 +354 552 6331

Jbnsson & Co H/F +354 551 3280
Fiskisloo 94 +354 552 1480
P.O. Box 605 mobile: +354 854 7180
IS-121 Reykjavik 1
India Asea Brown Boveri Ltd. +91 265 64 2141-7 +91 265 64 0715
Turbocharger Division +91 265 64 1675
P.O. Box 124 aft hrs: +91 265 64 3101-4
Maneja +91 265 43 7523
390001 Vadodara (Baroda)
Asea Brown Boveri Ltd. +91 22 230 8249 +91 22 230 8248 turbocharger@in.abb.com
Turbocharger Serv. Station sw brd: +91 22 230 8231 +91 22 230 8277
ASEA House, Dr. S.B. Path aft hrs: +91 22 770 4112
Ballard Estate +91 22 770 7267
400038 Mumbai (Bombay)
Indonesia ABB Turbocharger Service +62 21 650 6677 +62 21 650 6777 danny.wangsahardja@id.ab
A Div. of PT. ABB SAKTI +62 81 695 7404 +62 21 641 1547 b.com
emerg:
Ji. Danau Agung 1 +62 81 119 4347
Blok A4 No.14-15
Sunter Agung
Jakarta 14350
PT. ABB Sakti Industri +62 31 749 7999 +62 31 749 7130
JI. Margomulyo No. 29-B aft hrs: +62 81 133 8583
Surabaya 60183_______
Iran for service call

Reg. Office Dubai
Italy ABB Service Marine & sw brd: +39 010 254 6301-5 +39 010 254 6349
Turbochargers 24hrs: +39 335 596 5902
Division of ABB Industria mobile: +39 335 832 2462
Via Molo Giano
1-16128 Genova Porto

2000-09
Service Stations
Japan Turtx) SystefTTS United Co. Ltd 24 hrs: +81 78 842 8915 +81 78 842 8918 hiroki tanaka@turbo.co.|p
KHK-Nada Buildg. 3F mobile: +81 90 335 696 25 mark_phiHips@turbo.co.ip
6*10. Tomoda-Cho. +81 90 305176 92
Nada-Ku. Kobe-shi
657-0035 Hyougo4<en
Turbo Systems United Co. Ltd +81 3 5611 5985 +81 3 5611 5977 service@turbo.co.jp
Area Central Buildg. 18F 24 hrs: +81 3 3623 8911 +81 3 5611 5978
2-1 Kinshi 1-Chome Sumida-Ku w-shop: +81 3 5619 5021 +81 3 5619 5022
130-0013 Tokyo___________
Jordan for service call
Temeco,
ABB-Customer Support
Riyadh
Saudi Arabia
Kenya for service call

ABB Industry (Pty) Ltd.
Cape Town
South Africa
Korea Asea Brown Boveri Ltd. +82 51 264 1680

Pusan Branch, Marine & emerg: +82 11 841 1680
Turbocharger Division mobile: +82 11 851 1682
1507-10, Dadae-Dong, +82 11 578 0798
Saha-Ku
Pusan 604-050
Kuwait for service call
Reg. Office Dubai
Latvia ! for service call

ABB Zamech
Lithunia
Gdansk
Poland
Lebanon for service call

Temeco,
Riyadh
Saudi Arabia
Malta Malta Drydocks sw brd: +356 82 2451 +356 80 0021 lnfo@maltadrydocks.com.mt

The Docks +356 82 2491
P.O. Box 581 24 hrs: +356 09 42 8992
Valetta CMR01
Mexico for service call
North Brunswick
USA
Morocco ABB Turbocharger S.A. +212 8 84 6580 +212 8 84 6582 abbturbo@casanet-net.ma

Lot No. 10 +212 8 84 6581
Zone Chantier Naval aft hrs: +212 1 16 8329
Nouveau Port d’Agadir
Agadir_____________
- Casablanca for service call
ABB Turbocharger S.A.
Agadir_____________
Netherlands ABB Turbocharger BV 24 hrs: +31 10 407 8911 +31 10 407 8444 I
Marten Meesweg 5 Service: +31 10 407 8885
NL-3068 AV Rotterdam Spares: +31 10 407 8888
or
P.O. Box 547
NL-3000 AM Rotterdam
Netherlands for service call
ABB Turbocharger BV |
Antilles
Rotterdam
I
(Curagao, Bonaire. Saba, Netherlands
St Eustasius, St Marten)
B
2000-09
Service Stations
New Zealand ABB Service, Auckland 24 hrs: +64 9 276 6016 +64 9 276 1303
34 Saieyards Road
P.O. Box 22-167
Otahuhu
Auckland
Norway ABB Industri AS sw brd: +47 22 87 2000 +47 22 35 2190 noina.turbo@no.abb.com

Turbocharger Dept. +47 22 87 2647
Hasleveien 50 +47 22 87 2646
P.O. Box 6540 RodelOkka
24 hrs; +47 22 87 2600
N-0501 Oslo 5
SOren E. Skarvik A/S. +47 76 06 8044 +47 76 07 0272
N-8300 Lofoten
Oman for service call
Reg. Office Dubai
Pakistan ABB Turbocharger Workshop +92 42 527 2497 +92 42 527 2289
20 km Ferozepur Road +92 42 527 2498
Lahore aft hrs; +92 30 045 3922
Peru Asea Brown Boveri S.A. +51 1 561 0404 +51 1 561 3040
Service Turbocharger mobile: +51 1 900 9297 +51 1 561 2902
Av. Argentina 3120
P.O. Box 3846
Lima 100
Philippines ABB Industry Inc. 24 hrs: +63 2 824 4581 +63 2 824 4618
Turbocharger Division +63 2 824 4617 +63 2 824 4650
km 20 South Superhighway +63 917 813 4698
emerg:
Sucat, Paranaque
Metro Manila____________
ABB Industry, Inc +63 32 233 9924/34 +63 32 233 9937
Turbocharger Division
Reclamation Area
Turbocharger Division
Reclamation Area, Unit 11
Siment Warehouse Complex
Mandaue City, Cebu 6014
Poland ABB Turbocharger Service +48 58 346 2232 +48 58 346 3043 witold.ciesielski@pl.abb.com
ABB Zamech Marine +48 58 305 1558
ul Twarda 6B mobile: +48 60 167 6614
PL-80-871 Gdansk
- Szczecin for service call
ABB Zamech Marine
Gdansk
Portugal Asea Brown Boveri, S.A. sw brd: +351 22 999 2500 +351 22 999 2571
Service Division +351 22 999 2546 +351 22 999 2572
Rua Aldeia Nova aft hrs: +351 96 302 5684
4455-413 Perafita
mobile: +351 96 607 4346
PT-4450 Matosinhos Oporto
Lisbon
• Aveiro for sen/ice call
• Lisbon Asea Brown Boveri,
S.A.
Lisbon
Qatar for service call

Reg. Office Dubai

2000-09
Service Stations
Russia Novoship +7 861 729 4579 ■*■7 861 725 7760

Turtocharger Service +7 861 729 1199 +7 861 725 4932
1 ul. Svoboda +7 861 729 1198
RU-353900 Novorossiysk
ABB Vladivostock +7 4232 26 9973 +7 4232 26 9973
Branch Office Turbochargers aft hrs: +7 4232 46 1571
Pologaya Str. 66
Room 502
RU-690091 Vladivostock
Saudi Arabia Temeco, +966 2 620 9495 ext. +966 2 620 9488
ABB-Customer Support 222 or 223
Turbocharger Division +966 2 620 9465 ext.
P.O. Box 7937 224 or 225
21472 Jeddah
mobile: +966 5 521 7109
+966 5 541 8212
Singapore ABB Industry Re. Ltd sw brd: +65 861 9722 +65 861 8126
No. 2 Tuas Lane (6 lines)
638611 Singapore aft hrs: +65 9664 9080
South Africa ABB Automation (Pty) Ltd. +27 21 511 7331 +27 21 511 7472 richard.oberzaucher@za.ab
Turbocharger Dept. aft hrs: +27 21 557 2871 b.com
P.O. Box 180 +27 21 558 8771
Paarden Eiland mobile: +27 82 5666117+121
7420 Cape Town_____
ABB Automation (Pty) Ltd. +27 31 205 9033 +27 31 205 9045
Turbocharger Division aft hrs: +27 31 467 8261
P.O. Box 29053 mobile: +27 31 82 493 7706
Maydon Wharf
2A-4057 Durban
Spain ABB Sistemas Industriales, +34 91 581 9393 +34 91 581 5680
S.A. / Turbocompresores +34 91 581 9292
C/Cronos, 57 +34 91 581 9375
E-28037 Madrid +34 60 968 2158
emerg:
- Barcelona for service call
- Bilbao ABB Sistemas
- Cadiz Industrlaies, S.A.
-Vigo Madrid
ABB Sistemas Industriales, +34 95 667 7370 +34 95 667 8595
S.A. / Turbocompresores emerg: +34 61 909 8827
C/Bergantin. 8
Poiig. Ind. Palmones, I
E-11379 Los Barrios (Cadiz)
Algeciras
Gibraltar
ABB Sistemas Industriales, +34 92 846 3075 +34 92 846 3077
S.A. / Turbocompresores +34 92 846 5762
Sao Paulo 39 +34 60 951 0151
emerg:
El Cebadal
E-35008 Las Palmas
(Canary Islands)________
Sweden ABB Service AB +46 31 744 1930 +46 31 23 6080
Turbocharger Dept. mobile: +46 70 594 0485
Serv. Office w-shop: +46 31 744 1938
Inlandsgatan 16
S-40072 Gothenburg
Switzerland ABB Turbo Systems Ltd Sw brd: +41 56 205 7777 +41 56 205 7390
Turbocharger Headquarter aft hrs: +41 56 205 3200
Haselstr. 16
CH-5401 Baden
Al»l|
ABB Turbo Systems Ltd HZTL 93750 p\nn
2000-09
Service Stations
Syria for service call I

Temeco,!
Riyadh
Saudi Arabia
Taiwan, Asea Brown Boveri Ltd. +886 7 822 0710 +886 7 822 0704
No. 211 Ping-Ho Road 24 hrs: +886 7 822 0710
R.O.C.
Shaou-Kang aft hrs: +886 7 822 0710
Kaohsiung 812 +886 9 3364 4914
mobile;
+886 9 2873 6410
Thailand ABB Limited +66 (0) 2 709 3346 +66 (0) 2 709 3760
Automation Segm. Business ext 5410
322 Moo 4. Bangpoo Ind.
Estate, Soi 6
Sukhumvit Rd. Prekasa Distr
Amphur Muang
10280 Samutprakam______
Turkey ABB Elektrik San A.S. +90 216 493 5107 +90 216 493 7157 muaffak.ozdil@tr.abb.com
Marine & Turbocharger aft hrs: +90 533 273 5760
Service mobile: +90 532 794 7493 erkmen.ozar@tr.abb.com
Oezek is Merkezi C Blok
+90 542 314 1208
C1/C2G.50 SK NO:4
Tersaneler Boelgesi
81700 Tuzia Istanbul
United Arab ABB Industries (LLC) sw brd: +971 4 334 7788 +971 4 335 8603 abbturbo@emirates.net.ae
Reg. Office Dubai aft hrs: +971 4 336 8546 +971 4 334 7557
Emirates
Office Buildg. No. 250 B +971 50 658 0446
emerg:
P.O. Box 11070
24 hrs: +971 4 334 7788
Next to Sana, Karama
Dubai
United ABB Automation Ltd. 24 hrs: +44 1293 58 3600 +44 1293 58 3635
Marine & Turbocharger Div.
Kingdom
Unit 5, Faraday Centre
Faraday Road
Crawley
West Sussex RH10 2PX
- Falmouth for service call
- Hull / Immingham ABB Automation Ltd.
- Liverpool / Manchester Marine & Turbocharger
- London Division
- Newcastle-upon Tyne Crawley
- Swansea
ABB Automation Ltd. 24 hrs: +44 1952 20 5400 +44 1952 20 5401
Unit G. Stafford Park 12
Telford
Shropshire TF3 3BJ
ABB Automation Ltd. 24 hrs: +44 1224 59 2123 +44 1224 59 2690
21-25 Commerce Street
Aberdeen
Scotland AB11 5FE

2000-09
Service Stations
United States abb Turbocharger Co. 24 hrs: +1 732 932 6103 +1 732 932 6378
1460 Livingston Avenue
of America
North Brunswick, NJ 08902
(USA)
ABB Turbocharger Co. 24 hrs: +1 954 450 9544 +1 954 450 8957
Miami / Ft. Lauderdale
Service Center
3850 Executive Way
Miramar, FL 33025
ABB Turbocharger Co. 24 hrs; +1 281 930 8383 +1 281 930 9595
Houston Area Service Center
1109 Howard Street
Deer Park, TX 77536
ABB T urbocharger Co. 24 hrs; +1 310 324 4814 +1 310 324 5102
Los Angeles Area Service
Center
20350 So. Figueroa St.
Carson, CA 90745
- San Francisco for service call
Carson
or
Tacoma
ABB Turbocharger Co. 24 hrs: +1 253 383 1806 +1 253 383 1270
Tacoma / Seattle Sen/ice
Center
1640-B Marine View Drive
Tacoma, WA 98422
Uruguay for service call
Asea Brown Boveri S.A.
Buenos Aires
Argentina
Yemen for service call

Temeco,
Riyadh
Saudi Arabia

2000-09
Betriebshandbuch Kurzfassung
Operation manual abridged version 9
Betriebshandbuch Kurzfassung Kap. / Chap. 9 Operation manual abridged version
9 9
Betriebshandbuch Operation manual
Kurzfassung abridged version
Hinvkreis Eine Kurzfassung des vorliegenden An abridged version of this operation

Betriebshandbuches kann separat bestellt manual can be ordered separately.
werden.
Es ist in folgenden Sprachen erhaltlich; It is available in the following languages:

Franzosisch French
Spanisch Spanish
Russisch Russian
ABB Turbo Systems Ltd ik III!

2
Manual of Turbocharger Chap. 6-3
ii. mi Cleaning control
TPL
Reinigungssteuerung Cleaning control
1. Reinigungssteuerung 3 1, Cleaning device 3

1.1. Einleitung 3 1.1 Introduction 3
2. Einsatzgrenzen fur den Betrieb 2. Application limits for operation

6
der Reinigungssteuerung 6 of the cleaning device
6
2.1 Reinigungsdruckerhohung 2.1 Cleaning pressure increase unit 6
8
2.2 Ventileinheiten 2.2 Valve units 6
3. Komponenten der 3. Components of cleaning

Reinigungsdruckerhohung 9 pressure increase unit 9
3.1 Elektrische Anschlusse der 3.1 Electrical connections of cleaning
10 10
Reinigungsdruckerhohung pressure increase unit
3.2 Fluldische Anschlusse der 3.2 Fluid connections of cleaning
11 11
Reinigungsdruckerhohung pressure increase unit
4. Ventileinheiten 13 4. Valve units 13

4.1 Elektrische Anschlusse der 4.1 Electrical connections of
Ventileinheiten 13 valve units 13
4.2 Fluidische Anschiusse der 4.2 Fluid connections of valve units 17
Ventileinheiten 17
5. Pipe cross-sections
5. Notwendige Leitungs- required 19
querschnitte 19 5.1 Air supply 19
5.1 Luftversorgung 19 5.2 Pipe dimensions for 4-stroke
5.2 Leitungsdimensionen bei engines 19
4-Takt Motoren 19 5.3 Pipe dimensions for 2-stroke
20
5.3 Leitungsdimensionen bei engines
20
2-Takt Motoren
6. Diaphragm for compressor
6. Blende fiir Verdichter- und and turbine cleaning
21
21
Turbinenreinigung 6.1 Diaphragm for compressor
6.1 Blende fur die cleaning 21
21
Verdichterreinigung 6.2 Diaphragm for turbine washing 22
6.2 Blende fur das
22
Turbinenwaschen
Prepared: We reserve all nghts in this document and Language: No. of pages; Page number:
2000-06-26 / ZTP in the information contained therein. 1
Checked; Description of modification Reproduction, use or disclosure to third de / en 48
see last page of this chapter. parties without express authority Is slrictty Modiricatiort
Released: forbidden.
zve
Copyright ABB Turbo Systems Ltd 2000 HZTL 90624
Manual of Turbocharger TPL
7. Elektrische Steuerung 24 7. Electrical control unit 24

7.1 Bedienung derelektrischen 7.1 Operation of electrical
Steuerung 24 control unit 24
7.2 Anschliessen der elektrischen 7.2 Connection of electrical
Steuerung 26 control unit 26
7.3 Konfiguration der el. Steuerung 26 7.3 Configuration of electrical
7.4 Uberwachung der Gastemperatur control unit 27
vor Turbine 29 7.4 Monitoring exhaust gas
7.5 Klemmenleiste der elektrischen temperature before turbine 29
Steuerung 31 7.5 Terminal strip of electrical
7.6 Parametrisierung der control unit 32
Analog-Eingange und weiterer 7.6 Parametrizing the analogue inputs
Steuergrossen 33 and other control variables 33
7.7 Ablauf der Programme der 7.7 Program sequences of electrical
elektrischen Steuerung 37 control unit 37
8. Auswahl der Reinigungs- 8. Selecting cleaning

komponenten 40 components 40
8.1 Auswahl der Reinigungs- 8.1 Selecting cleaning components
komponenten fur for 4-stroke applications 40
4-Takt Anwendungen 40 8.2 Selecting cleaning components
8.2 Auswahl der Reinigungs- for 2-stroke applications 41
komponenten fur
2-Takt Anwendungen 41 9. Installation of cleaning
control 42
9. Installation der
9.1 Installation of cleaning pressure
Reinigungssteuerung 42 increase unit 43
9.1 Installation der Reinigungs- 9.2 Installation of valve units 43
druckerhohung 43 9.3 Commissioning of cleaning
9.2 Installation der Ventileinheiten 43 control 44
9.3 Inbetriebnahme der Reinigungs
steuerung 44 10. Functional checks and
maintenance 45
10. Funktionskontrollen
10.1 Checks of cleaning procedures 45
und Wartung 45 10.2 Maintenance of cleaning control 48
10.1 Kontrollen der
Reinigungsprozeduren 45 11. Performance of cleaning
10.2 Wartung der operations 48
Reinigungssteuerung 48
11. Durchfuhrung der

Reinigungen 48
Language: No. of paQes: Page number:
de / en 48 2 Chap. 6-3
Modtficaliort
Cleaning control ABB Turbo Systems Ltd
HZTL 90624
1
1.
Reinigungssteuerung Cleaning device
1.1
1.1
Eine Steuerung (elektrisch und fluidisch) zur Reini- A control unit {electrical and fluid) for cleaning the
gung von Verdichter und Turbine im Betrieb, kann bei compressor and turbine in operation can be obtained
ABB Turbo Systems erworben warden. from ABB Turbo Systems.
In Fig. 1-1 und Fig. 1-2 ist diese Reinigungssteuerung Figs 1-1 and 1-2 show schematic diagrams of this
schematisch dargestellt. Eine Steuerung kann fur fol- cleaning device. A control unit can be used for the
gende Anwendungen eingesetzt warden: following applications:
Anzahi Motoren Anzahi Turbolader pro Motor
Number of engines Number of turbochargers per engine
4-Takt Motor (Fig. 1-1)
1 ... 4 1 ... 2
4-stroke engine (fig. 1-1)
2-Takt Motor (Fig. 1-2) 1
1 ... 4
2-stroke engine (fig. 1-2)
Die Steuerung ist so konzipiert, dass die Reinigungs- The control unit is designed for performance of the
sequenzen nach den in Kapite! 6-1 & 2 beschriebe- cleaning sequences as described in sections 6-1 & 2.
nen Vorgaben durchgefuhrt warden.
Stromversorgung Luftzufuhr Luftzufuhr

Power supply Air supply Air supply
24 V DC/~ 50 VA 5.5-10.0 bar 4.0-8.0 bar
Druckreduzierventil I
Elektrische
Motorlast
ft
Pressure reducing valve
Steuerung {
Signal * Ruckschlagventil
Electrical Steuerventii ^ Check valve
Engine load
signal Control valve Manometer, I __ T
Entluftungsventil Uberdruckventill i=p^'

4 - 20mA
Bleed .Pressure gauge] j p.^>
Niveauschalter Pressure relief
Wasser- Level switch M valve
zufuhr Druckbehalterg
Water Pressure tank^ Niveauanzeige
supply Level indicator
TS
~ 2 - 6 bar I TE
= lr:l
I
I
Eingangseinheit / Input unit Konsole / Mounting panel
VS
Reinigungsdruckerhohung Ventileinheiten CE
Cleaning pressure increase unit Valve units
Blende
Alle angegebenen Drucke sind Uberdrucke. All pressures specified are over-pressures. Orifice
Fig. 1-1
Reinigungssteuerung fur 4-Takt Motoren
Cleaning control for 4-stroke engines
Lar^guage: No. of pages: Page number
Chap. 6-3 de / en 48 3
Modificaliort
ABB Turbo Systems Ltd Cleaning control
HZTL 90624
Stromversorgung Luftzufuhr Luftzufuhr

Power supply Air supply Air supply
24 V DC/- 50 VA 4.0 - 8.0 bar 4.0-8.0 bar
{
i
Elektrische \
Motorlast Steuerung
Signal ! T
Electrical i
Engine load control system II
signal I i
j I
4 - 20mA I II \
Wasser- it
zufuhr j
Water j j
I
supply > P TS
1 tr
-2-6 bar TE
L' -C-l- ITS’
tjO ■ Konsole /
Eingangseinheit //npu/ unit Mounting panel
vs
CE
Steuereinheit Ventileinheiten
Control unit Valve units Blende
Orifice
Alle angegebenen Drucke sind Uberdrucke. All pressures specified are overpressures.
Fig. 1-2
Reinigungssteuerung fur 2-Takt Motoren
Cleaning control for 2-stroke engines
Die Reinigungssteuerung besteht aus einer Reini- The cleaning device comprises a cleaning pressure
gungsdruckerhbhung {elektrische Steuerung, Druck- increase unit (electrical control unit, pressure tank
behalter [nur bei 4-Takt Anwendungen], Eingangs- [only for 4-stroke applications], input unit and mounting
einheit und Konsole), welche im Maschinenraum auf- panel) installed in the engine room, In addition to the
gestellt wird, sowie aus den Ventileinheiten, welche valve units, which are preferably installed on the engine
vorzugsweise in Turboladernahe am Motor montiert close to the turbocharger. For compressor cleaning
werden. Fur die Verdichterreinigung bei 4-Takt An on 4-stroke applications, a diaphragm must also be
wendungen muss Im Anschluss des Filterschall- fitted after the filter silencer or air suction branch (cf.
dampfers resp. Luftsaugstutzen zusatzlich eine Blen section 6.1).
de installiert werden (vgl. Abschnitt 6.1) The connecting pipes between the cleaning pressure
Die Verbindungsleitungen zwischen Reinigungsdruck- increase unit and the valve units (incl. shut-off valve)
erhohung und Ventileinheiten (inkl. Absperrventil), so and between the valve units and the turbocharger do
wie zwischen Ventileinheiten und Turbolader gehoren not form part of the delivery from ABB Turbo Systems
nicht zum Lieferumfang von ABB Turbo Systems AG. Ltd, nor do the pneumatic and electrical connections
Ebenfalls gehoren die pneumatischen und elektrischen or the cleaning component connections.
Anschlusse und Verbindungen der Reinigungs- The cleaning sequences are controlled electrically
komponenten nicht zum Lieferumfang von ABB Turbo (programmable logic control). The various cleaning
Systems AG. operations must be started manually. The engine
Die Reinigungssequenzen werden elektrisch gesteu- load (exhaust gas temperature before turbine) of all
ert (Speicherprogrammierbare Steuerung). Die ver- engines connected must be monitored to ensure that
schiedenen Reinigungen mussen dabei manuell ge- the cleaning operations are performed in the
startet werden. Damit die Reinigungen in den vorge- prescribed engine load ranges (exhaust gas
schriebenen Motorlastbereichen (Abgastemperatur) temperature). The electrical control unit has the
durchgefuhrt werden, muss die Motorlast (Abgas necessary analogue inputs for this purpose.
temperatur vor Turbine) aller angeschlossenen Mo
toren uberwacht werden. Die elektrische Steuerung
verfugt uber die dazu notwendigen Analog-Eingange.
Language: No. of pages: Page number
de / en 48 4 Chap. 6-3
Modificaiion:
HZTL 90624
Zur Verhinderung von Ablagerungen (Kalk) in den The pipe sections from the valve unit are blown out
Leitungen zum Turbolader werden die Leitungsstucke with air following every cleaning sequence to prevent
ab Ventileinheit nach jeder Reinigung mit Luft leer- deposits (scale) in the pipes to the turbocharger. The
geblasen. Die Verbindungsleitung von der Ventileinheit connecting pipe from the valve unit to the gas inlet
zum Gaseintrittsgehause wird zudem periodisch mit casing is also blown out with air periodically to prevent
Luft durchblasen, damit sich darin keine Ablagerun adhesion of deposits from the turbine.
gen aus der Turbine festsetzen konnen. Minimum pipe cross-sections (cf. section 5) and
Urn zu hohe Druckabfalle zu verhindern, sind mini maximum pipe lengths (cf. section 9) are specified to
male Leitungsquerschnitte (vgl. Abschnitt 5) und ma prevent excessive pressure drops.
ximale Leilungsiangen (vgl. Abschnitt 9) vorgeschrie- The connection dimensions for the various
ben. components are shown in the dimension drawings.
Die Anschlussmasse der verschiedenen Komponen-
ten sind aus den Massbildern ersichtlich.
Caution! It is important that the pipe dimensions

specified in section 5 (tables 5-1 and 5-2)
Vorsicht I Es ist wichtig, dass die Leitungsdimen- are observed. If the pipes are dimensioned
sionen, welche in Abschnitt 5 (Tabelle 5-1, too small, the pressure drop is too big,
Tabelle 5-2) angegeben sind, eingehalten which results in poor water distribution to
werden. Bei zu knapp dimensionierten Lei nozzle ring and turbine, and therefore in
tungen resultiert ein zu hoher Druckab- less effective cleaning.
fall, was zu schlechter Wasserverteilung
auf Dusenring und Turbine und damit zu
schlechter Reinigungswirkung fuhrt.
Caution! The cleaning control does not satisfy Ex

protection requirements.
Vorsicht! Die Reinigungssteuerung erfullt Ex

Schuztanforderungen nicht.
Lar>guage: No. of pages: Page number:
Chap. 6-3 de / en 48 5
Modified tiorv
HZTL 90624
2 2
Einsatzgrenzen fiir den Betrieb der Application limits for operation of

Reinigungsteuerung the cleaning device
2.1 2.1
Reinigungsdruckerhohung Cleaning pressure increase unit
2.1.1 2.1.1
Wasserversorgung Water supply
Fur den Betrieb der Reinigungssteuerung ist ein Was- A water pressure of
serdruck von = 2-6 bar (overpressure)
= 2 ... 6 bar (Uberdruck) is required for operating the cleaning control. For
erforderlich. Fur das Waschen der Turbine muss der washing the turbine the water pressure must be set
Wasserdruck mit dem Regulierventil so eingestellt with the control valve (cf. section 6.2) so that the
warden (vgl. Abschnitt 6.2), dass die Reinigungs- cleaning parameters in chapter 6-1 & 2, section 2.6
parameter nach Kapitel 6-1 &2, Abschnitt 2.6 einge- are observed.
halten warden.
Caution! Only pure water, and in no event salt water,

Vorslcht! Es darf aus Grunden der Korrosionsgefahr must be used in order to avoid any danger
nur reines Wasser. keinesfalls Saizwasser of corrosion. The water should also not
verwendet warden. Das Wasser soil auch contain any cooling water treatment
keine Kuhlwasseraufbereitungsmittel ent- agents, which can be deposited as coating
halten, die sich als Belag in den Strdmungs- In the flow ducts.
kanalen niederschlagen kdnnen.
Caution! In the event a malfunction of the control

Vorsicht! Bei einer Funktionsstorung des Steuer- valve of the input unit (cf. section 3) the
ventils der Eingangseinhelt (vgl. Ab water supply system may be pressurized
schnitt 3) ist es moglich, dass das during a cleaning operation (pressure of
Wasservorsorgungssystem wahrend ei- air supply of pressure tank). If the water
nes Reinigungszykiuses unter Druck ge- supply system is not designed to withstand
setzt wird (Druck der Luftspeisung des this pressure (- 5.5-6 bar overpressure)
Druckbehalters). Falls das Wasserver- suitable protection must be provided.
sorgungsystem nicht fur diesen Druck (~
5.5... 6 bar Uberdruck) ausgelegt ist, muss
eine entsprechende Absicherung Integriert
werden.
Language: No. of pages: Page number:
de / en 48 6 Chap. 6-3
ModificatiorT
HZTL 90624
2.1.2 2.1.2
Stromversorgung Power supply
FOr den Betrieb der Reinigungssteuerung ist eine A 24 V DC ± 10% supply is required to operate the
24 V DC ± 10 % Versorgung erforderlich. Die cleaning control. The maximum power consumption
Leistungsaufnahme der Steuerung betragt im Maxi of the control unit is approx. 50 VA.
mum ca. 50 VA. Since the entire cleaning control is operated at low
Da die gesamte Reinigungssteuerung mit Niederspan- voltage (24 V DC) it is unnecessary to use earthing
nung (24 V DC) betrieben wird, ist die Verwendung conductors, though this is recommended to ensure
von Erdungsleitungen nicht erforderlich, wird aber immunity from electromagnetic interference.
aus Grunden der elektromagnetischen Storsicherheit
empfohlen.
2.1.3
Air supply
2.1.3
Luftversorgung The air supplied to the pressure increase unit is filtered
in the pressure reducing valve and the condensation
Die Luft, die der Druckerhohungseinheit zugefuhrt water is separated.
wird, wird im Druckreduzierventil gefiltert und das It is recommended to use air from the control air
Kondenswasser wird abgeschieden. system for the cleaning control, and not start air.
Wir empfehlen fur die Reinigungssteuerung Luft des An air supply pressure of at least
Steuerluftsystems und keine Slartiuft zu verwenden.
pLm.n = 5.5 bar (overpressure)
Fur die Reinigungsdruckerhdhung ist ein Luftspeise-
is necessary for increasing the cleaning pressure.
druck von mindestens
The maximum permissible pressure (before the
Pimin “ (Uberdruck)
pressure reducing valve) is
notwendig.
Pumax ” '' 5ar (overpressure).
Der maximal zulassige Druck (vor Druckreduzierventi!)
betragt
Plmax = 10.0 bar (Uberdruck)
"K
Note The safety valve of the pressure tank
opens at an air pressure of p^ > 8 bar.
Hinweis Ab einem Luftdruck Pj^ > 8 bar offnet das

Sicherheitsventil des Druckbehalters.
Note To ensure good water distribution during

thermal shock cleaning of the turbine, the
air pressure must be set accurately (cf.
Hinweis Damit bei der Thermoschockreinigung der chapter 6-1, section 2.7.2.2).
Turbine eine gute Wasserverteilung er-
zielt wird. muss der Luftdruck exakt ein-
gestellt werden (vgl. Kapitel 6-1, Abschnit 2.1.4
2.7.2.2). Temperatures
The maximum permissible ambient temperature for
2.1.4 the cleaning pressure increase unit is 50®C.
Temperaturen
Die maximal zulassige Umgebungstemperatur fur die
Reinigungsdruckerhdhung betragt 50°C.
Language: No. of pages; Page number:
Chap. 6-3 de / en 48 7
Modification:
HZTL 90624
2.2 2.2
Ventileinheiten Valve units
2.2.1 2.2.1
Luftversorgung Air supply
Fur die Ventileinheiten ist ein Luftdruck von An air pressure of
= 4.0 ... 8.0 bar (Oberdruck) p^ = 4.0 - 8.0 bar (overpressure)
zulassig. is permissible for the valve units.
2.2.2 2.2.2
Temperaturen Temperatures
Fur die Ventileinheiten gelten folgende Einsatz- The following application limits apply to the valve
grenzen; units:
- die maximal zulassige Temperatur des Steuerfluids The maximum permissible temperature of the
(Luft) betragt 60 ®C control medium (air) is 60®C
- die maximal zulassige Umgebungstemperatur be The maximum permissible ambient temperature
tragt 85 “C is85X
2.2.3 2.2.3
Vibrationen Vibration
Die Ventileinheiten sind fur Vibrationen gem. VDI2063 The valve units are designed for vibration according
ausgelegt. to VDI 2063.
Language: No. of pages: Page number;
de / en 48 8 Chap. 6-3
Mo<>ificalion:
HZTL 90624
3 3
Komponenten der Reinigungs- Components of cleaning pressure
druckerhohung increase unit
Die Reinigungsdruckerhohung besteht aus folgen- The cleaning pressure increase unit comprises the
den Komponenten: following components;
li” n
Druckbehalter (DG..)
Pressure tank (DG..)
Elektrische Steuerung mit SPS (PG..)

in) U) Electrical control unit with PLC (PG..)
Konsole
Mounting panel
Eingangseinheit (EG..)
73—^ Input unit (EG..)
Manometer Steuerventil
Pressure gauge Control valve
Absperrventil
Shut-off valve
Verschraubung mit integrierter Blende Schieberventil Schmutzfanger (Maschenweite 0.3 mm)

Screwed coupling with integral orifice Slide valve Dirt trap (mesh width 0.3 mm)
Fig. 3-1
Komponenten der Reingungsdruckerhohung
Components of cleaning pressure increase unit
Druckbehalter zur Erreichung des fur die Thermo- Pressure tank to obtain the necessary water
schockrelnigung der Turbine und zur Reinigung pressure for thermal shock cleaning of the turbine
des Verdichters notwendigen Wasserdrucks. (Nur and for cleaning the compressor (only required for
bei 4-Takt Anwendungen erforderlich.) 4-stroke applications).
Eingangseinheit zur sicheren Abtrennung der Input unit for reliable separation of the water supply,
Wasserspeisung, zum kontrollierten Pullen des for controlled filling of the pressure tank and for
Druckbehalters, sowie zum Einstellen des Wasser- setting the water volume flow for turbine washing.
volumenstroms fur das Turbinenwaschen. Electrical control unit with programmable logic
Elektrische Sleuerung mit speicherprogram- control (PLC).
mierbarer Steuerung (SPS). Mounting panel for accommodating pressure tank.
Konsole zur Befestigung von Druckbehalter. Ein Input unit and electrical control unit.
gangseinheit und elektrischer Steuerung.
Language; No. of pages: Page number;
Chap. 6-3 de / en 48 9
Modification:
HZTL 90624
3.1 3.1
Elektrische Anschliisse der Reinigungs- Electrical connections to cleaning
druckerhohung pressure increase unit
Niveauschalter
Entluftungsventil Level switch
Bleed valve
Steuen/entil Luftzufuhr I U) <n)
Air supply control valve

Kabeldurchfuhrungen
Cable bushings
Klemmenkasten
Steuerventil Wasserzufuhr Terminal box
I
Water supply control valve ‘
H
Kabeldurchfuhrungen
Cable bushings Eingange PG9
IVariante 1* Variante 2* Inputs PG9
Version 1 * Version 2*
2
PG9 5
Ausgange PG11
2
PG11 5 Outputs PG11
*) vgl. Abschnitt 7 / See section 7
Fig. 3-2
Elektrische Anschlusse der Reinigungsdruckerhohung
Electrical connections for cleaning pressure increase unit
Samtiiche elektrischen Anschlusse der Steuerorgane All electrical connections of the control elements for
des Druckbehalters sowie der Eingangseinheit sind the pressure tank and input unit are taken to a terminal
am Druckbehalter in einem Klemmenkasten zusam- box on the pressure tank. From there they are taken
mengefuhrt. Von da sind sie auf die Klemmenleiste to the terminal strip of the electrical control unit.
der elektrischen Steuerung gefuhrt.
Anschusse im Klemmenkasten des Druckbehalters sowie im Steuerungsschrank

Connections in terminal box of pressure tank and control cabinet
Eingange Klemmenkasten am Druckbehalter Klemmen im Steuerungsschrank

Inputs Terminal box in pressure tank Terminals in control cabinet
Niveauschalter X6: 1 (+ 24 V DC) X2: 1 (+ 24 V DC)

Level switch X6: 2 (0 V DC) X2: 2 (0 V DC)
Steuerventil Luftzufuhr X6: 3 (+ 24 V DC) X4: 5 (+ 24 V DC)

Valve air in X6: 4 (0 V DC) X4; 6 (0 V DC)
Entluftungsventil X6: 5 (+ 24 V DC) X4: 7 (+ 24 V DC)

Valve air out X6: 6 (0 V DC) X4: 8 (0 V DC)
Steuerventil Wasserzufuhr X6: 7 (+ 24 V DC) X4; 9 (+ 24 V DC)

Valve water in X6: 8 (0 V DC) X4: 10(0VDC)
Language; No. of pages: Page number
de / en 48 10 Chap. 6-3
Modification;
HZTL 90624
3.2 3.2
Fluidische Anschliisse der Reinigungs- Fluid connections of cleaning pressure
druckerhohung increase unit
Die Montagemasse der Druckerhdhungseinheiten sind The installation dimensions for the pressure increase
aus den Massbildern ersichtlich. units are shown on the dimension drawings.
m
U p
Lufteintritt
Air inlet in) <i)
WasserAustritt Wasser Eintritt

Water outlet \-
Water inlet
Losbare Verschraubung
Detachable screwed coupling
Fig. 3-3
Fluidische Anschlusse der Reingungsdruckerhdhung
Fluid connections of cleaning pressure increase unit
Wassereintritt Wasseraustritt Lufteintitt Druckbehalter El. Steuerung Merkmal

Water inlet Water outlet Air inlet Pressure tank Elec, control unit Feature
1 Motor
EG01, DG01, PG01
G1 G1%
1 Engine
G/2 20 I
2 ... 4 Motoren
EG01. DG01, PG02
2 - 4 Engines
1 Motor
EG02, DG01, PG01
G1 1 Engine
G2 G/2 20 I
2 ... 4 Motoren
EG02, DG01, PG02
2-4 Engines
1 Motor
EG01, DG02, PG01
G1 GV/4 G/2
1 Engine
40 I
2 ... 4 Motoren
EG01, DG02, PG02
2-4 Engines
1 Motor
EG02, DG02. PG01
G1 G2 G/2 1 Engine
40 I
2 ... 4 Motoren
EG02, DG02. PG02
2-4 Engines
1 Motor
EG02, DG03. PG01
G1 G2
1 Engine
G/2 60 I
2 ... 4 Motoren
EG02, DG03, PG02
2-4 Engines
Chap. 6-3 de / en 48 11
Modification:
HZTL 90624
Der Wassereintritt zur Druckerhohungseinheit ist The water inlet to the pressure increase unit is made
standardmassig von der rechten Seite. Der Wasser- as standard on the right-hand side. The water outlet
austritt zur Ventileinheit ist links angeordnet. Im Be- to the valve unit is placed on the left. If necessary, the
darfsfall konnen Wasserein- und Austritt gewechselt water inlet and outlet can be interchanged. The
werden. Dazu muss die Ibsbare Verbindung der Ein- detachable connector to the Input unit must be
gangseinheit aufgetrennt werden (vgl. Abbildung). Das disconnected for this purpose (cf. illustration). The T-
T-Stuck, welches die EIngangseinheit mit dem Druck- piece connecting the input unit with the pressure tank
behalter verbindet, muss um einen Drehwtnkel von must be tightened by an angle of 180°. The part of the
180° angezogen werden. Das abgetrennte Stuck der input unit disconnected can then be re-fitted on the
Eingangseinheit kann nun von der anderen Seite wie- other side.
der montiert werden.
a b c d
T
JI
I I 1 >i ■ i a a
H© I ■ I I
u
I *-■ 0
‘i.
0
•T «u 'V
^ 'i l!--r
I J I 1C
I I
a Ausgangszustand der Steuerung bei Ablieferung. a Initial status of control unit when supplied.
b Losen der Eingangseinheit. Vorsicht, in dieser Ver- b Disconnection of input unit. Caution: the diaphragm
schraubung ist die Blende fur das Turbinen Wa- for turbine washing is inserted in this coupling.
schen eingesetzt.
c Tightening or slackening the T-plece by 180°. The
c Anziehen resp. Losen des T-Stucks um 180°. Falls screwed coupling must be re-sealed if necessary.
erforderlich muss die Verschraubung neu abge-
dichtet werden. d Fitting of input unit from opposite side. The screwed
coupling must be re-sealed if necessary.
d Montage der Eingangseinheit von der gegenuber- The diaphragm must be inserted before fitting the
liegenden Seite. Falls erforderlich muss die Ver input unit.
schraubung neu abgedichtet werden.
Vor der Montage der Eingangseinheit muss die
Blende eingesetzt werden.
Caution! The diaphragm for turbine washing is

incorporated in the screwed coupling of
the input unit to the pressure tank.
Vorsicht! In der Verschraubung der Eingangseinheit It must be ensured that this is re-inserted
zum Druckbehalter ist die Blende fur das in the new position of the input unit.
Turbinenwaschen integriert.
Es muss darauf geachtet werden, dass
diese in der neuen Position der Eingangs
einheit wieder eingesetzt wird.
Language: No. of pages; Page number
de / en 48 12 Chap. 6-3
Modilfcatiort Cleaning control ABB Turbo Systems Ltd
HZTL 90624
4 4
Ventileinheiten Valve units
Es sind zwei verschiedene Arten von Ventileinheiten Two different types of valve units are available for
erhaltlich, die fur verschiedene Einsatze bestimmt different applications.
sind. Valve unit with one turbine, one compressor and
Ventileinheit mit einem Turbinen-, einem Verdich- one air valve:
ter- sowie einem Luftventil: - 4-stroke in-line engine with one turbocharger
- 4-Takt Reihenmotor mit einem Turbolader - 2-stroke engine
- 2-Takt Motor (with 2-stroke engines one valve unit must be

(bei 2-Takt Motoren muss pro Turbolader eine used for each turbocharger)
Ventileinheit verwendet werden)
Valve unit with two turbine, one compressor and
Ventileinheit mit zwei Turbinen-, einem Verdich- one air valve:
ter- sowie einem Luftventil: - 4-stroke V-engine with two turbochargers
- 4-Takt V-Motor mit zwei Turboladern (parallel or sequential cleaning of turbines possible)
(parallele Oder sequentielle Reinigung der Turbi-
nen moglich)
4.1 4.1
Elektrische Anschliisse der Ventil Electrical connections of valve units
einheiten
4.1.1
4.1.1 Valve unit with one turbine, one
Ventileinheit mit einem Turbinen-, einem compressor and one air valve:
Verdichter- sowie einem Luftventil
(n): engine number
(n): Motorennummer (x): turbocharger number
(x): Turboladernummer
E(n)TS(x)
TS-Ventil Vorsteuerventil zu TS-Ventil
TE valve Pre-control valve to TE valve
E(n)CS(x)
Vorsteuerventil zu VS-Ventil
Pre-control valve to CE valve
E(n) Air(x)
Vorsteuerventil zu Luftventil
Pre-control valve to air valve
Ruckschlagventil
Clack valve
VS-Ventil Luftventil
CE valve Air valve
Fig. 4-1
Ventileinheit mit einem Turbinen-, einem Verdichter- sowie einem Luftventil
Valve unit with one turbine, one compressor and one air valve
Lar>guage: No. of pages: Page number-
Chap. 6-3 de / en 48 13
Modification
HZTL 90624
Anschluss der Ventileinheiten tm Steuerungsschrank bei 4-Takt Motoren

Connection of valve units in control cabinet for 4-stroke engines
Klemmenbezeichnung / Terminal designation

Ventileinheit TS-Ventil VS-Ventil Luftventil
Valve unit TE valve CE valve Air valve
Motor 1 E1TE1 //X4: 1 12 E1CE//X4: 11/12 E1Air//X4: 13/14
Engine 1 Valve / TS_Engine_1 /1. TL Valve / CS_Engine_1 /1. and 2. TL Valve / BlowOuLI /1. and 2. TL
Motor 2 ’I E2TE1 //X4: 19/20 E2CE // X4: 23 / 24 E2Air//X4: 25/26
Engine 2 Valve/TS_Engine_2/1.TL Valve / CS_Engine_2 /1. and 2. TL Valve / BlowOuL2 /1. and 2. TL
Motor 3 E3TE1 //X4: 27/28 E3CE//X4: 31 / 32 E3Air// X4: 33/34
Engine 3 Valve / TS_Engine_3 /1. TL Valve / CS_Engine_3 /1. and 2. TL Valve / BlowOut_3 /1. and 2. TL
Motor 4 E4TE1 //X4: 35/36 E4CE//X4: 39/40 E4Air//X4: 41 / 42
Engine 4 Valve / TS_Engine_4 /1. TL Valve / CS_Engine_4 /1. and 2. TL Valve / BlowOut_4 /1. and 2. TL
1) Diese Anschlusse sind nur bei der Steuerung Va- 1) These connections are only available on version 2
riante 2 verfugbar. of the control unit.
Anschluss der Ventileinheiten im Steuerungsschrank bei 2-Takt Motoren

Ventileinheit TS-Ventil VS-Ventil Luftventil

Valve unit TE valve CE valve Air valve
Turbolader 1 E1TE1 //X4: 1 /2 E1CE//X4: 11 / 12 E1Air//X4: 13/14
Turbocharger 1 Valve/TS_Engine_1 /1. TL Valve / CS_Engine_1 /1. and 2. TL Valve / BlowOuLI /1. and 2. TL
Turbolader 2 E1TE2//X4: 3/4 E1CE2//X4: 15/16 E2Air2//X4: 17/18
Turbocharger 2 Valve/TS_Engine_2/1.TL Valve / CS_Engine_2 /1. and 2. TL Valve / BlowOut_2 /1. and 2. TL
Turbolader 3 E1TE3//X4: 43/44 E1CE3//X4:45/46 E3Air3 // X4: 47 / 48
Turbocharger 3 Valve / TS_Engine_3 /1. TL Valve / CS_Engine_3 /1. and 2. TL Valve / BtowOut_3 /1. and 2. TL
Turbolader 4 E1TE4//X4: 49/50 E1CE4//X4: 51 / 52 E4Air4 // X4: 53 / 54
Turbocharger 4 Valve / TS_Engine_4 /1. TL Valve / CS_Engine_4 /1. and 2. TL Valve / BlowOut_4 /1. and 2. TL
1) Nur bei elektrischer Steuerung Variante 2 (vgl. 1) Only possible on version 2 of electrical control unit
Abschnitt 7) moglich. (cf. section 7).
de / en 48 14 Chap. 6-3
Modification:
HZTL 90624
4.1.2 4.1.2
Ventileinheit mit zwei Turbinen-, einem Valve unit with two turbines, one
Verdichter- sowie einem Luftventil compressor and one air valve:
TS-Ventil 2 TS-Ventil 1
TE valve 2 TE valve 1
E(n)TS2
Vorsteuerventil zu TS-Ventil
Pre-control valve to TE valve
E(n) TS1
Vorsteuerventi! zu TS-Ventil
Pre-control valve to TE valve
E(n)CS
Vorsteuerventil zu VS-Ventil
_I
W Pre-control valve to CE valve
E(n) Air
Vorsteuerventil zu Luftventil
Pre-control valve to air valve
Ruckschlagventil
\/
Clack valve
VS-Ventil Luftventil
CE valve Air valve
Fig. 4-2
Ventileinheit mit zwei Turbinen-, einem Verdichter- sowie einem Luftventil
Valve unit vîth two turbines, one compressor and one air valve
“K
Hinweis Die Minus-Leitungen [-] der Ventile der Note The minus [-] wiring to the valves of the
Ventileinheiten kbnnen gesammelt in die valve units can be taken together to the
elektrische Steuerung gefuhrt werden. electrical control unit. This common wiring
Diese Sammelleitung kann auf der can be connected to the terminal strip on
Klemmenleiste auf dem Minus-Eingang the minus input [-] of any valve in this
[-] eines beliebigen Ventils dieser Ventil valve unit.
einheit angeschlossen werden.
Language: No. of pages; Page number
Chap. 6-3 de / en 48 15
Modificalioa
HZTL 90624
Anschluss der Ventileinheiten im Steuerschrank bei 4>Takt Motoren


Ventileinhelt TS-Ventil 1 TS-Venti! 2
Valve unit TE valve 1 TE valve 2
Motor 1 E1TE1 //X4: 1 12 E1TE2//X4: 3/4
Engine 1 Valve/TE_Engine_1 /1.TL Valve / TE_Engine_1 / 2. TL
Motor 2 E2TE1 //X4: 19/20 E2TE2 // X4: 21 / 22
Engine 2 Valve / TE_Engine_2 /1. TL Valve / TE_Engine_2 / 2. TL
Motor 3 E3TE1 // X27/28 E3TE2 // X4: 29 / 30
Engine 3 Valve/TE_Engine_3/1.TL Valve / TE_Engine_3 / 2. TL
Motor 4 E4TE1 // X4: 35 / 36 E4TE2 // X4: 37 / 38
Engine 4 Valve / TE_Engine_4 /1. TL Valve / TE_Engine_4 / 2. TL
Ventileinheit VS-Ventil Luftventil
Va/i'e unit CE valve Air valve
Motor 1 E1CE//X4: 11 / 12 E1Air//X4: 13/ 14
Engine 1 Valve / CE_Engine_1 /1. and 2. TL Valve / BlowOut_1 /1. and 2. TL
Motor 2 E2CE // X4: 23 / 24 E2Air//X4: 25/26
Motor 3 E3CE // X4: 31 / 32 E3Alr// X4: 33/34
Motor 4 E4CE // X4; 39 / 40 E4Air//X4: 41 /42
1) Nur bei elektrischer Steuerung Variante 2 (vgl. 1) Only possible on version 2 of electrical control unit
Abschnitt 7) moglich. (cf. section 7).
Language: No. of pages: Page number
de / en 48 16 Chap. 6-3
Modifâtiorc
HZTL 90624
4.2 4.2
Fluidische Anschlusse der Ventileinheiten Fluid connections of valve units
Die Montagemasse der Ventileinheiten sind aus den The fitting dimensions of the valve units are shown in
Massbildern ersichtllch. the dimension drawings.
C C
[1 |‘| n ]i
Luftfilter f45um^ Luftfilter (45um^
Air filter (45 ^m) Air filter (45 ^m)
.1 ^ B
j—{
■Ruckschlaoventil Ruckschlaaventil
Clacke valve Clacke valve
D
A B C
Wasseraustritt zu Merkmal
Wassereintritt Lufteintritt Wasseraustritt zu Turbine
Water inlet
Verdichter Feature
Air inlet Water outlet to turbine
Water outlet to compressor
GV/4 GV* G1 GVa SA01, SG01, SR01
G1% Gy4 GV/4 GVa SA01, SG02. SR01
G2 GY* G2 Gy4 SA01, SG03. SR02
GV/4 Gy4 2 xG1 Gy4 SA02, SG01, SR01
G2 Gy4 2xG1Va Gy4 SA02, SG02, SR02
G2 Gy4 GV/4 Gy4 SA01, SG02. SR02
G2 Gy4 2 xG2 Gy4 SA02, SG03, SR02
Chap. 6-3 de / en 48 17
Modificalion:
HZTL 90624
Die Anschlussstellen der Ventile und der Vorsteuer- The connection points of the valves and pre-control
ventile sind auf dem Ventilblock eingraviert: valves are engraved on the valve block:
TS1 erstes turbinenseitiges Ventil resp. Vorsteuerventil TS1 first turbine-end valve or pre-control valve
TS2 zweites turbinenseitiges Ventil resp. Vorsteuer TS2 second turbine-end valve or pre-control valve
ventil (nur bei Ventileineit fur V-Motoren) (only on valve unit for V-engines)
CS verdichterseitiges Ventil resp. Vorsteuerventil CS compressor-end valve or pre-control valve
Air Luftventil resp. Vorsteuerventil zu Luftventil Air Air valve or pre-control valve to air valve
Hinweis Urn die turbinenseitigen Ventile optimal Note The turbine-end valves are set In the
vor Verbrennungsruckstanden zu schut- opposite direction of flow (opposite to
zen warden diese in entgegengesetzer direction of cast arrow) to provide them
Durchflussrichtung eingesetzt (entge- with optimum protection against
gengesetzt zu eingegossener Pfeilrich- combustion residues.
tung). This prevents combustion residues
Es kann dadurch verhindert warden, dass penetrating the valve bodies; it represents
Verbrennungsruckstande in den Ventil- no restriction of any kind on application of
korper eindringen konnen. Fur den Ein- the valve.
satz des Ventils ergeben sich dadurch
keinerlei Einschrankungen.
de / en 48 18 Chap. 6-3
Modificalion;
HZTL 90624
5 5
Notwendige Leitungsquerschnitte Pipe cross-sections required
5.1 5.1
Luftversorgung Air supply
Fur die Luftversorgung von Reinigungsdruckerhohung A pipe of dimension G'A or larger must be used for
sowie Ventileinheit muss eine Leitung der Dimension the air supply to the cleaning pressure increase unit
G'A Oder grosser verwendet werden. and valve unit.
5.2 5.2
Leitungsdimensionen bei 4-Takt Motoren Pipe dimensions for 4-stroke engines
Leitungsquerschnitte
Pipe crosS‘$ections
Anzahl Turbolader Ventileinheit -

pro Motor Wasserzuleitung zu Druckbehalter < Druckbehalter • Ventileinheit -
Saugstutzen /
TPL Number of Druckerhohung- Ventileinheit Ventileinheit GEG
Valve unit • Filterschali-
turbochargers per seinheit Pressure tank - Pressure tank -
engine
Water supply pipe valve unit valve unit GEG dampfer
to pressure Valve unit -
suction branch I
increase unit
<10 m <25 m <5 m filter silencer
1
DN11 DN15 DN18
61 2
DN15
DN14 DN19 DN23
1
DN13 DN17 DN20
65 DN17
2
DN16 DN22 DN26
1
DN14 DN19 DN23
69 DN19
2
DN18 DN25 DN30
1
DN16 DN21 DN25
73 2
DN21 DN15
DN20 DN27 DN32
1
DN18 DN23 DN27
77 DN23
2 DN23 DN29 DN35
1 DN20 DN27 DN32
80 DN27
2 DN25 DN35 DN42
1 DN23 DN31 DN37
85 DN31
2 DN30 DN40 DN48
Tabelle/Table 5-1
Language: No. of pages: Page number.
Chap. 6-3 de / en 48 19
Modificatiorv
HZTL 90624
5.3 5.3
Leitungsdimensionen bei 2-Takt Motoren Pipe dimensions for 2-stroke engines
Da bei 2-Takt Anwendungen keine Thermoschock Since thermal shock cleaning of the turbine cannot
Reinigung der Turbine durchgefuhrt werden kann. be performed with 2-stroke applications, the pipes
konnen die Leitungen kleiner dimensioniert werden can be smaller than for 4-stroke applications.
als bei 4-Takt Anwendungen.
Leitungsquerschnitte
Pipe cross-sections
Anzahl Turbolader Ventileinheit -

pro Motor Wasserzuleitung zu Eingangseinheit - Eingangseinhelt - Ventileinheit •
Saugstutzen /
TPL Number of Druckerhohung- Ventiieinheit Ventileinheit GEG
Input unit • Valve unit - Filterschall-
turbochargers per seinheit Input unit -
Water supply pipe valve unit valve unit GEG dampfer
engine
to pressure Valve unit -
suction branch I
increase unit
<10 m <25 m <5 m filter silencer
1
DN16 DN16 DN19
2
DN20 DN20 DN24
73 DN16
3 DN24 DN24 DN28
4 DN26 DN26 DN31
1
DN18 DN18 DN21
2
DN23 DN23 DN27
77 DN18
3 DN27 DN27 DN32
4 DN29 DN29 DN35
1
DN15
DN20 DN20 DN24
2
DN25 DN25 DN30
80 DN20
3 DN30 DN30 DN35
4 DN33 DN33 DN39
1
DN23 DN23 DN27
2
DN30 DN30 DN35
85 DN23
3 DN34 DN34 DN41
4 DN38 DN38 DN45
Tabelle / Table 5-2
"K
Hinweis Um bei Ausnutzung der zugelassenen Note The pipe cross-sections specified must
Leitungslangen (vgl. Abschnitt 1) nicht zu be observed without fail In order not to
hohe Druckverluste zu haben, mussen die cause excessive pressure losses when
angegebenen Leitungsquerschnitte unbe- using the permitted pipe lengths (cf.
dingt eingehalten werden. section 1).
de / en 48 20 Chap. 6-3
Modification:
HZTL 90624
6 6
Blende fiir Verdichter- und Diaphragm for compressor and

Turbinenreinigung turbine cleaning
6.1 6.1
Blende fiir die Verdichterreinigung Diaphragm for compressor cleaning
Bei 4-Takt Anwendungen (Reinigungsdruckerhohung For 4-stroke applications (increase of cleaning
mit Druckbehalter) wird die Wassereinspritzung bei pressure with pressure tank) the water injection for
der Verdichterreinigung uber den Druckbehalter vor- compressor cleaning is performed via the pressure
genommen. Aufgrund des Niveauunterschieds am tank. This enables the volume of water injected to be
Druckbehalter kann so die eingespritzte Wassermen- checked from the difference in level in the pressure
ge uberpruft werden. tank.
Zur Regulierung des Wasservolumenstroms muss A diaphragm must therefore be fitted in the water
bei 4-Takt Anwendungen deshalb eine Blende in den connection on the filter silencer or suction branch to
Wasseranschluss am Filterschalldampfer resp. Saug- control the flow of water in 4-stroke applications.
stutzen montiert werden. Screwed couplings (cf. fig. 6-3) with integral diaphragm
Verschraubungen (vgl. Fig. 6-3) mitintegrierten Blen- can be obtained from ABB Turbo Systems Ltd.
den konnen bei ABB Turbo Systems AG erworben
werden.
X r 2
ir
/i
1/
k-
+ /
I
/ / /^ 9 //,
Merkmal
y g- ^ TPL
1
Feature
rrrr>i 61 UG01
U/ 1/
65 UG02
om 69 UG03
J_L
73 UG04
77 UG05
W IO X I ■ o
80 UG06
85 UG07
Fig 6-3
Verschraubung mit integrierter Blende
Screwed coupling with integral diaphragm
Diese Verschraubungen konnen in den Anschluss These screwed couplings can be screwed into the
am Filterschalldampfer resp. Saugstutzen geschraubt connection on the filter silencer or suction branch.
werden.
Language: No. of pages; Page number:
Chap. 6-3 de / en 48 21
Modificalioa'
HZTL 90624
6.2 6.2
Blende fur das Turbinen Waschen Diaphragm for turbine washing
Fur das Turbinen Waschen (vgl. Kapitel 6-2, Ab- The flow of water must be set exactly for turbine
schnitt 2.6) muss der Wasservolumenstrom exakt washing (cf. chapter 6-2, section 2.6). This is
eingestellt warden. Dies geschieht mit dem Schieber- performed with the slide valve and the diaphragm of
ventil und der Blende der Eingangseinheit. Das the input unit. The slide valve must be set so that the
Schieberventil muss so eingestellt warden, dass das pressure gauge before the diaphragm indicates a
Manometer vor der Blende wahrend der Wasser- pressure 2.0 ± 0.2 bar higher than the gas pressure
einspritzung einen Druck von 2.0 ±0.2 bar uber dem before the turbine during water injection. The
Gasdruck vor Turbine anzeigt. Die Biendendurch- diaphragm diameters are shown in the following tables
messer sind den nachfolgenden Tabellen zu entneh- (table 6-1 for 4-stroke applications, table 6-2 for
men (Tabelle 6-1 fur 4-Takt Anwendungen; Tabelle 2-stroke applications). The diaphragm diameters were
6-2 fur 2-Takt Anwendungen). Die Blendendurch- selected so that the flow of water specified in chapters
messer wurden so ausgelegt, dass mit einem Uber- 6-1 & 2, section 2.6 is obtained with an overpressure
druck gegenuber dem Gasdruck vor Turbine von 2 bar above the gas pressure before the turbine of 2 bar
vor der Blende, der in Kapitel 6-1&2, Abschnitt 2.6 before the diaphragm.
vorgeschriebene Wasservolumenstrom resultiert.
Blende fur das Turbinenwaschen

4-Takt Motoren
Diaphragm for turbine washing on
4-stroke engines
lAnzahl Turboladerj
pro Motor
Merkmal
TPL Number of
Feature
turbochargers per
engine
1
EB01
61 2
EB02
1
EB03
65 2
EB04
1
EB05
69 2
EB06
1
EB07
73 2
EB08
1
EB09
77 2
EB10
1
EB11
80 2
EB12
1
EB13
85 2
EB14
Tabelle/Table 6>1
Language; No. of pages. Page number:
de / en 48 22 Chap. 6-3
Modification:
HZTL 90624
Blende fur das Turbinenwaschen

2-Takt Motoren
Diaphragm for turbine washing on
2-stroke engines
I Anzahl Turbolader
pro Motor
Merkmal
TPL Number of
Feature
turbochargers per
engine
1
73 EB07
3
4
1
77 EB09
3
4
1
80 EB11
3
4
1
85 EB13
3
4
Tabelle/Table 6-2
Da die Turbinen sequentiell gereinigt werden. ist der Since the turbines are cleaned in sequence, the
Blendendurchmesser nicht von der Anzahl Turbo diaphragm diameter is not dependent on the number
lader pro Motor abhangig. of turbochargers per engine.
Chap. 6-3 de / en 48 23
Modification:
HZTL 90624
7 7
Elektrische Steuerung Electrical control unit
Der Reinigungsablauf wird uber das Programm der The cleaning sequence is controlled by the PLC pro
SPS gesteuert. Fur die Anwendung der Reinigung gram. Two different electrical control units are used
kommen zwei verschiedene elektrische Steuerungen for the cleaning application:
zum Einsatz: - Electrical control unit version 1
- Elektrische Steuerung Variante 1 Electrical control unit for cleaning with one 4-stroke
Elektrische Steuerung zur Durchfuhrung der Rei engine with one or two turbochargers.
nigung bei einem 4-Takt Motor mit einem Oder
zwei Turboladern. Electrical control unit version 2
Electrical control unit for cleaning up to four
Elektrische Steuerung Variante 2 4-stroke engines with one or two turbochargers or
Elektrische Steuerung zur Durchfuhrung der Rei- with a 2-stroke engine with a maximum of four
nigung bei bis zu vier 4-Takt Motoren mit einem turbochargers.
Oder zwei Turboladern Oder bei einem 2-Takt Mo
tor mit maximal vier Turboladern.
7.1 7.1
Bedienung der elektrlschen Steuerung Operation of electrical control unit
Variante 1 Variante 2
Version 1 Version 2 Notstopp Schalter
Emergency stop switch
Startknopf und Kontroilampe

Thermoschock Turbinenreinigung
Start button and signal lamp
Thermal shock turbine cleaning
Startknopf und Kontrollampe

Verdichterreinigung
Startknopf und Kontrollampe

Turbinenwaschen
Turbine washing
Kontrollampe (grun)
Steuerung eingeschaltet
Signal lamp (green)
Control unit switched on
MotorZ-Turboladerwahlschalter
Engine/turbocharger selector switch
Hauptschalter
iMain switch
Fig 7-1
Elektrische Steuerung
Electrical control unit
de / en 48 24 Chap. 6-3
Mo<>ificatlon:
HZTL 90624
Hauptschalter Main switch

Mit dem Haupschalter (On/Off) kann die Steue- The control unit can be switched on with the main
rung eingeschalten werden. switch (On/Off).
1st die Steuerung eingeschalten so werden die If the control unit is switched on, the pipes between
Leitungen zwischen den Ventiieinheiten und den the valve units and gas inlet casings are blown out
Gaseintrittsgehausen alle 5 Stunden mit Luft (Luft- with air every 5 hours (air pulse for 5 seconds).
puls von 5 Sekunden) durchgeblasen. Unabhan- This takes place on all turbochargers connected
gig von der Stellung des Motorwahlschalters ge- to the control unit regardless of the position of the
schieht dies bei alien an die Steuerung angeschlos- engine selector switch.
senen Turboladern. Cleaning cannot be started during the blow-out
Wahrend dem Ausbiasezykius {alle Kontrolllampen cycle (all signal lamps flashing in start buttons).
der Startknopfe blinken) kann keine Reinigung It is recommended to couple the power supply of
gestartet werden. the control unit with the engine operation, i.e. the
Wir empfehlen die Stromversorgung der Steue control unit is always supplied with power when an
rung mit dem Motorbetrieb zu koppeln. Das heisst, engine is running.
dass die Steuerung immer dann mit Strom ver-
sorgt wird, wenn ein Motor lauft. Signal lamp (control unit switched on)
If the main switch is set to "On”, the green signal
Kontroliampe (Steuerung eingeschalten) lamp is lit.
1st der Haupschalter auf "On" gestellt, so brennt
die griine Kontroliampe. Engine/turbocharger selector switch
The engine selector switch is used with 4-stroke
Motor-/ Turboladerwahlschalter engines to select the engine for which the
Mit dem Motorwahlschalter wird bei 4-Takt Moto- turbochargers are to be cleaned.
ren der Motor gewahit, dessen Turbolader gerei- With 2-stroke engines this switch selects the
nigl werden sollen. turbocharger to be cleaned.
Bei 2-Takt Motoren kann mit diesem Schalter der
Turbolader. der gereinigt werden soil, gewahit wer
den.
Note The positions of the selector switch must
be designated according to the specific
application:
Hinweis Die Positionen des Wahlschalters mus- 4-stroke designation of engines
sen anwendungsspezifisch gekennzeich- 2-stroke designation of turbochargers
net werden:
4-Takt Bezeichnung der Motoren Start button and signal lamp for cleaning
2-Takt Bezeichnung der Turbolader operations
(Thermal shock turbine cleaning, turbine washing,
Startknopf und Kontrolllampe der Reinigungen compressor cleaning)
(Thermoschock Turbinenreinigung, Turbinen Wa- These start buttons are used to start the relevant
schen, Verdichterreinigung) cleaning sequences.
Mit diesen Startknopfen konnen die entsprechen- The corresponding signal lamp Is lit throughout
den Relnigungssequenzen gestartet werden. the cleaning sequence. The signal lamp flashes
Wahrend den gesamten Reinigungssequenzen during water injection. If a cleaning operation is
brennt die entsprechende Kontrollampe. Wahrend started with an impermissible engine load (exhaust
den Wassereinspritzungen blinkt die Kontrollampe. gas temperature) (cf. 7.4), all three signal lamps
flash. Cleaning is not performed.
Wird eine Reinigung bei einerunzulassigen Motor-
last (Abgastemperatur) gestartet (vgl. 7.4), so blin
ken alle drei Kontrolllampen. Die Reinigung wird
nicht durchgefuhrt.
Chap. 6-3 de / en 48 25
Modification:
HZTL 90624
7.2 7.2
Anschliessen der elektrischen Steuerung Connecting the electrical control unit
Fur die Stromversorgung der elektrischen Steuerung The following limiting conditions must be satisfied for
rniissen folgende Randbedingungen eingehalten wer- the power supply to the electrical control unit:
den: Supply voltage 24 V± 10%
Speisespannung 24V± 10% Analogue inputs 4-20mA± 10%
analoge Eingange 4... 20 mA±10% Power consumption 50 VA max.
Leistungsaufnahme max 50 VA (The effective power consumption depends on the
(Die effektive Leistungsaufnahme hangt von der number of valve units connected and on the type
Anzahl der angeschlossenen Ventileinheiten sowie of cleaning [parallel, sequential]).
von der Reinigungsart [parallel, sequentiell] ab.)
7.3 7.3
Konfiguration der elektrischen Steuerung see next page
Die Anwendung der Steuerung sowie die Reinigungs-
ablaufe kbnnen mit Jumpern konfiguriert werden.
Jumper Zustand Auswirkung

offen Reinigung inaktiv
X3 / J1 Verdichterreinigung
geschlossen Reingiung aktiv
offen Reinigung inaktiv
X3 / J2 Turbinenwaschen
geschlossen Reingiung aktiv
Thermoschockreinigung offen Reinigung inaktiv
X3/J3
der Turbine geschlossen Reingiung aktiv
Turbinenwachen offen parallele Reinigung
X3/J4
(sequentiell / parallel^ geschlossen sequentielle Reinigung
Thermoschockreinigung offen parallele Reinigung
X3/J5
(sequentiell / parallel) geschlossen sequentielle Reinigung
offen Reinigung ohne Motorlast-Signal moglich
X3 / J6 Motorlast-Signal
geschlossen Reinigungen nur in Abhangigkeit des Signals moglich
offen 2-Takt Motor
X3/J7 Motortyp")
geschlossen 4-Takt Motor
offen 2-Draht-Verbindung ohne DC Versorgung
X3 / J8 Analog Eingang
geschlossen 2- Oder 3-Draht-Verbindung mit DC Versorgung
1) Die Thermoschockreinigung der Turbine kann nur 3) Dieser Jumper beinflusst den Reinigungablauf nur
bei 4-Takt Motoren durchgefuhrt werden (Jumper bei 4-Takt V-Motoren bei Anwendung der Ventil-
X3 / J7: geschlossen). einheit mit zwei Turbinenventilen.
2) Dieser Jumper beinflusst den Reinigungablauf nur 4) Dieser Jumper 1st nur bei der Steuerung Variante
bei 4-Takt V-Motoren bei Anwendung der Ventil- 2 vorhanden
einheit mit zwei Turbinenventilen.
de / en 48 26 Chap. 6-3
Modification:
HZTL 90624
7.3
Configuration of electrical control unit
Application of the control unit and the cleaning
sequences can be configured with jumpers.
Jumper Status Effect

Open Cleaning inactive
X3 / J1 compressor cleaning
Closed Cleaning active
Open Cleaning inactive
X3 / J2 turbine washing
Closed Cleaning active
thermal shock cleaning Open Cleaning inactive
X3/J3
of turbine Closed Cleaning active
turbine washing Open Parallel cleaning
X3/J4
(sequential/parallel) Closed Sequential cleaning
thermal shock cleaning Open Parallel cleaning
X3/J5
(sequential/parallel) 3) Closed Sequential cleaning
Open Cleaning possible without engine load signal
X3 / J6 engine load signal
Closed Cleaning only possible depending on signal
Open 2-stroke engine
X3 / J7 engine type
Closed 4-stroke engine
Open 2-wire connection without DC supply
X3 / J8 analogue input
Closed 2- or 3-wire connection with DC supply
1) Thermal shock cleaning of the turbine can only be 3) This jumper only influences the cleaning sequence
performed with 4-stroke engines (jumper X3/J7; with 4-stroke V-engines when using a valve unit
closed). with two turbine valves.
2) This jumper only influences the cleaning sequence 4) This jumper is only present on version 2 control
with 4-stroke V-engines when using a valve unit units.
with two turbine valves.
7.3.1 7.3.1
Empfehlung fiir die Konfiguration der Recommended configuration of control
Steuerung unit
X3/J1 Verdichterreinigung
Dieser Jumper sollte eingesetzt sein. Da- X3/J1 Compressor cleaning
durch ist das Programm "Verdichter This jumper should be inserted. This
reinigung" aktiv. activates the “Compressor cleaning” pro
gram.
X3/J2 Turblnen Waschen
Dieser Jumper sollte eingesetzt sein. Da- X3/J2 Turbine washing
durch ist das Programm "Turbinen Wa This jumper should be inserted. This
schen" aktiv. activates the “Turbine washing” program.
X3/J3 Thermoschock Reinigung derTurbine X3/J3 Thermal shock cleaning of turbine

Dieser Jumper sollte eingesetzt sein. Da- This jumper should be inserted. This
durch ist das Programm ’Turbinen Thermo activates the “Turbine thermal shock
schock Reinigung" aktiv. (Dieser Jumper cleaning" program. (This jumper is only
hat nur bei der Anwendung bei 4-Takt Mo- effective when used with 4-stroke engines.)
toren Einfluss.)
Language. No. of pages; Page number.
Chap. 6-3 de / en 48 27
Modincatiort
HZTL 90624
X3 / J4 Turbinenwaschen parallel oder sequen- X3 / J4 Turbine washing, parallel or sequential

tiell From experience it is recommended to per
Aufgrund der Erfahrungen empfehlen wir form parallel washing of the turbine with
das Turbinen Waschen bei 4-Takt V-Moto- 4-stroke V-engines (jumper J4 open).
ren parallel durchzufuhren (Jumper J4 Sequential washing of the turbines increases
offfen). Bei sequentiellem Waschen der Tur the danger of surging.
binen wird die Pumpgefahr erhoht.
X3 / J5 Thermal shock cleaning of turbine paral
X3 / J5 Thermoschockreinigung der Turbine par lel or sequential
allel Oder sequentiell From experience it is recommended to per
Aufgrund der Erfahrungen empfehlen wir form parallel thermal shock cleaning of the
die Thermoschockreinigung der Turbinen turbine with V-engines (jumper J5 open).
bei V-Motoren parallel durchzufuhren (Jum Sequential thermal shock cleaning of the
per J5 offen). Bei sequentieller Thermo turbines increases the danger of surging.
schockreinigung der Turbinen wird die
Pumpgefahr erhoht. X3/J6 Engine load signal
(Gas temperature before turbine)
X3/J6 Motorlast-Signal If this jumper is removed, all cleaning
(Gastemperatur vor Turbine) operations can be performed independent
Wird dieser Jumper entfernt, so konnen alle of the engine load. This jumper must always
Reinigungen unabhangig von der Motorlast be inserted for safety reasons.
durchgefuhrt warden. Aus SicherheitsgrOn- In emergencies, if the analogue signal has
den muss dieser Jumper immer eingesetzt failed, jumper J6 can be temporarily
sein. removed to permit a cleaning operation. In
In Notfallen, wenn das Analog-Signal aus- this case, however, it must be ensured that
gefallen ist, kann der Jumper J6 voruberge- the engine load (gas temperature before
hend entfernt werden, damit das DurchfCih- turbine) is in the range specified for the
ren einer Reinigung moglich ist. In diesem cleaning.
Fall muss aber sichergestellt werden, dass
sich die Motorlast (Gastemperatur vor Tur
X3 / J7 Engine type (4-stroke or 2-stroke)
bine) in dem fur die Reinigung vorgeschrie-
This jumper is used to select the engine
benem Bereich befindet.
type and therefore the cleaning programs
which can be performed. Jumper J7 must
X3/J7 Motortyp (4-Takt Oder 2 Takt) be inserted for 4-stroke engines and
Mit diesem Jumper wird der Motortyp und removed for 2-stroke engines. If this jumper
damit die Reinigungs-Programme, die is not configured correctly, the cleaning
durchgefuhrt werden konnen, gewahit. Fur operations cannot be performed properly.
4-Takt Motoren muss der Jumper J7 einge
setzt und fur 2-Takt Motoren entfernt wer X3/J8 Analogue input
den. Wird dieser Jumper nicht richtig konfi-
The control unit can be set to the transmitter
guriert, so konnen die Reinigungen nicht
of the analogue signal with this jumper.
richtig durchgefuhrt werden.
If jumper J8 Is Inserted, the analogue signal
transmitter is supplied with power by the
X31J8 Analog Eingang control unit. This jumper must be removed
Mit diesem Jumper kann die Steuerung auf if a transmitter with its own power supply is
den Geber des Analog-Signals eingestellt used.
werden.
Ist dieser Jumper J8 eingesetzt, so wird der
Geber des Analog-Signals von der Steue
rung mit Strom versorgt. Wird ein Geber mit
eigener Stromversorgung verwendet, so
muss dieser Jumper entfernt werden.
de / en 48 28 Chap. 6-3
Modificatioa
HZTL 90624
7.4 7.4
Uberwachung der Abgastemperatur vor Monitoring exhaust gas temperature
Turbine before turbine
Die verschiedenen Reinigungssequenzen durfen nur The various cleaning sequences may only be
bei bestimmten Abgastemperaturen vor Turbine performed at specific exhaust gas temperatures before
(Motorlastbereiche) durchgefuhrt werden (vgl. Fig. the turbine (engine load ranges) (cf. fig. 7-2). The
7-2). Damit eine Relnigung nicht bei unzulassiger exhaust gas temperature before the turbine must be
Abgastemperatur vor Turbine durchgefuhrt werden monitored by the electrical control unit to ensure that
kann, was zu Schaden an Turbolader und Motor fuh- a cleaning operation cannot be performed at
ren kbnnte, muss die Abgastemperatur vor Turbine impermissible exhaust gas temperature before the
durch die elektrische Steuerung uberwacht werden. turbine, which could result in damage to the
Es ist dazu von jedem Motor ein analoges Signal turbocharger and engine.
(4 ... 20 mA) erforderlich, welches einen Ruckschluss An analogue signal (4-20 mA) is required for this
auf die Abgastemperatur (Motorlast) zulasst. purpose from every engine that provides information
about the exhaust gas temperature (engine load).
Verdichterreinigung / Compressor cleaning
-t
Thermoschock-Reinigung
der Turbine |=
Turbinen-Waschen Thermal shock cleaning
Turbine washing of turbine _______
-6-
Minimale Motorlast fur Reinigung T^ = 430 •’C T,. = 500 "C Motorlast
Tl
Minimum engine load for cleaning Engine load
Fig 7-2
Motorlastsignal
Engine load signal
Der Wert A, dient der Erfassung einer minimalen Value A, serves to identify a minimum exhaust gas
Abgastemperatur vor Turbine (Motorlast) bei der Rei- temperature before the turbine (engine load) at which
nigungen durchgefuhrt werden durfen. Damit kann cleaning may be performed. This prevents cleaning
verhindert werden, dass eine Reinigung bei stehen- taking place with the engine stationary.
dem Motor durchgefuhrt wird. Value A^ corresponds to an exhaust gas temperature
Der Wert A2 entspricht einer Abgastemperatur vor Tur before the turbine (engine load) of 430°C. This is the
bine (Motorlast) von 430 “C. Dies ist die hochstzulassi- highest permissible temperature for performing turbine
ge Temperatur zur Durchfuhrung des Turbinen- washing and also the minimum temperature necessary
Waschens und zugleich die minimal notwendige Tem for thermal shock turbine cleaning.
peratur fur die Thermoschock Turbinenreinigung. Value A3 corresponds to an exhaust gas temperature
Der Wert A^ entspricht einer Abgastemperatur vor before the turbine of 500“C. This is the highest
Turbine von 500 ®C. Dies ist die hochste, zugelasse- permissible temperature for thermal shock turbine
ne Temperatur fur die Thermoschockreinigung der cleaning.
Turbine. The exhaust gas temperature before the turbine, or
Fur die Oberwachung kann direkt die Abgastemperatur another signal from which this information can be
vor Turbine Oder ein anderes Signal, von welchem derived, can be used for monitoring (e.g. engine load,
diese Information abgeleitet werden kann, verwendet fuel rack position).
werden (z.B. Motorlast, Regelstangenposition). The signal values A, must be entered as percentages
Die Signalwerte A mussen in Prozent (0 .. 100) des (0-100) of the possible input signal (4-20 mA) as
mbglichen Eingangssignals (4 ... 20 mA) als Parame parameters in the controller (PLC).
ter In die Steuerung (SPS) eingegeben werden.
-K
“K Note For V-engines, monitoring of the exhaust
Hinwels Bei V-Motoren ist die Uberwachung der gas temperature before the turbine of one
Abgastemperatur vor Turbine von einem turbocharger is sufficient.
Turbolader ausreichend.
Chap. 6-3 de / en 48 29
Modificatioa
HZTL 90624
Hinweis Fur die Ubertragung des Signals zur elek- Note A screened cable with earthed screen is
trischen Steuerung der Reinigungseinheit recommended for transmission of the
empfehlen wir ein abgeschirmtes Kabel signals to the electrical control unit of the
zu verwenden, dessen Abschirmung ge- cleaning unit.
erdet werden muss.
Example 1
Beispiel 1
The exhaust gas temperature before the turbine is
Als Eingang in die Steuerung wird die Abgas- used as input to the control unit:
temperatur vor Turbine verwendet: Temperature Signal strength
Temperatur Signalstarke OX 4 mA {= 0%)
OX 4 mA ( = 0 %) 600X 20 mA (=100%)
600 X 20 mA ( = 100%) AT = 600X Al = 16 mA
AT = 600 X Al = 16 mA
An exhaust gas temperature before the turbine of
Eine Abgastemperatur vor Turbine von 430 ®C ent- 430”C corresponds to an analogue signal of 15.47 mA
spricht einem analog Signal von 15.47 mA [= 430 / [=430/600*Ai+4].
600 * A! +4]. An analogue signal of 15.47 mA corresponds to 72%
Ein Analog-Signal von 15.47 mA entspricht 72 % [={i 430*C - 4)/ Al = (15.47 - 4)/16] of the value range
[= (I 430 ’C - 4) / Al = (15.47 - 4) /16] des Wertebereichs (4-20 mA). The value 0072 must be entered for A^ in
(4 ... 20 mA). In der Steuerung muss fur A^ der Wert the control unit (cf. 7.6).
0072 eingegeben werden (vgl. 7.6). An exhaust gas temperature before the turbine of
Eine Abgastemperatur vor Turbine von 500 ®C ent 500“C corresponds to an analogue signal of 17.33
spricht einem analog Signal von 17.33 mA mA [= 500/600*Al + 4].
[= 500/600*Al + 4j. An analogue signal of 17.33 mA corresponds to 83%
Ein Analog-Signal von 17.33 mA entspricht 83 % (=(l
500*C
- 4)/ Al = (17.33 -4)/16] of the value range
[= (I 500 *C -4)/AI = (17.33-4)/16] des Wertebereichs (4-20 mA). The value 0083 must be entered for Aj in
(4 ... 20 mA). In der Steuerung muss fur A3 der Wert the control unit (cf. 7.6).
0083 eingegeben werden (vgl. 7.6).
Example 2
Beispiel 2 The control rod position (L) is used as input to the
Als Eingang in die Steuerung wird die Regelstangen- control unit:
position (L) verwendet: Position Signal strength
Position Signalstarke 0 mm 4 mA (= 0%)
0 mm 4 mA ( = 0 %) 43 mm 20 mA (=100%)
43 mm 20 mA (=100%) AL = 43 mm Al = 16 mA
AL = 43 mm Al = 16 mA
An exhaust gas temperature before the turbine of
430®C is reached with a control rod position of 21.3
Eine Abgastemperatur vor Turbine von 430 “C wird
mm (analogue signal: 11.93 mA [L^3q.j,/AL*Al + 4).
bei einer Regelstangenposition von 21.3 mm (Ana
log-Signal: 11.93 mA [L 430 *C / AL * Al +4) erreicht. The control rod position of 21.3 corresponds to 49.5%
[L_^3p.^ AL] of the value range 0-43 mm (or the signal
Die Regelstangenposition von 21.3 entspricht 49.5 %
strength of the analogue signal [11.93 mA]
[L 430’C / AL] des Wertebereichs 0 ... 43 mm (resp. die
corresponds to 49.5% of the value range [4-20 mA]).
Signalstarke des Analog-Signals [11.93 mA] entspricht
The value 0049 must be entered for A^ in the control
49.5 % des Wertebereichs [4 ... 20 mA]). In der
unit (cf. 7.6).
Steuerung muss fur der Wert 0049 eingegeben
werden (vgl. 7.6). The value 99% (0099) must be entered for signal
values with an exhaust gas temperature before the
Fur Signalwerte bei einer Abgastemperatur vor Turbi-
turbine of 500*C that are over 20 mA.
ne von 500 X. welche uber 20 mA liegen, muss der
Wert 99 % (0099) eingegeben werden.
de / en 48 30 Chap. 6-3
Modification;
HZTL 90624
7.5 7.5
Klemmenleiste der elektrischen Steuerung see next page
Verwendung der Anschliisse bei Verwendung der Anschlusse bei Steuerung Steuerung
Klemme
4-Takt Motoren 2-Takt Motoren Variante 1 Variante 2
XI 1+ Speisung 24 VDC Speisung 24 V DC X X
XI 1- Speisung 0 V DC Speisung 0 V DC X X
XI PE Erdung Erdung X X
XI 0 Taster Verdktiterreinigung Taster Verdichterreinigung X X
1
XI Taster Turbinen Waschen Taster Turbinen Waschen X X
X1 2 Taster Thermoschockreinigung Taster Thermoschockreinigung X X
X1 11 Eingang 1 des Wahlschalters Eingang 1 des Wahlschalters X
XI 12 Eingang 2 des Wahlschalters Eingang 2 des Wahlschalters X
XI 13 Eingang 3 des Wahlschalters Eingang 3 des Wahlschalters X
X2* +1 /-2 Niveauschalter Niveauschalter X X
+3 / ±4 / -5 analog Signal Motor 1 Analog-Signal Motor 1 X X
+6/±7/-8 analog Signal Motor 2 Analog-Signal Motor 2 X
+9/±10/-11 analog Signal Motor 3 Analog-Signal Motor 3 X
+ 12/±13/-14 analog Signal Motor 4 Analog-Signal Motor 4 X
X3 J1 Jumper Verdichterreinigung Jumper Verdichterreinigung X X
J2 Jumper Turbinenwaschen Jumper Turbinenwaschen X X
J3 Jumper Thermoschock Jumper Thermoschock X X
J4 Jumper TS-Waschen p/s Jumper TS-Waschen p/s X X
J5 Jumper Thermoschock p/s Jumper Thermoschock p/s X X
J6 Jumper Motorlastsignal Jumper Motorlastsignal X X
J7 Jumper Motortyp Jumper Motortyp X
J8 Jumper Analog-Signal Jumper Analog-Signal X X
X4 +5/-6 Luftzufuhr Druckbehalter Luftzufuhr Druckbehalter X X
+7/-8 Entluftung Dnjckbehalter Entluftung Druckbehalter X X
+9/-10 Wasserzufuhr zu Druckbehalter Wasserzufuhr zu Druckbehalter X X
+1 1-2 TS-Ventil 1. TL Motor 1 TS-Ventil 1.TL Motor 1 X X
+3/-4 TS-Ventil 2. TL Motor 1 TS-Ventil 2. TL Motor 1 X X
+11 /-12 VS-Ventil 172. TL Motor 1 VS-Ventil 1.TL Motor 1 X X
+13 /-14 Luft-Ventil 1./2. TL Motor 1 Luft-Ventil 1.TL Motor 1 X X
+15/-16 VS-Venlil 2, TL Motor 1 X
+17/-18 Luft-Ventil 2. TL Motor 1 X
+ 19/-20 TS-Ventil 1.TL Motor 2 X
+21 1-22 TS-Ventil 2. TL Motor 2 X
+23 / -24 VS-Ventil 1./2. TL Motor 2 X
+25 / -26 Luft-Ventil 1./2. TL Motor 2 X
+27 /-28 TS-Ventil 1.TL Motor 3 X
+29 / -30 TS-Ventil 2. TL Motor 3 X
+31 /-32 VS-Ventil 1./2. TL Motor 3 X
+33 / -34 Luft-Ventil 1./2. TL Motor 3 X
+35 / -36 TS-Ventil 1.TL Motor 4 X
+39 / -40 VS-Ventil 172. TL Motor 4 X
+41 /-42 Luft-Ventil 172. TL Motor 4 X
+45 / -46 VS-Ventil 3.TL Motor 1 X
+47 / -48 Luft-Venti! 3. TL Motor 1 X
+49 / -50 TS-Ventil 4.TL Motor 1 X
+51 1-52 VS-Ventil 4. TL Motor 1 X
+53 / -54 Luft-Ventil 4.TL Motor 1 X
+55 / -56 Reserve Reserve X
+57/ -58 Reserve Reserve X
*) Die Polaritat von X2: 4, 7, 10.13 variiert je nach Anschlussart
Language' No. of pages: Page number:
Chap. 6-3 de / en 48 31
Modification:
HZTL 90624
7.5
Terminal strip for electrical control unit
Use of connections with 4-stroke Use of connections with 2-stroke Control unit Control unit
Terminal
engines engines Version 1 Version 2
XI 1+ Power supply 24 V DC Power supply 24 V DC X X
XI 1- Power supply 0 V DC Power supply 0 VDC X X
XI PE Earth Earth X X
XI 0 Compressor cleaning button Compressor cleaning button X X

1
XI Turbine washing button Turbine washing button X X
2
X1 Thermal shock cleaning button Thermal shock cleaning button X X
X1 11 Input 1 of selector switch Input 1 of selector switch X
XI 12 Input 2 of selector switch Input 2 of selector switch X
XI 13 Input 3 of selector switch Input 3 of selector switch X
X2* +1 /-2 Level switch Level switch X X
+3/±4/-5 Analogue signal, engine 1 Analogue signal, engine 1 X X
+6 / ±7 / -8 Analogue signal, engine 2 Analogue signal, engine 2 X
+9/±10/-11 Analogue signal, engine 3 Analogue signal, engine 3 X
+ 12/+13/-14 Analogue signal, engine 4 Analogue signal, engine 4 X
X3 J1 Compressor cleaning jumper Compressor cleaning jumper X X
J2 Turbine washing jumper Turbine washing jumpem X X
J3 Thermal shock jumper Thermal shock jumper X X
J4 TE washing p/s jumper TE washing p/s jumper X X
J5 Thermal shock p/s jumper Thermal shock p/s jumper X X
J6 Engine load signal jumper Engine load signal jumper X X
J7 Engine type jumper Engine type jumper X
J8 Analogue signal jumper Analogue signal jumper! X X
X4 +5 / -6 Air supply to pressure tank Air supply to pressure tank X X
+7/-8 Venting of pressure tank Venting of pressure tank X X
+9/-10 Water supply to pressure tank Water supply to pressure tank X X
+1 1-2 TE valve 1st TC Engine 1 TE valve IstTC Engine 1 X X
+3/-4 TE valve 2nd TC Engine 1 TE valve 2nd TC Engine 1 X X

+11 /-12 CE valve 1st/2nd TC Engine 1 CE valve 1st TC Engine 1 X X
+13/-14 Air valve 1st/2nd TC Engine 1 Air valve IstTC Engine 1 X X
+15/-16 CE valve 2nd TC Engine 1 X
+17/-18 Air valve 2nd TC Engine 1 X
+19/-20 TE valve 1st TC Engine 2 X
+21 /-22 TE valve 2nd TC Engine 2 X

+23 / -24 CE valve 1st/2nd TC Engine 2 X
+25 / -26 Air valve 1sV2nd TC Engine 2 X
+27 / -28 TE valve 1st TC Engine 3 X
+29/ -30 TE valve 2nd TC Engine 3 X
+31/-32 CE valve 1st/2nd TC Engine 3 X
+33/ -34 Air valve 1st/2nd TC Engine 3 X
+35 / -36 TE valve 1st TC Engine 4 X
+37 / -38 TE valve 2nd TC Engine 4 X

+39 / ^0 CE valve 1st/2ndTC Engine 4 X
+41 /-42 Air valve 1st/2ndTC Engine 4 X
+43 / -44 TE valve 3rd TC Engine 1 X
+45 / -46 CE valve 3rdTC Engine 1 X
+47 / -48 Air valve 3rdTC Engine 1 X
+49/ -50 TE valve 4th TC Engine 1 X
+51/-52 CE valve 4th TC Engine 1 X
+53/ -54 Air valve 4th TC Engine 1 X
+55 / -56 Spare Spare X
+57/ -58 Spare Spare X

•) Polarity of X2: 4, 7, 10. 13 vary according to type of connection!
Language; No. of pages; Page number;
de / en 48 32 Chap. 6-3
Modification
HZTL 90624
7.6
7.6
Parametrisierung der Analog-Eingange
Parametrizing the analogue inputs and
und weiterer Steuergrossen
other control variables
Wit dem APT-Terminal (APT 40A-22A / Omron NT2S-
The values of the analogue signals used to monitor
100-CZ) konnen die Werte der Analogsignale, wel-
the engine load can be entered or changed with the
che zur Uberwachung der Motorlast dienen, eingege-
APT terminal (APT 40A-22A/Omron NT2S-100-CZ).
ben resp. verandert werden. Zudem kdnnen verschie-
Various other control parameters can also be changed.
dene weitere Steuerungsparameter verandert wer
den.
7.6.1 7.6.1
Layout der Frontplatte Layout of front panel
7.6.2 7.6.2
Benutzung der Tastatur Using the keyboard
Folgende Tasten des APT-Terminals werden fur die The following keys of the APT terminal are required
Veranderung von Parametern benotigt: for changing parameters:
- [PgDn] Wechsein zur nachsten Seite des Dis - [PgDn] Change to next page of display
plays - [PgUp] Change to preceding page of display
- [PgUp] Wechsein zur vorangegangenen Seite - [Enter] Input preparation/confirmation of input
des Displays - [Esc] Exit during input
- [Enter] Eingabe Vorbereitung / Bestatigung der - [0]-[9] Value input
Eingabe
[■] Decimal point for value input
[Esc] Ausstieg wahrend Eingabe
[0]-[9] Werteeingabe
[■] Dezimalpunkt fur Werteeingabe
Lar>guage; No. of pages: Page number;
Chap. 6-3 de / en 48 33
Modification:
HZTL 90624
7.6.3 7.6.3
Display des APT-Terminals APT terminal display
Auf der ersten Zeile des Displays wird jewells der The control parameter is described in each case on
Steuerungsparameter beschrieben. Auf der zweiten the first line of the display. The second line shows the
Zeile wird der ubergeordnete Programmteil (CSW: higher-order program part (CSW: compressor
Verdichterreinigung / TSW: Turbinen Waschen / cleaning / TSW: turbine washing / TSTH: thermal
TSTH: Thermoschockreinigung der Turbine), der mog- shock cleaning of turbine), the possible input range
liche Eingabebereich, sowie der aktuelle Wert der and the current software version.
Software angegeben.
|W| t r I n J c t j 0 n T m
t
|Wl t r I n J e c t I o n T I m c s |w
(IlMo 1|5| .|0|s|)|l|0|.|0|s|
c s \\N Parameter values (current value) flashing on the
Parameterwerte (aktueller Wert), welche auf der An- display (shown in bold type below, not shaded) can
zeige blinken (im Folgenden mit fetter Schrift, nicht be altered. Values not flashing cannot be altered. The
schattiert symbolisiert), konnen verandert warden. values which cannot be changed are exclusively va
Werte die nicht blinken, konnen nicht verandert wer- riables which influence the cleaning system but not
den. Bei den Werten die nicht verandert warden kon the cleaning.
nen, handelt es sich ausschliesslich um Grossen wel
che das Reinigungssytem, nicht aber die Reinigung
beeinflussen. 7.6.4
Procedure for changing a parameter
7.6.4 1. Power supply
Vorgehen zum Verandem eines Parameters The cleaning control must be connected to a 24 V
DC power supply and switched on before control
1. Stromversorgung parameters can be changed with the APT terminal
Damit mit dem APT-Terminal Steuerungs (main switch In "On” position).
parameter verandert warden kdnnen, muss die
Reinigungssteuerung an eine 24 V DC Stromver 2. Connecting the mounting panel
sorgung angeschlossen und eingeschalten sein The APT terminal should be connected to the
(Hauptschalter auf Position "On"). “Peripheral" connection point of the Omron PLC.
This PLC interface is under a protective cap. The
2. Anschliessen der Konsole following picture appears on the terminal display:
Anschliessen des APT-Terminals an die An- Languagle / | S | p | r | a | c | h | e
H I
schlussstelle "Peripheral" der Omron-SPS. Diese
/ D e u t
0 c h 1 0
Schnittstelle der SPS liegt unter einer Schutzkappe.
Auf dem Display des Terminals erscheint folgen- The dialogue language of the terminal can be
selected in this display (0 = English, 1 = German).
des Bild:
H
\ I L a n g
g u / S p r a c h ej
E|n|g|_ill h / D 0 u t s c h
101
In dieser Ansicht kann die Dialogsprache des Ter

minals angewahit warden (0 = Englisch;
1 = Deutsch).
Language; No. of pages; Page number:
de / en 48 34 Chap. 6-3
Modification:
HZTL 90624
t
I
GEA
Luftkiihler
GEA Charge air cooler

Description, Operating and IVIaintenance manual
1
Luftkiihler
Contents
1. General
2. Block c ooler
2.1 General
2.2 Installation and removal of cooler
3. Removable stack cooler

3.1 General
3.2 Installation and removal of cooler
4. Commissioning
4.1 General
4.2 Cooling water velocity
5. Protective film
6. Standstill
7. Service cx)nfrol
7.1 General
7.2 Performance test
8 . Cleaning
8.1 General
8.2 Cleaning of the water side
8.2.1 Mechanical cleaning
8.2.2 Hydraulic cleaning
8.2.3 Chemical cleaning
8.2.3.1 Chemical cleaning -In-situ
8.2.3.2 Chemical cleaning - Cooler removed
8.3 Cleaning of the air-side
8.3.2 Hydraulic cleaning
8.3.3 Chemical cleaning
9. Tube leaks
9.1 General
9.2 Pressure test of individual tubes
9.3 Pressure test of cooler
9.4 Pressure test with air under water
9.5 Plugging of tubes
9.6 Replacement of single tubes ( partial re-tubing )
9.7 Insertion of a second core tube
9.8 Pressure test after repair of cooler
2
GEA
Luftkuhler
1. General
The GEA Charge air cooler is a finned tube heat exchanger. The hot air flows over the
fins on the outside of the tubes and the cooling fluid flows through the tubes. The heat
exchange surface of the cooler consists of round elliptical core tubes with rectangular
threaded-on fins or round core tubes with either wound-on fins or continuous flat plate
fins. The bond between fin and tube is achieved either by mechanical means and or by
soldering.
The core tubes are rolled into the tube sheets at each end of the tubes by the use of tube
expanders.
Side walls form an integral part of the cooler and are bolted to tube sheets.
Water Headers (Namely Nozzle and Return headers) are provided for water handling.
The number of separating baffles conform to the number of water passes. The headers
are bolted to the tube sheets, gaskets interposed to form a seal. Plugs in the headers are
provided for cooler venting and draining.
The materials for headers, tube sheets and core tubes are chosen in accordance with
the specification of the cooling water to be used and the recommended water velocity in
the tubes.
The charge air cooler is mounted in the air duct between the turbo charger and the
Diesel engine air inlet manifold. Mounting can be done as an integral part of the air duct
(Block cooler). The cooler side walls and tube sheets being bolted directly to the air duct.
As an alternative the cooler can be mounted into a casing which in turn is bolted to the
air duct (Removable stack cooler), this method enables the cooler to be removed for
servicing without dismanting air ducts.
3
GEA
Luftkiihler
2. Block cooler
2.1 General
The term “Removable stack cooler" refers to a design where a cooler casing is fitted with
a removable tube stack into the air duct of the engine. As already explained under part
1the cooler casing is bolted into the air duct. The tube stack is slid into the casing. The
protruding tube sheet (fixed end) of the tube stack is bolted to the casing using a gasket
to form an air seal. The expansion end tube sheet is sealed by means of a rubber o-ring
and a sealing frame which form a gland packing. Alternatively a cover plate header is
used. All bolt connections are to be air tight.
Removable stack coolers are designed as single-circuit, multi-stage coolers.
A multi-circuit cooler is designed with common tube sheets and if necessary can have a
split tube sheet on the expansion end to accommodate differential expansion. A multi
stage cooler consists of separate tube stacks which are mounted into a common casing.
The number of circuits refers to water flows through the cooler. The twin-circuit cooler
has two water flows which are independent from one other. These two flows can be used
for different purposes, i.e. for engine cooling, air or oil preheating etc.
Since the tube stacks can be connected in series on the water side the number of stages
in a multi-stage cooler refers to the number of tube stacks fitted into the common casing
and need not to be identifical with the number of water flows through the cooler.
4
GEA
Luftkiihler
2. Block cooler
2.2 Installation and removal of the cooler
Prior to installing the cooler, the transport covers at the air faces and the blanks on the
water connection flanges are to be removed. The air and water side sealing faces, which
are protected prior to shipping, must be cleaned by the use of turpentine.
The cooler can either be mounted to the engine as a self supporting unit on a bracket, or
alternatively it can be mounted in the air duct as a cantilever unit. The air side
connections are bolted to the air ducts on all type of units using gaskets or sealing
compound provided by the engine supplier.
The cooling water pipes are bolted to connection flanges on the nozzle header using
gaskets also provided by the engine supplier.
To avoid deformation and stresses when installing the cooler all connecting surfaces
must be parallel and the tolerances should be kept as small as possible.
All connections are to be air and water tight.
Transport lugs are provided on the for lifting and handling of the complete cooler. Lifting
lugs are also welded to the tube stack side walls.
Prior to installation of the cooler casing into the air duct the tube stack can be removed
by means of unscrewing the bolts holding the protruding tube sheet to the casing frame
and removal of the gland packing or cover plate at the expansion end tube sheet. At the
fixed end of tube stack threads are provided in the water header for eyebolts to be used
when lifting and pulling out. When the casing is installed the tube stack is fitted (New
gaskets interposed) by bolting the protuding tube sheet to casing frame and mounting of
the gland packing or hood.
When removing the tube stack after final installation the bolts holding the protruding tube
sheet are unscrewed, the expansion end gland packing or cover plate and the cooling
water pipes are removed. Any parts of the engine installation possibly hindering
withdrawing of the tube stack are removed and the tube stack is pulled out of the casing
by the use of suitable lifting gear. To ease breaking the tube sheet from casing frame
gasket seal threaded holes with the same dimension as the bolts used for the casing
frame are provided in the protuding tube sheet for jacking screws. The casing bolts may
be used for this purpose.
Installation is done by use of new gaskets as described above.
5
GEA
LuftkUhler
3.1 General
The term “Block cooler” refers to the design. Mounted directly into the air duct of the
engine. As already explained under part 1the block cooler is bolted into the air duct at
its side walls and tube sheets resp.
There are two types of block coolers, namely Single- and twin circuit coolers.
The number of circuits corresponds to the number of water flows passing the cooler. The
twin circuit cooler has two flows can be used for different purposes, i.e. for engine
cooling, air or oil preheating etc.
3.2 Installation and removal of the cooler
Prior to installation of the cooler, the transport covers at the air faces and the blanks on
the water connection flanges are to be removed. The air and water side sealing faces,
which are glazed prior to shipping, must be cleaned by the use of turpentine.
The cooler can either be mounted to the engine as a self supporting unit on a bracket, or
alternatively it can be mounted in the air duct as a cantilever unit. The air side
connections are bolted to the air ducts on both type of units using gaskets or sealing
compound provided by the engine supplier.
The cooling water pipes are bolted to connection flanges on the nozzle header using
gaskets also provided by the engine supplier.
To avoid deformation and stresses when installing the cooler all connecting surfaces
must be parallel and the tolerances should be kept as small as possible.
When removing the block cooler the following procedure should be used.
1. drain c.w. circuit.
2. supporting cooler with suitable lifting gear.
3. disconnect c.w. pipe work.
4. disconnect cooler from air side trunking and remove.
Installation is done by use of new gaskets as described above.
6
GEA
Luftklihler
4. Commissioning
4.1 General
The cooler is subject to a hydraulic pressure test in our factory, it is however

recommended to carry out a test with the specified test pressure before installation.
If after prolonged storage or extended standstill the header gaskets are leaking,
tightening of the header bolts might prevent further leakage. If this does not sufficient the
header gaskets must be replaced. A pressure test with specified test pressure should be
carried out after replacement.
After assembly of the cooler is completed the cooler is circulated with the specified
cooling water quantity prior to venting.
For cooler venting, the vent plugs in the headers are removed. After the air has escaped
from the cooler the plugs are fitted again. Venting should be repeated shortly after cooler
is taken into operation. Venting of the complete cooling system is better than venting only
the cooler and should therefore be preferred.
With multi-circuit or multi-stage coolers, each circuit or stage should be vented

separately.
After a leak test has been carried out on all plant components, and the water flow has
been checked to ensure there are no restrictions, the cooler can be put into operation.
Upon accelerating the engine to the nominal load the air temperatures should be
measured before and after the cooler and the cooling water flow set in accordance with
the nominal water flow as stated in the performance data sheet for the cooler in question.
7
GEA
Luftkiihler
4. Commissioning
The following water velocities should be maintained during operation:
Tube Material Min, velocity Max, velocity
CuZn28Sn (SOMS71) 1,0 m/s 2.0 m/s

CuZn20Al (SOMS76) 1,0 m/s 2,2 m/s
CuNiSOFe (CuNi70/30) 1,5 m/s 3.0 m/s
CuNilOFe (CuNi90/10) 1,5 m/s 2,5 m/s
Cu/SB or SF 1.0 m/s 2.0 m/s
Steel 2.0 m/s 2,5 m/s
* Never operate at min. velocity for a prolonged period of time.The nominal water flow
stated in the performance data sheet for the cooler in question should be maintained.
Frequent fluctuations of the water velocity impede the formation of a protective film
on
the cooler materials, which are vital for corrosion protection. A too low water velocity
encourages dirt deposits and a too high velocity causes erosion. Throttling of the water
flow or improper positioning of the water intake could lead to oxygen enriched water
which favors corrosion. To keep the water flow, and so the water velocity, constant also
during partload operation, control devices should be installed.
8
GEA
Luftkiihler
4. Commissioning
The bypass control as shown below has proved suitable for this requirement. Bypassing
can be done in such way that the discharged warm cooling water is mixed with the too
cold water at the suction side of the c.w. pump to assure operation at almost uniform
charge air outlet temperature. Subsequently water flow, velocity and charge air outlet
temperature can be kept without the recommended range at all load conditions.
Layout of a bypass control system
1. Charge air cooler

2. Charge air inlet
3. Cooling water outlet
4. Flow control valve
5. Cooling water inlet
6. Pump
7. Temperatur sensor
©
F0 ©
©
9
GEA
Luftkiihler
5. Protective film
5. Messiires to assure the formation of

a strong and durable protective film.
The inherent good chemical corrosion resistance of copper and cooper alloys is due to
their ability to form a difficult to dissolve natural protective film.
New cooler tubes lacking a sufficiently strong protective film should never be operated
with contaminated water, as deposits on the material surface would prevent the
formation of such a protective film.
For the above reason clean fresh water is used for the hydraulic test of the heat
exchanger. The utilization of contaminated water should also be avoided during test
runs.
During test runs it is recommended to add small quantities of easily soluble ferrous
sulphate (FeS04 7H2O) to the cooling water to make sure that a good protective film is
formed before operating with contaminated water.
It is sufficient to add about 5 mg/I to cooling water during a period of one hour within
every 24 hours. Adding of ferrous sulphate should, if possible, be repeated during normal
operation until the first inspection is carried out.
An appropriate valve for adding ferrous sulphate should be provided in the piping close
to the water inlet nozzle of the cooler.
10
GEA
LuftkUhler
6. Standstill
6. Standstill
A standstill incorporating the cooling water system, leaving the cooler undrained, is
hazardous for cooler parts made of copper, copper alloys, steel and castiron.
For copper and copper alloys standstills are especially hazardous prior to the formation
of a protective film or in the case that the destruction of the same must be feared for
reason of deposit attack by putrefaction products such as ammonium compounds and
hydrogen sulphide.
If possible, cooler operation should not be interrupted during the first 2 months after
commissioning if the cooler can not be drained.
However, if there is a failure in cooling water supply and operation is resumed within 3
days time and then for a prolonged period of time kept uninterrupted, the cooler may be
left undrained.
It must be then guaranteed that the tubes are free from deposits. If deposits have
formed, the cooler should be drained, the tubes cleaned and flushed with clean water
prior to being dried. We recommend the use of warm or pre-dried air for blowing through
the tubes. The coolers need to be vented adequately. If sea water, brakish or saline
water (chloride content > 500 mg/I) is used as cooling water, water with low salinity
(Drinking water quality) should be used for flushing.
!n case of standstill within the start-up period of 2 months which is expected to last for
more than 3 days, and where deposits must be feared, the coolers should be drained,
flushed and dried.
To avoid standstill corrosion after the first 2 months of operation the above described
cleaning procedure should be repeated by every standstill lasting longer than 2 weeks.
In case of permanent service interruptions after the start-up period it may be necessary
to limit the standstills where the cooler is kept undrained to 3 days and operate the unit
under conditions as recommended for the start-up period.
During short standstills the cooler can be operated at low cooling water velocity if
formation of deposits in the tubes can be prevented. Operating with low water velocities
is to be preferred to cooling water standstill in the tubes as putrefaction products, such as
ammonium compounds and hydrogen sulphide are washed away from their point of
origin.
By a winter time standstill where a frost injury to the cooler could occur the cooler should
be drained also during the shortest standstill.
11
GEA
Luftkiihler
7. Service control
7.1 General
For Service control, thernnometers are to be installed in the air ducts and in the cooling
water piping before and after the cooler. We recommend to keep record of the air and
water temperatures in the machine log book periodically. Further control instruments can
be provided in accordance with the individual requirement.
In case of the occurrence of a major amount of condensate after the cooler, further
condensation can be prevented, or at least limited, by the use of a bypass control of the
cooling water as previous described.
A possibility to drain the condensate must be assured.
7.2 Performance Test
The performance guarantee given by GEA is mainly expressed by the temperature

difference between cold water and cold air during normal operation and should be
checked from time to time .
In the event that a considerable increase of the guaranteed temperature difference is

observed during normal operation, this might be due to accumulation of air in the cooler.
To remedy the above the cooler should be vented using the procedure previous
described.
In case a performance increase cannot be achieved by proceeding as above and

provided no other disturbance can be found, the cooler needs cleaning.
A differential pressure gauge can also be used to check whether or not cleaning of the
air or water side of the cooler is necessary. We recommend to install differential pressure
gauges in the air duct and water piping before and after the cooler.
12
GEA
Luftkiihler
8. Cleaning
8.1 General
Cleaning of the water- and air-side heat exchange surfaces is imperative for a long and
trouble free operation of the cooler. The cleaning intervals vary with the mode of
operation, cooling water quality, intake air characteristics etc.
Cleaning can be done either mechanical, hydraulic or chemical.
8.2 Cleaning of the water side
Regular cleaning is necessary. The cleaning intervals depend on the cooling water used.
Cleaning of the water side is not only required to maintain the thermal performance of the
cooler. Seating increases the risk of pitting corrosion and obstacles partly blocking the
tubes favors erosion.
8.2.1 Mechanical Cleaning
Mechanical cleaning is done by use of nylon brushes fitted to a rod. The length of the rod
corresponds to the tube length of the cooler in question and the type of brush is chosen
in accordance to the finned tube type. The brush with rod is part of each cooler delivery.
Mechanical cleaning can be done in-situ or with the cooler removed. At least one header
needs to be removed when cleaning. For header removal threaded holes with the same
dimension as the header bolts are provided in the header flange to serve as jacking
screws. The wet tubes should be thoroughly brushed clean one after the other and the
dirt flushed out until no residues are left. After the cleaning is completed the headers are
re-fitted using new gaskets. Venting must be repeated after cooling water re-fed.
8.2.2 Hydraulic Cleaning
Hydraulic cleaning is carried out with the cooler removed using a high pressure spray
gun with special nozzle to remove dirt deposits inside the tubes.
8.2.3 Chemical Cleaning
Chemical cleaning can be carried out in-situ or with the cooler removed.
13
GEA
Luftkuhler
8.2,3.1 Chemical Cleaning - In-situ
To ensure that the cooler is always operated without fouling or scaling in the tubes we
recommend an integrated and continuously operating chemical cleaning system to be
fitted.
Such a cleaning system comprises of a circulating pump and a detergent tank with the
necessary piping and shut off valves. The detergent circuit is connected to the cooling
water inlet and outlet piping between their shut off valves and the water header flanges.
Prior to cleaning, the cooling water flow is interrupted to allow the cooler to drain via the
cooling water outlet piping. For draining the vent screws are removed. After draining, the
cooling water valves are closed. The valves of the cleaning circuit are opened and the
circulating pump switched on. The vent screws are fitted after venting completed.
It is recommended to connect the cleaning circuit to the cooling water outlet piping in
such a way that the detergent flows is opposite to the normal cooling water flow.
When cleaning completed the cooler is drained leaving no detergent in the cooler. The
valves of the cleaning circuit are closed and the cooling water valves opened. Flushing is
done with normal cooling water.
Re venting of the cooler is necessary.
8.2.3.1 Chemical Cleaning - In-situ
Scaling deposits in the cooling tubes can be removed by chemical cleaning as well. For
removal, a 10% HCL-acid is used and a 0,5% inhibitor (Specifically suitable for the
individual tube material) added.
After cleaning, the cooler is to be flushed thoroughly, i.e. no detergent residues are
allowed to be left in the cooler. This is most important in case the cooler is shutdown for
a short time after cleaning.
If the cooler is chemical cleaned while being mounted the headers need not be
dismantled. For chemical cleaning we recommend to use commercial detergents such as
Name of detergent Manufactured bv

P3 -T288 HENKEL KGaA
Dusseldorf
SAP-ACID DREWAMEROID GmbH
Hamburg
VECOM BA-S VECOM GmbH
Hamburg
14
GEA
Luftkuhler
8.2.3.1 Chemical Cleaning - In-sitii
The instructions and handling guidelines provided by the manufacturer of the detergent
in question should always be observed when using the chemical.
8.2.3.2 Chemicîl Cleaning - Cooler Removed
Chemical cleaning while the cooler is removed is required if neither mechanical

or
hydraulic cleaning proved successful and if the cooler is not connected to a continuously
operating cleaning system.
The water headers are detached from the cooler bundle. The tube bundle is then
immersed into a chemical cleaning bath. The time of immersion is a function of the
degree of fouling. When cleaning completed, the cooler is to be flushed by applying a
powerful water jet. If the result is still not satisfying, cleaning should be repeated.
Cleaning procedure and detergents are described under 8.2.3.1
8.3 Cleaning of the air-side Genenil
Cleaning of the air-side should be done early enough to avoid accumulations of soot and
oil on the fins, which after a period of time form a hard crust that is difficult to remove
, as
well as the deposition of other crack products as for instance residues that form a
sulphuric acid (Compound with condensate) when left on the fins and tubes for
some
time.
8.3.2 Hydraulic Cleaning
Hydraulic cleaning is effected when the cooler is removed. A high pressure spray gun
as
described under 7.2.2 is suitable also for this requirement. We recommend a nozzle size
of 3 mm. If the water jet attacks the cooling tubes vertical, i.e. in parallel to the fins, a
pressure of 120 bar is suitable to be applied at a distance of 2m from the fin surface.
15
GEA
Luftkiihler
8.3.3 Chemiail Cleaning
We recommend chemical cleaning of the air side while the cooler is removed.
The water headers are detached from the cooler bundle. The tube bundle is then
immersed into a chemical cleaning bath. The time of immersion is a function of the
degree of fouling. When cleaning completed, the cooler is to be flushed by applying a
powerful water jet. If the result is still not satisfying, cleaning should be repeated.
To intensify the cleaning effect of the bath and shorten the cleaning time, it is
recommended to circulate the detergent. The chemical detergents can also be applied by
spraying. The following detergents are recommended for air side cleaning.
Name of detergent Manufactured

P3- GRATO 90 HENKEL KGaA
Dusseldorf
AMEROID DREWAMEROIDGmbH
EDGETM Hamburg
H.D.E 777 DREWAMEROID GmbH

Hamburg
AMEROID DREWAMEROID GmbH

ONE STEP Hamburg
The instructions and handling guidelines provided by the manufacturer of the detergent
in question should always be observed when using the chemical.
16
GEA
Luftkiihler
9. Tube Leaks
9.1 General
Tube leaks can be caused by corrosion, erosion or improper operation of the cooler.
if a leakage is observed, the defective tube or tubes must be identified, if this can not be
done by a visual inspection, a pressure test of the cooler or an individual pressure test of
each tube has to be carried out.
9.2 Pressure test of individual tubes
Prior to pressure testing, the nozzle and return header need to be removed. In case of
ample free space around the cooler it is not necessary to remove the cooler. Rubber
plugs can be used for pressure testing. One of the plugs must have a connection for air
or water supply. The tube to be tested is plugged at both ends and tested at low pressure
applied via the plug having a pressure connection.
Pressure gauges can be installed to indicate a loss of pressure. Even if there is only a
small leak in the tube pressure loss is indicated shortly after pressure application.
If the cooler is to be tested without the use of a pressure gauge it has to be dismounted
to able leakages to be found through visual control carried out from the fin side.
9.3 Pressure test of cooler
If pressure testing of the cooler is done as a hydraulic test, without removing the water
headers, the fin side is searched with a flashlight for wet points indicating leaks. To avoid
that damaged rating being impaired by wet points on neighboring tubes, the air side
should be dried by blowing with air prior to testing.
9.4 Pressure test with air under water
If no pressure gauges are installed pressure testing with air should be done under water.
The cooler is immersed into a water tank and tubes are tested by applying 0.5 bar air
pressure on the water-side without removing headers or by testing the tubes one by one
as previous described. If a tube is defective bubbles will rise. However note that bubbles
can form from air accumulated on the cooling fins and that such bubbles do no indicate
leaks.
17
GEA
Luftkuhler
9.5 Plugging of Tubes
Once the defective tube is found it can be sealed with hard wood or rubber plugs on both
sides. Metal plugs should not be used. Plugging can be done on all tube types without
exception.
In the case that several tubes are leaking it must be decided at location whether or not
the cooler performance will be satisfactory after plugging.
9.6 Replacement of Single Tubes (Partial re-tubing)
if the cooler has single fin tubes, i.e. elliptical tubes with threaded on rectangular fins or
round tubes with wound-on fins, it is possible to replace single tubes. If the leaking tube
is found in the middle of the tube bundle, the neighboring outer tubes must be also be
removed and replaced to gain access to the leaking tube. After the tubes to be replaced
are removed the tube sheet holes must be cleaned.
The replacement tubes are provided with an extended un-finned portion at one end. The
tube is inserted into the tube hole in one tube sheet (Long un-finned end first) then
retracted and slid into the corresponding tube hole in the second tube sheet. Then the
new tubes are then roiled into the tube sheets.
9.7 Insertion of a Second Core Tube
Replacement of single tubes is not possible on coolers with compact fin tube system
consisting of continuous fins with several inserted and expanded core tubes. To remedy
tube leaks, plain tubes of smaller diameter than the defective tube can be inserted and
expanded to form thermal contact with the latter and rolled into the tube sheets.
9.8 Pressure test after repair of cooler
After repair the cooler must undergo a pressure test with the specified test pressure
which is stated on the nameplate fitted to the cooler sidewall or casing.
Replacement tubes, tools and other materials for leak remedy can be purchased directly
from GEA Heme or from our service centers world wide.
18
4
VN 115/87 EMC, VN 115/87
m
Operating Instructions
VN116/87EMC, VN 116/87 111
Article No.: 10024
Edition: 04 U VN 215/87 EMC, VN215/87
INDUSTRIELLE AUTOMATIONSTECHNIK KG
D-66440 Blieskastel/Saar ■ Industriering 14 • Germany / SW

Tel. ++ 49 (0) 6842 / 508-0 • Telex 44 685 ■ Fax ++ 49 (0) 6842 / 508-260
It is recommended to read this instruction manual
before commencing the repair, assembly or
commissioning of the oil mist detector system!
CAUTION: The manufacturer’s warranty will become

void if these instructions are not followed!
Unless notified to the contrary, these operating

instructions are applicable for:
VN 115/87- EMC
VN 116/87- EMC
VN 215/87- EMC
VN 115/87
VN 116/87
VN 215/87
In case of an oil mist alarm, the oil mist

detector (OMD) must be in condition to react
within the next few seconds and shut down
the engine, in order to minimise immediate or
consequential damages!
The corresponding relay contacts are instantly

connected to trigger the alarm safety system!
Safety Signs
A in general
Safety Signs
A electrical
A C'mos
Inhalt,
Index
1. Product Description
2. Installation
0
3. Commissioning
4. Performance Test / Maintenance
5. Failures and Corrective Action
6. Repairing
7. Spare Parts
8. Service Facility Addresses
9. Brochures, Leaflets, etc.
• • • 10. General Information
/ 11. Notes
12. Options
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I 1. 01
Product Description
Application
Oil mist detectors of the VISATRON series protect large diesel engines of all
operation classes against serious damages originating from crankdrive bearing or
piston component overheating.
Functional Description
The atmosphere of the crankcase compartments is continuously drawn out by
means of headers and directed through an optical opacity measuring track. In this
measuring track the opacity (turbidity) of the drawn crankcase atmosphere is
determined by means of infrared light.
Main Structural Components ( see Fig. 1.01 / I to 1.01 / 3 )

1. Base plate with air jet pump for generating the required negative
pressure (1 ) and main connector plug ( 5 )
2. Measuring head with electronic module, display window (2 )
and inspection cover ( 3 )
3. Connection for headers ( 4 ) or individual pipes ( 6 )
Connection for headers designed as:
VN 115/87, VN 115/87- EMC (see Fig. 1.01 /1 )

Connecting box for connecting two header pipes
(This type of oil mist detector may show an oil mist alarm, without identifying
the individual compartment of damaged engine side )
VN 116/87, VN 116/87- EMC (see Fig. 1.01/2)
Valve box for connecting two header pipes
(This type of oil mist detector may show an oil mist alarm, identifying in the
valve box window whether a damage has occurred in compartments located
either to the left side or the right side of the detector)
VN 215/87, VN 215/87- EMC ( see Fig. 1.01/3)
Valve box for connecting up to ten individual pipes
(This type of oil mist detector may show an oil mist alarm, identifying in the
valve box window in which individual compartment the damage has occurred )
VN 115/87- EMC VN 116/87- EMC VN 215/87- EMC

VN 115/87 VN 116/87 VN 215/87
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1.01 /I 1.01 /2 1. 01/3 12.95

k.
1.02
Technical Data
Operating voltage: 24 V DC +/- 25%, with reverse battery protection

Electrical Data
Power consumption: Maximum 3 A
Electromagnetic
compatibility: Wiring failures:
50 Hz to 10 kHz, 3 V eff. /10 kHz to 50 MHz, 1 V eff.
Only
Electromagnetic fields:
VN 115/87 30 kHz to 200 MHz, field strength 10 V / m,
VN 116/87 Damped oscillation:
VN215/87 1 MHz.l kV, 400 pulses per second,
High- energy pulses:
0.5 joule, 5 kV. Ri = 500 Q
Electromagnetic fields:
30 kHz to 1 GHz with 10 V/m, Acc. to lEC 801 - 3
VN 115/87-EMC ( ambient class 3, 10 V / m, 30kHz -16Hz )
VN 116/87-EMC Fast transients ( burst):
VN 215/87-EMC Acc. to lEC 801 - 4, ( ambient class 3 )
In addition: Electrostatic discharge:

Acc. to lEC 801 - 2
Load to relay outputs: Maximum 60 V AC / DC, 2 A AC / DC, 60 W, 125 VA
Sensitivity: 1st row: switch position, 2nd and 3rd row: required
opacity for triggering an alarm
Switch position: 1 2 I 3 4 5 6 7 8 I 9 10
r
Alarm level: (% of opacity)
ofVN 115/87-EMC 0,5 1,0 ^ 1,5 2,0 3,0 5,0 7,0 10,0 15,0 25,0
and VN 115/87
Alarm level: (% of opacity)

of VN 116/87- EMC
and VN 116/87 0,7 1,1 1,6 2,4 3,7 5,5 8,2 12,4 18,5 27,8
of VN 215/87-EMC
and VN 215/87
12. 95
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1. 03
Technical Data
Negative
pressure measured: At least 60 mm, maximum 80 mm W.G.
in Measuring Unit
Pneumatic Data
Driving air for air jet pump: 0.3 to 0.5 bar
Air consumption: Dependent on the number of

suction points, however, max. 1 normal m^/ h
Protection: IP 44
Admissible operating
temperature range: 0° C bis +70° C
Admissible oil mist

temperaturerange: Maximum +70° C
Ambient Conditions
Admissible storage and
transport temperature range: - 25° C bis +80° C
Humidity: Maximum 90% relative humidity
Vibration: Maximum acceleration 6 g
Dimensions: (see drawings 1.04 /1, 1.04 / 2, 1.05 /1 )
Weights: VN 115/87, VN 115/87- EMC 7.5 kg

VN 116 / 87, VN 116 / 87 - EMC 9.4 kg
VN 215 / 87, VN 215 / 87 - EMC 9.6 kg
Mechanical
Pipe connections for Data
suction system: VN 115 / 87, VN 115 / 87 - EMC and
VN116/87, VN116/87-EMC
Header (two pieces, 0 22 x 2 (i.d. 18 mm )
maximum length: 9 m, R 1/2" and R 3/4"
VN 215 / 87, VN 215 / 87 - EMC
Individual pipes (maximum 10 pieces ),
0l4 X 2 (i.d. 10mm ) maximum length: 9 m
12.95
1.04
Dimensions
ca.159
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VN 115/87 G3/4A cQ
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19. 146.
172.5 171
1.04/ 1
ca.159
1205.
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VN 116/87-EMC a
G 1/2 A
VN 116/87
% <1
G3/4A
CD
4S
43. iia
172.5 171
12.95 1. 04/2
1. 05
VN 215/87-EMC
VN 215/87
1. 05/ 1
4 threads or holes for screws M8
Fastening
VN 115/87-EMC
VN 116/87-EMC
VN 215/87-EMC
VN 115/87
VN 116/87
VN215/87
120
1.05 / 2
12.95
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2, 01
Installation
General
It is important to emphasize cleanliness during the assembly work!
Clean pipelines and fastening parts before assembly.
Lay pipes in a stress- free manner!
Installation position of the device:
Locate the oil mist detector in a vertical position!

Make sure not to install the device within the airflow of blowers or air deflectors.
Suction pipes VN 115 / 87 - EMC and VN 116 / 87 - EMC ( see Fig. 2.1/1)
Material: Seamless steel pipes,
header (1 ) 22 x 2 mm (i.d. 18mm ), max. length: 9 m

suction pipes (2)10x2 mm (i.d. not less than 6mm )
Pipe Laying: Ascending to the device,

Ascending
ascending gradient 2% to 4%, without sagging, avoid oil collection
Gradient 2% to 4%!
( see Fig. 2.01 /1 )
Consider toavoid oil

collection when laying
the headers! OH must
always drain back to
engine
VN 115/87-EMC
VN 116/87-EMC
VN 115/87
VN 116/87
2. 01 /1 12.95
2. 02
Headers above suction points for:

VN 115/87-BMC
VN 116/87-EMC und
VN 115/87
VN 116/87
o
A without
ir
<1)
<?)
pipe end- siphon
Lay headers in
ascending direction
to the detector! 2. 02 /1
Headers below suction points:
with
pipe end- siphon O
<1)
Lay headers in m <2)
asccending direction
to the detector!
2.0212
© Header pipe o22 mm x 2 mm (i.d. 18mm )
Compartment suction pipes to header o 10 mm x 2 mm
(i.d. not less than 6mm )
© Pipe end- siphon 100 mm with oil return back to the engine,
or 200 mm with oil discharge outside the engine
12.95
2- 03
VN 215/87-EMC
VN215/87
A
Lay suction pipes in
descending manner!
2. 03 /1
Suction pipes VN 215 / 87 - EMC, VN 215 / 87
Material; Seamless steel pipes, 14 mm x 2 mm (i.d. 10mm )
Pipe Laying: Ascending to the device, ascending gradient 2 - 4%

( see Fig. 2. 03 /1 )
Siphon blocks
0^
—a
a
□
□
A
n
a
on
(1
a
g
Pipes can be
mounted horizontally
Ffl f!
Avoid sagging or
'— Suction funnel oil collection
2. 03/2
12.95
2. 04
Suction funnel in the crankcase compartment
The suction funnels have to be fitted in such a way that flooding by splashing
bearing oil or returning Piston cooling oil is avoided ( see Fig. 2. 04 /1 ).
Caution: Make sure funnels are not interfering with
rotating or moving parts of the engine.
Sense of
engine rotation
Suction funnel Suction funnel Suction funnel

for siphons and for sipons and only for
engine wall connection engine wall connection engine wall connection
2. 04 /1
Suction funnel with

oil discharge labyrinth
Sense of
engine rotation
Push in
■ - N.
suction funnel pipe
firmly to the stop
Oil mist
during assembly!
Crankcase
VA
compartment
Oil return
Engine wall
2. 04 / 2
Straight engine wall connection Engine wall connection LL - type
[fli
Observe mounting
position!
Engine wall connection L - type
2.04/3
12.95
2. 05
Installation of siphon blocks
cutting ring
2.05/1
Tightening torque: 30 Nm
12.95
2. 06
Suction piping of VN 215 / 87 - EMC
Connecting flange,
Valve box
left right
O
O
4 - cylinders
5 - cylinders
5 - cylinders
6 - cylinders
7 - cylinders
Connection numbers
©
to valve box
Closed by
drain plug
o Connection for Unused pipe connection bores in flangeare to be plugged

suction pipe
with the supplied viton plugs.
12.95
2. 07
Suction piping of VN 215 / 87 - EMC
Connecting flange,
Valve box
right
7 - cylinders
8 - cylinders
9 - cylinders
9 - cylinders
10- cylinders
Connection numbers
©
to valve box
Closed by
drain plug
Unused pipe connection bores in flangeare to be plugged o Connection for

suction pipe
with the supplied viton plugs.
12.95
2. 08
Air supply
^—k
1
1
No back pressure
and no oil collection
is allowed in
exhaustair pipe!
2. 08 /1
@ Discharge funnel
@ Draft air connection set
Parts are not included @ Exhaust air connection
in the scope of supply, Pressure regulator unit consisting of:
but they can be @ Throttle block
purchased as an option! (D Pressure connection 2 -12 bar

(D Pressure regulator
If parts are not included in the scope of supply they can be purchased as an option!
To avoid backpressure, lay exhaust pipes without any reducers (DN 22).
Avoid sagging and oil collection in pipes ( See drawing 2. 08 /1 )
Electrical connection ( see Fig. 2. 09 /1 )

Connection: 24 V DC
A Power consumption:
min. 18 V
max. 30 V
3 A
Protection: 4 A with semi time- lag
A
When power is supplied by batteries, charging voltages of more than 30 V
might occur. These voltages are not permitted. Device will go into failure mode.
Voltage limiters must be installed! ( See Fig. 2. 09 / 2 )
12.95
2. 09
Terminal Plan
Oil mist detector Ship system /

Alarm system
2 A with semi time*lag r 4 A with semi time-lag
Heating
1
24 V (XJ 25%, maximum 3 A
system
2. 0
Ready relay Oil mist detector in operation

Contact load
6- Device in operation: green READY LED on,
Voltage: U contacts 4 and 5 closed,
maximum 60 V AC / DC contacts 3 and 5 open
Current: 1 Device faulty; green READY LED off.
maximum 2 A 9^ contacts 3 and 5 closed
maximum 60 W /125 VA contacts 4 and 5 open
I
Oil mist alarm for alarm system
Alarm relay
I Oil mist alarm: green READY LED on,
Resistor for red ALARM LED on.
wire break contacts 7 and 8 dosed
(Interrupted circuit contacts 6 and 8 open
monitoring) No oil mist alarm: contacts 6 and 8 closed
contacts 7 and 8 open
2 lines shielded:
Analog display. Art. No. 150 066
0 -1 mA
Ri S 400 n
Reserved for the manufacturer,

do not utilise!
Oil mist alarm for safety system

Alarm relay Oil mist alarm: green READY LED on,
red ALARM LED on
Resistor for contacts 15 and 16 closed
wire break inspection contacts 14 and 16 open
No oil mist alarm: contacts 14 and 16 closed
contacts 15 and 16 open
I
2. 09 /1
Power supply connection for battery supply
2.09/2 12.95
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3. 01
Commissioning
Adjust suction pressure

The suction pressure must be calibrated by adjusting the pressure regulator when
the engine is at a standstill. Make sure ventilation of the engine room is in operation
( pressure difference in room ). An increase or decrease of the pressure
in the crankcase compartment during operation and its effect on the flow velocity
of the oil mist in the suction pipes, is largely compensated by the internal restriction
integrated in the device, (e.g., +25 mm W. G. in the crankcase compartment against
the atmosphere account for an increase of the oil mist flow velocity in the suction
pipes of approx. 8%; +50 mm W. G. of approx. 14%, a negligible figure).
This is important because precipitation of minute oil droplets of the oil mist
increases with a too high flow rate, thus reducing the sensitivity of the device.
Pressure regulator unit
(D
[I I 1
2
3.01/1
1. Connect U-tube pressure gauge at inspection cover. ( See Fig. 3. 02 /1 )
( Pressure gauge is included in the service box, available as an option )
2. Loosen nut (1) and turn setscrew (2) in clockwise direction gently up to the stop.
3. Open safety cover ( 3) at the throttle ( 5 ) and manually turn setscrew ( 4 )

A
Adjust 60 mm W. G.!
in clockwise direction gently up to the stop.
4. Switch on compressed air supply with inlet pressure (range 2 to 12 bar).
The pressure gauge should now read zero pressure. After adjustment,
5. Turn setscrew ( 4 ) in counterclockwise direction until the U- tube remove U- tube
pressure gauge indicates a negative pressure of 80 mm W. G. pressure gauge

6. Close safety cover. and screw in the
7. Turn setscrew ( 2 ) in counterclockwise direction until the negative pressure previously removed
is only 60 mm W. G. plug
8. Tighten counternut (1 ).
12.95
3. 02
U-Tube pressure gauge
3. 02/ 1
Filling of siphons
MHczl
' ILM-^
'— Slide pump filling

pipe up to the stop!
3. 02 / 2
1. Remove plug (1 ) and seal ring ( 2 ).
2. Introduce filling pump ( 3 ) against the stop.

3. Secure filling pump with fitting and slightly tighten union nut.
4. Pump 10 to 12 times with fast strokes.

5. After the filling process has been completed, remove pump and tighten
plug (1 ) and seal ring ( 2 ).
6. Measure negative pressure in the last siphon.
Apply power supply

Switch on power supply after checking the wiring.
12.95
(D 3. 03
Device Operation
Control and display elements
After the preparation work has been carried out (commissioning ) the device sets
itself to normal operation in approx. 30 seconds, after the power supply has been
switched on. This phase is indicated by a blinking LED No. 1.
The device only needs to be controlled, if:
- an oil mist alarm is recognized
- a malfunction of the oil mist detector is recognised
- the oil mist detector has to be maintained.
The present state of the device is indicated in the display window:
Visatron Display Window
Left side: LED No. (= error code) Right side: opacity in %
(flashlight) (steady burning light)
/ No %
Alarm LED Alarm 14 7
5
Opacity display
10
(Opacity)
Test 1
Test LED
0,6
4
0,3
Ready LED
1 0
4 6
Alarm level switch
Alarm Level
\ /
3. 03 /1
12.95
3. 04
Display and function during normal operation;
The basic state ( oil mist opacity below alarm level) is marked by
( see Fig. 3. 03 /1 ):
- green READY LED is on
- the percentage of change in oil mist opacity with regard to basic opacity is
shown on the opacity display

- TEST LED is off
- ALARM LED is off

s\ !/ “ READY relay switched on
//
(5), - ALARM relay switched off
y
- RESET button showing no function
- all valves in the valve box are opened, visible by the symbols displayed in the
inspection windows of the valve box
( only VN 116 / 87 - EMC, VN 116 / 87 and VN 215 / 87 - EMC, VN 215 / 87 )
Opacity increase beyond search run level

only
VN 116/87-EMC The search run level is fixed to 10 % of the adjusted alarm level. Valves in the
VN 116/87 valve box are activated according to a defined algorithm in order to find the
VN 215/87-EMC corresponding engine side or compartment showing an increasing opacity
VN215/87 ( search run ). The search run can be interrupted by pressing the RESET button.
Further opacity increase beyond alarm level marked by:
- blinking red ALARM LED

- READY relay is switched on
- ALARM relay is switched on
// - 3 red symbols in the inspection window of the valve box showing the
engine side on which the damage has occurred
( only VN 116 / 87 - EMC, VN 116 / 87 )
:s): - a red symbol in the inspection window of the valve box showing the
compartment in which there is the highest opacity.

( only VN 215/ 87- EMC. VN 215/ 87 )
Alarm condition reset to basic state
- By pressing the RESET button

“ If there is a device failure, e. g. breakdown of driving air supply
( READY LED is off)
12.95
3. 05
Display and function in case of a failure
A failure is shown by;
- green READY LED switched off

- the LED assigned to the failure is blinking in the opacity display
- TEST LED switched off
- ALARM LED switched off
- READY relay switched off
- ALARM relay switched off

- RESET button toggling from fault indication to opacity display and vice versa
Oil mist opacity exceeds alarm level
- TEST LED is additionally switched on
- READY LED remains switched off
- ALARM LED remains switched off!
Assignment of blinking LEDs on the opacity display showin device failure:
LED No. Cause of failure

14 Negative pressure in the measuring compartment too low
13 Infrared filter dirty
12 Not assigned
11 Ambient temperature < = 0° C
10 Ambient temperature > = 70° C
9 Electronics temperature < = 0° C
8 Electronics temperature > = 75° C
7 Reset button defective
6 Not assigned
5 Switch for adjusting sensitivity defective
4 Infrared light track defective
3 Flow control defective
2 Electronic module defective
1 Blinking for about 30 seconds after the oil mist detector
has been switched on ( warm-up phase )
To eliminate malfunctions see chapter “Failures”!
12.95
0
3. 06
ALARM LEVEL Switch
A
Modifications
Meaning of switch positions:
1 = Highest sensitivity
only permitted by
4 = Factory-set sensitivity
consultation with the
10 = Lowest sensitivity
manufacturer!
To change sensitivity
(this must be done by authorized personnel only!):
A
Touch electronic
- Pull out plug with RESET button
- Unscrew measuring head casing

- Remove electronic module (see Fig. 6.02/1)
module only at
- Adjust new sensitivity at ALARM LEVEL switch by means of a screwdriver
exterior edges
- Reinsert electronic module
of printed circuit
- Screw on measuring head casing
board!
- Reconnect plug with RESET button
12.95
3. 07
Function of relay outputs
Function of READY relay

( corresponding to the state READY LED ) (see Fig. 2. 09/1)
- The relay is switched on when the oil mist detector is in operation
Function of ALARM relay
- The relay is switched on when the opacity exceeds the adjusted alarm level.
- Wire break monitoring by the alarm system is made possible by wire break
resistors installed between contacts 7 and 8 as well as between 14 and 16
( 33 kO. factory-preset).
- To replace the line break resistors the electronic module must be removed.
The resistors are located near the relay on the lowest printed electronic board
(R222, R 223).
Attention:
In case of an oil mist alarm, the oil mist detector (OMD) must be in condition
to react within the next few seconds and shut down the engine,
in order to minimise immediate or consequential damages
12.95
3. 08
Performance Test
Attention
The engine is uncontrolled during this performance test!
A performance test of the device without an alarm being indicated externally
can be carried out as follows:

- Open the cover of the measuring head casing
- Wait until the READY LED is switched off ( after about 10 seconds ) and LED14
is blinking ( negative pressure in the measuring compartment too low )
Search Run only:
- Darken the measuring track with filter glass or another object
VN 116/87-EMC
- Search run (as described in 3. 04 ) is started
VN 116/87
- TEST LED lights up when alarm level is reached
VN 215/87-EMC
- Alarm reset by pressing the RESET button
VN215/87
- By pressing the RESET button once again the display switches over
from fault indication to opacity display
- Close cover again
- Device is again ready for operation after about 15 seconds

( READY LED is switched on )
Attention
Take care that the cover of the measuring head casing is definitely closed
after the performance test has been carried out in order to ensure that the
engine is controlled again!
12.95
3. 09
When painting works are carried out near the device,
the draft air supply to the device has to be turned off,

in order to prevent the scavenging air filters from clogging.
Shut Down
- Stop driving air supply
- Do not switch off the power supply
Storage
in closed rooms
T min Avoid
T max +80X
condensation!
Maximum air humidity 85%
12.95
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4. 01
Performance Test / Maintenance
Performance test
(To be preformed before the engine is started):
- Pull out the main supply plug,

green READY LED will go off
- Re- install main supply plug,
LED No. 1 is blinking for about 30 seconds, then:
the green READY LED and LED No. 1 light up.
Device is ready for operation
- Open inspection cover at the measuring head.
After about 15 seconds the green READY LED and
LED No. 1 turn off simultaneously.
LED No. 14 is blinking
( meaning: negative pressure in the measuring compartment is too low)
- Close inspection cover at the measuring head again.
LED No. 1 is blinking for about 15 seconds.
The green READY LED subsequently switches on.
Device is ready for operation.
Performance test with test vapour, e. g. vapour distillate from the service box
(to be performed only when engine is not running )
- Open crankcase - cover of a compartment in order to access

a suction pipe or sampling funnel.
- Fill the plastic bag (found in the service box ) with vapour
- Affix the plastic bag to suction pipe or sampling funnel.
- Allow the oil mist detector to draw in the distillate vapour for
a minimum of 20 seconds.
- It depends on the vapour density and suction time ( at least 20 seconds )
1. whether an oil mist alarm is triggered, or
2. whether an oil mist alarm is triggered, and a search run is started, or during Search Run only:
the search run only one half or the engine or the VN 116/87-EMC
affected compartment is indicated. VN 116/87
(If the amount of vapour is insufficient or the suction time is too short, a wrong and
compartment may be indicated in the display window of the valve box.) VN 215/87-EMC
VN215/87
12.95
4. 02
Maintenance work to be carried out regularly. In case of non-compliance, the
manufacturer’s liability expires. Maintenance work has to be documented.
Monthly: Check the negative pressure in the measuring head

(range 60 - 80 mm H2O )
Quarterly: Replace the sintered bronze filter In the measuring head.

Rough filter side
Attention: Filters cannot be cleaned.
outwards!
( see Fig. 5. 03 /1 )
Clean the two fresh air bores in the measuring head

Use cotton sticks only,
( see Fig. 5. 03 / 2 )
otherwise the glasses
Clean the infrared filter glasses in the measuring head
may be damaged!
( see Fig. 5. 04 /1 )
Every 6 months: ( only with siphon block assembly system,

optional for all OMD device types )
4.02 /1
In order to do so:
Remove header pipes from the connecting box,
( VN 115/87- EMC, VN 115/87) or from the valve box of

VN 116/87- EMC, VN 116/87, or individual pipes from
valve box of VN 215 / 87 - EMC. VN 215 / 87

(to ensure that the device is not contaminated during the
cleaning operation). Remove siphon block plug, blow-clean the
siphons with compressed air (max. 7 bar), mount the header or
the individual suction pipes and siphon block plug,
tighten accordingly.
Subsequently fill the siphon blocks with lubricating oil
( see Fig. 3. 02 /1 )
12.95
4. 03
Annually: Replace the sintered bronze filter in the pressure reducer
(see Fig. 4. 03 /1 )
4. 03 /1
In order to do so:
Turn off control air supply, remove plug ( 1 ) with O- ring ( 2 ),

detach sintered bronze filter (3), insert new filter, install and
tighten plug (1 ) with 0-ring ( 2 ) and turn on the air supply.
12.95
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5. 01
Malfunctions
Failures and corrective action

A malfunction in the operation of the oil mist detector has occurred if:
" the green READY LED Is off

- an LED assigned to the failure mode is blinking in the opacity display
A pending oil mist alarm is reset.
Failure:
No display In the inspection window, all LEDs off.
Possible cause: Remedy:
Breakdown of power supply Check power supply
or voltage too low by: pulling off the main supply plug.
Between terminals 1 and 2 in the socket

on the base plate, check if 18V to 30V
is available.
Push on main plug and lock into place.
Make sure that the power supply does not
break down under the load of the

oil mist detector. ( voltage not below 18V )
Fuse in the measuring head Replace fuse In the measuring head

defective (see Fig.5. 06 /1 ) ( 2 A, semi time lag )
by: pulling off the main supply plug.
Detach measuring head ( 8 screws )
Replace fuse by a new one.
Mount measuring head into position.
Push on main supply plug
and lock into place.
Should there still be no indication Replace the electronic module
( see Fig. 6. 02 /1 )
12.95
\
5. 02
Failure
LED No. 14 is blinking - negative pressure in the measuring head too low.
nN I
K
10^----
'No..
0.3
Possible causes: Remedy:
Atann L*v«l
Open inspection cover Close inspection cover
Filter or water separator in the Clean accordingly, empty if necessary
air supply pipe clogged or filled
Pressure reducer misadjusted Readjust ( see chapter 3. 01 )
by vibration
Pressure restrictor misadjusted Readjust ( see chapter 3. 01 )
by vibration
Sintered bronze filter in the Replace bronze filter
pressure reducer clogged ( see Fig. 5. 03 /1 )
by: Turn off the control air supply.
Release plug (1 ),
remove O- ring ( 2 ),
Do not clean filters,
detach filter ( 3 ),
but always replace
insert new filter ( 3 ),
by new ones!
mount O- ring ( 2 ),
install and tighten plug (1 ),
Turn on air supply.
Sintered bronze filters in the Replace sintered bronze filters
measuring head clogged ( see Fig. 5. 03 /1 )
by: opening the inspection cover.
Remove circlips.
Mount new filters ( always on both sides,
rough side outwards),
insert circlips,
close cover.
12.95
\
5. 03
Fresh air bores for Clean both bores ( see Fig.5. 03 / 2 )

flow control clogged by; opening the inspection cover.
Press cleaning pin contained in the
service box into the left or right fresh air
bore, respectively.
The bores can be seen from the side

of the scavenging air chamber.
Close inspection cover.
Leakage at the device Check all pipes and seals
by: checking flexible expansion bellows

( accessible after the measuring head
has been dertached)
Replace damaged seals or
expansion bellows.
Exhaust air pipe malfunction Eliminate blockage of the exhaust air pipe,
the air must flow without restriction.
Needle length |
maximum 11 mm
K
5. 03 / 2
12.95
5. 04
Failure
LED No. 13 is blinking - infrared filter clogged -
\4
Possible causes: Remedy: ( see Fig. 5. 04 /1 )

Infrared filter clogged Clean infrared filter
OJ
by: opening the inspection cover.
y Soak cotton stick (plastic only!) with alcohol.
Clean infrared filter with
cotton stick several times.

Rub infrared filter dry by means of
cotton stick. Make sure no fluff remains on
the infrared filter

Close inspection cover again.
If failure continues: Replace electronic module

(see Fig. 6. 02 /1 )
5. 04 /1
Failure:
LED No. 11 Is blinking - ambient temperature below 0° C

-4
0.6
06 Possible causes: Remedy:
(S)’. Engine compartment ventilator Change blowing direction of ventilator,

y blows cold air onto the device. away from oil mist detector.
Failure:
14
LED No. 10 is blinking - ambient temperature above 70° C
06
06
■(S>; Source of heat radiates Protect device against sources of heat
on the device. radiation, ensure an improved fresh air
12.95
\
'9-
5. 05
Failure
LED No. 9 is blinking - electronic temperature below 0° C Mo
10
Possible causes: Remedy: DO
OJ
Engine room ventilator blows Change blowing direction of the ventilator to
:s):
cold air onto the device. ensure that cold air it is not directed to the oil
mist detector
Failure
LED No. 8 is blinking - electronic temperature above 70° C
Possible causes: Remedy: OJ
Source of heat radiates Protect device against sources of heat :(S);

V
on the device. radiation, improve fresh air circulation.
Failure
LED No. 7 is blinking - RESET button defective
Blocked RESET button Eliminate blocking
14
Failure
10
LED No. 5 is blinking - OMD sensitivity switch defective
04
N.
Possible causes: Remedy: :(S):

Switch defective Replace electronic module
( see Fig. 6. 02 / 1 )
Failure
LED No. 4 is blinking - infrared light track defective
Infrared filter clogged Clean infrared filter ( see failure LED No. 13 )
If failure continues Replace electronic module ( see Fig. 6. 02 /1 )
Mo
Failure
LEDs No. 3 or 2 are blinking 10

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Electronic module defective Replace electronic module ( see Fig. 6. 02 /1 )
12.95
\
,0:
5. 06
Replace fuse
in the measuring
head!
5.06/1
12.95
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6. 01
Repairing
Replace electronic module / measuring head
Attention
If these factory pre- settings (resistors) are replaced by those with other values,
it must be ensured that a spare electronic module or the one in a
replacement measuring head is also modified accordingly!
Modifications have to be printed on the protecting cover plate on the rear side of the
measuring head casing, in the fields provided for this purpose.

( see Fig. 6. 01 /1 )
Examine Module or
spare when received

Type Serial No. from shipment
VN 11S/87I
VN 116/871
VN21SW7I If you return the
M/V
Ollmist - detector mounted on
electronic module,
Main engine^! Aux. engine ^B
ensure that the
completed form
Display
<( Why do you declare
Adjuitment by manulecturer:
this unit faulty »»
RaMior between alarm contact 7 • 6
ReMtor between alarm ctjntaci ts ■ I6
Moda < awncti S2. Option) PoarUon
is included!
Altered ad|ustmenl for H / V:
Alarm Level (swic*i S1 )Poa«on
ReaMor between atarm contact 15-16

Mode {awicn S2. OpMn) Poeaian If the electronic module
is replaced, take care

For mamifaclurer
only that the same wire break
resistors are used and
that the Alarm Level

6. 01 /1 switch is set on the
same position!
The wire break resistors are located on the first visible printed circuit board,
Observe locks!
which is under the protecting cover plate, near the relays (R 222 and R 223)!
The resistors are designed as plug- in resistors and can be replaced
without soldering!
You find the ALARM LEVEL switch on the front display plate of the
electronic module ( see Fig. 3. 03 /1 ).
12.95
6. 02
Procedure: ( see Fig. 6. 02 /1 )
- Pull off the main supply plug
- Dismantle the measuring head ( 8 screws )
If the electronic module is replaced or needs to be modified:
- Remove protecting cover plate ( 3 screws)
- Remove the 3 hexagon distance bolts

- Remove defective electronic module from the casing, first pulling off the
lateral flat cable plug from the socket in the casing.
“ Mount new electronic module in reverse order
- Install protecting cover plate, fasten 3 screws
- Fasten measuring head, tighten 8 screws moderately.
- Push on main supply plug and lock it into place

- Carry out performance test ( see chapter 4.01 )
Detach electronic
module!
Examine Module or
spare when received
from shipment.
If you return the Eimmw

electronic module,
ensure that the o
completed form
“Why do you declare

this unit faulty''
6. 02/1
is included!
(T) Dismantle cover plate by removing 3 screws
Loosen 3 hexagonal screws of module
(3) Extract module
Attention:
The electronic module is equipped with components which are sensitive
against electrostatic discharges. A replacement must be carried out by
skilled personnel only! Do not touch infrared tenses or circuitry! Utilise
grounding strap on your wrist.
12.95
6. 03
Leaks or failure of the valve box of VN 115 / 87 • EMC, VN 115 / 87
Remedy: ( see Fig. 6. 03 /1 )
Disconnect header pipes on the left and right side of connecting box ( 1 ),
push pipes aside to get free access.
Loosen the two screws ( 2 ) and ( 3 ) of the connecting box
Detach the connecting box and remove the gasket On principle, use new
Check if bores 1,2 and 3 are free from dirt, blow them free with connecting box gasget!
compressed air
Clean the base plate cavity from oil.
Assembly in reverse order, utilising new gasket.
(3) (P
s\J 0~V o
n Bore 1
S
Bore 2
A Bore 3 VN 115/87-EMC
xz
<3=1 IS IB
<3=
VN 115/87
6. 03 /1
Leaks or failure of the valve box of VN 116 / 87 - EMC, VN 116 / 87

Remedy: ( see Fig. 6. 04 /1 )
Dismantle the pipe connecting blocks with the headers on the

right and left side
Push away the header pipes for free access to the valve box
Unscrew the valve control cable plug and loosen the four screws On principle, use new
( 3 )- ( 4 ), (5 ) und ( 6 ) of the valve box. valve box seals!
Detach valve box and remove seal
Check if bores 1, 2 and 3 are free from dirt, blow them free
with compressed air.

Assembly In reverse order, utilising new seals and gasket
12.95
6. 04
® (3) (5) (6) ®
o O Q V y~Q Q
n -----------------n----- n Bore )
0 D Bore 2
0 0
ol D 0 K:^l Bore 3
3.
VN 116/87-EMC
<^=i
tl
VN 116/87
6.04/1
Leak or failure of the valve box of VN 215 / 87 - EMC, VN 215/87

Remedy: ( see Fig.. 6. 04 / 2 )
Release the pipe connecting blocks (1 ) und (2 )
on the right and on the left side.
Push away blocks with with individual suction pipes for free access
to the valve box.
On principle, use new Unscrew valve control cable plug and loosen screws (3), (4), (5) und (6)
of the valve box

valve box seals and
Detach valve box and remove seal
gasket!
Check if bores 1,2 and 3 are free from dirt, blow them free with
compressed air.
Assembly in reverse order, on principle, use new valve box seals and gasket.
‘
O II ^
/~Q II O
Bore 1
Bore 2
VN 215/87-EMC A Bore 3
VN215/87
12.95 6. 04 / 2
6. 05
False alarm in the case of fire with smoke development in the engine room
In case of a fire with smoke development in the engine room, a false alarm cannot
be prevented since smoke may pass into the measuring track through the sintered
bronze filters in the measuring head. This condition induces an opacity which can
A
trigger an oil mist alarm.
Remedy: Install optional pressurised air scavenging system, available from the
manufacturer { Press RESET button to reset the alarm )
Further possible failures

Sudden false alarms in very warm or cold climatic areas can be triggered by
humidity (in the crankcase ) falling below the dew point;
water droplets passing the measuring track or dew on the filter glasses may trigger
a false alarm.
A
Remedy: Check negative pressure and calibrate to 60 mm W. G., if required.
Caution!
Ventilation air fans, if any, blowing towards the device and
Danger of burns
its suction pipes.
T max = 12a C
Change blowing direction (install deflectors ) of the ventilator to ensure
that cold air it is not directed to the oil mist detector or suction pipes.
Check VISATRON heating system. (The heating element is located in
the base plate and is hooked up with the connector plug

to the 24 V power supply!)
Furthermore, a measuring head heating system is available as an option
(see chapter “Options”!).
12.95
7. 01
VN 115/87-EMC
•-V- <*■ 'i' VN 115/87
^j 2 '« (jj)
f
f
It 4
7.01/1
VN 116/87-EMC
VN 116/87
7.01/2
VN 215/87-EMC
VN215/87
7.01/3
7. 02
Item Description Article No. No. of Item Description Article No. No. of
pieces pieces
VN 115/87
1. Connecting casing 10202 1 14. Measuring head for VN 115/87 10201 1

2. Heating element 10051 1 15. Expansion bellows 10023 2
3. Cable clip 10052 1 16. Measuring head suspension, top 10018 2

4. Lower VN part 10032 1 17. Measuring head seal 10022 1
5. Seal 10206 1 18. Srew plug R 1/2" 10208 3
6. Connecting socket 10033 1 19. Screw plug seal 10209 3
7. Valve box seal 10049 1 24. Protecting cover for E-module 10084 1
8. Measuring head suspension, bottom 10019 2 25. Fastening screw for E-module 10085 3
9. Cap seal 10054 2 26. Electronic module for VN 115/ 87 10203 1
10. Screw plug R 1/4" 10083 1 27. Fuse 2 A 10043 1
11. Cover for measuring head 10088 1 28. Fuse cap 10087 1
12. Scavenging air filter 10042 2

13. Circlip for scavenging air filter 10041 2
VN 116/87
1. Valve box VN 116/87 10302 1 16. Expansion bellows 10023 2

2. Heating element 10051 1 17. Measuring head suspension, top 10018 2
3. Cable clip 10052 1 18. Measuring head seal 10022 1
4. Base plate 10032 1 19. Screw plug R 1/2" 10208 2

5. Oil reflux seal 10306 1 20. Seal for Item 19 10209 2
6. Connecting socket 10033 1 21. Pipe connection 10312 2
7. Oil mist seal 10307 1 22. Seal for connecting casing 10313 2
8. Seal for valve box 10305 1 24. Protecting cover for E-module 10084 1
10. Screw plug R 1/4" 10083 1 26. Electronic module VN 116/ 87 10303 1
11. Seal for Item 10 10082 2 27. Fuse 2A 10043 1
15. Measuring head VN 116/87 10301 1
VN215/87
1. Valve box VN 215/87 10402 1 16. Circlip for scavenging air filter 10041 2
2. Heating element 10051 1 17. Measuring head for VN 215 / 87 10401 1
3. Base plate 10032 1 18. Expansion bellows 10023 2
5. Oil reflux seal 10406 1 20. Measuring head seal 10022 1
6. Connecting socket 10033 1 21. Pipe connection, right 10430 1
7. Oil mist seal 10407 1 22. Drain plug for pipe connection 10412 6
8. Valve box seal 10405 1 23. Rubber sleeve for pipe connect. 10411 2
9. Measuring head suspension, bottom 10019 2 24. Protecting cover for E-module 10084 1
10. Clamping plate for pipe connection 10409 2 25. Fastening screw for E-module 10085 3
11. Screw plug R 1/4" 10083 1 26. Electronic module for VN 215/ 87 10403 1

14. Pipe connection, left 10408 1
12.95
7. 03
Item Description Article No. No. of Item Description Article No. No. of
VN 115/87-EMC
pieces pieces
1. Connecting casing 10202 1 14. Measuring head for VN 115/8 -EMC 10601 1
2. Heating element 10051 1 15. Expansion bellows 10023 2
4. Lower VN part 10032 1 17. Measuring head seal 10698 1
5. Seal 10206 1 Srew plug R 1/2“ 10208 3
6. Connecting socket 10033 1 19. Screw plug seal 10209 3
7. Valve box seal 10049 1 24. Protecting cover for E-module 10084 1
9. Cap seal 10054 2 26. Electronic module. VN 115/ 87-EMC 10603 1
10. Screw plug R 1/4" 10083 1 27. Fuse 2 A 10043 1
VN 116/87-EMC
1. Valve box VN 116 / 87 - EMC 10302 1 16. Expansion bellows 10023 2

2. Heating element 10051 1 17. Measuring head suspension, top 10018 2
3. Cable clip 10052 1 18. Measuring head seal 10698 1
4. Base plate 10032 1 19. Screw plug R 1/2" 10208 2
5. Oil reflux seal 10306 1 20. Seal for Item 19 10209 2
6. Connecting socket 10033 1 21. Pipe connection 10312 2
7. Oil mist seal 10307 1 22. Seal for connecting casing 10313 2
8. Seal for valve box 10305 1 24. Protecting cover for E-module 10084 1
10. Screw plug R 1/4" 10083 1 26. Electronic module VN 116/ 87- EMC 10707 1
15. Measuring head VN 116 / 87- EMC 10706 1
VN 215/87-EMC
1. Valve box VN 215 / 87 - EMC 10402 1 16. Circlip for scavenging air filter 10041 2
2. Heating element 10051 1 17. Measuring head.VN 215 / 87- EMC 10801 1
3. Base plate 10032 1 18. Expansion bellows 10023 2
5. Oil reflux seal 10406 1 20. Measuring head seal 10698 1
6. Connecting socket 10033 1 21. Pipe connection, right 10430 1
7. Oil mist seal 10407 1 22. Drain plug for pipe connection 10412 6
8. Valve box seal 10405 1 23. Rubber sleeve for pipe connect. 10411 2
9. Measuring head suspension, bottom 10019 2 24. Protecting cover for E-module 10084 1
10. Clamping plate for pipe connection 10409 2 25. Fastening screw for E-module 10085 3
11. Screw plug R 1/4" 10083 1 26. Electronic module VN 215/ 87- EMC 10802 1
14. Pipe connection, left 10408 1
12.95
7. 04
Service - Box
A
Re - order
spare parts
taken out!
12.95
7. 05
Item Designation Art. No. Quantity
1. Manual in English 10024 1

2. Quick connecting for U- tube manometer 10053 1
3. Gasket 10054 1
4. Wrench mounting of electronic module 10031 1
5. Filter for pressure reducer 10002 1
6. "Upper" spring for elastic mounting of the measuring head 10018 2
7. "Upper" distance bolt for elastic mounting of the measuring head 10019 2
8. Flexible clamp ring for distance bolts for mounting of the measuring head 10020 4
9. "Lower" spring for elastic mounting of the measuring head 10033 2
10. "Lower" distance bolt for elastic mounting of the measuring head 10034 2
11. Oil return gasket VN 115 / 87 - EMC, VN 115 / 87 10155 1
12. Bottle with alcohol 10035 1
13. Cleaning needle 10135 1
14. Cottonstick for cleaning of infrared filters 10036 5
15. Bottle with slacked water 10040 1
16. Screwdriver for mounting of measuring head 10037 1
17. Screwdriver for adjustment of alarmborder 10038 1
18. Coloured glas, 5% 10039 1
19. Safety ring for fresh air filter 10041 4
20. Fresh air filter 10042 6
21. Flexible bellow for connection of measuring head with base plate 10023 2
22. Fuse 2A / semi time- lag 10043 10

23. Oil return gasket VN 116 / 87 - EMC, VN 116 / 87 10406 1
24. Hexagon wrench for valve box mounting 10044 1
25. Oil mist gasket valve box VN 116/87- EMC, VN 116/87, and 10407 2
VN 215 / 87 - EMC and VN 215 / 87
26. Lockplug for not connected tube at VN 215 / 87- EMC and VN 215 / 87 10412 3
27. Rubberplate for tube connection at VN 215 / 87- EMC, VN 215 / 87 10411 2
28. Mouth piece for cigarette burner 10045 1
29. Ring box end wrench 10156 1
30. Hexagon wrench for release of lockscrew at cover of measuring head 10047 1
31. Screwdriver 4 mm 10157 1
32. Pliers for mounting of safety rings for fresh air filters 10048 1
33. Gasket for valve / box connecting frame / connecting cover 10049 1
34. Plastic bag for cigarette smoke 10050 1
35. Clamp plate for tube connection at VN 215 / 87- EMC, VN 215 / 87 10409 2
36. U- tube manometer 10046 1
12.95
8- 01
VISATRON - Service Facility Adresses
Australia Finland
CJA Marine Technology Schaller Automation
Division of C. Johow & Assoc. PTY. LTD. Industrielle Automationstechnik KG
Unit 3 Industriering 14
136 Cochranes Road 66440 Blieskastel
Moorabbin- Victoria 3189 Germany
Phone-no.: ++61 - 3 - 95 32 13 86 Phone-no.: ++49 - 68 42 / 508 - 0
Telefax-no.: ++61 - 3 - 95 32 14 13 Telefax-no.: ++49 - 68 42 / 508 - 260
Telex-no.: 44 685
Brazil France
Teletronic Sofraret
Equipamentos Eletronics Ltda. 48, Rue de Rome
Av. Venezuela, 3- salas 602- 03- 04 75008 Paris
CEP 20081 Phone-no.: ++33 - 1 - 45 22 40 84
Rio de Janeiro, R. J. Telefax-no.: ++33 - 1 - 42 94 99 01
Phone-no.: ++55 -21 -2 53 60 07 Telex-no.: 280 430
Telefax- no.: ++55 -21 - 5 16 16 29
Greece
Th. Mantanovitch S. A.
Croatia 5 - 7 Aghiou Nicolaou Street
Lemaar Co. 18537 Piraeus
Bosnaska 4 Phone-no.: ++30 - 1 - 4 51 38 68
21000 Split Telefax Nr.: ++30 - 1 - 4 13 69 49
Phone-no.: ++385 -21-584 325 Telex-no.: 2117 71
Telefax- no.: ++385 -21-584 325
Hong Kong
Hua Xing Equipment Ltd.
Denmark 11/ F Hong Kong
J. KlitsoA/S Computer Centre,
Hirsemarken 1 54 - 62 Lockhart Road
3520 Farum Wanchai, Hong Kong
Phone-no.: ++45 - 44 - 99 70 00 Phone-no.: ++852 - 8 65 68 03
Telefax- no.: ++45-44-99 70 10 Telefax-no.: ++852 - 8 61 14 70
Telex-no.: 3 33 10 Telex-no.: 6 53 97
Italy
International Marine
Germany Equipment and Services
Claus- D. Christophel Ing. A. Cacciottoli Sas
Automations- und Elektrotechnik GmbH Via Cassa di Risparmio 6
Georgswerder Bogen 7 34121 Trieste
21109 Hamburg Phone-no.: ++39 - 40 - 66 05 50
Phone-no.: ++49 - 40 - 75 49 66 0 Telefax-no.: ++39 - 40 - 66 06 20
Telefax- no.: ++49 - 40 - 75 49 66 24 Telex-no.: 46 02 09
12. 95
8- 02
VISATRON - Service Facility Adresses
Japan Singapore 2262

Nippon Vulkan Co. Ltd. Bond Instrumentation
Nikko Building, 2nd Floor (Singapore) Pte. Ltd.
3- 372 Miyahara- Cho, Omiya 8 Gul Street 3
Saitama- PFT, Japan 330 Singapore 629265
Phone-no.: ++81 - 48 - 6 54 48 11 Phone-no.: -I-+65 - 8 61 42 79
Telefax-no.: ++81 - 48 - 6 54 48 10 Telefax-no.: ++65 -8 62 40 62
Telex-no.: 5 06 50
Korea Spain
BUM- A Trading Co. Ltd. Guillermo F. Mallet S.A.
Hongsun Building, 166- 5 Boix Y Merer, 6
Samsung- Dong 28003 Madrid
Kangnam- Ku Phone-no.: ++34 - 1 - 5 54 91 05
Seoul Telefax-no.: ++34 - 1 - 5 34 01 82
Phone-no.: ++82 - 2 - 5 66 33 40
Telefax-no.: ++82 - 2 - 5 65 00 64 Bygap S.L.
Rambla de Montserrat, 21
08290 Cerdanyola (Barcelona)
Benelux Phone-no.: ++34 - 3 - 5 80 94 44
Van Stigt B. V. Te!efax-no.: ++34 - 3 - 5 80 98 20
Avelingen- West 30
4202 MS Gorinchem
Phone-no.: ++31 - 183 - 63 29 06 USA
Telefax-no.: ++31 - 183 - 63 10 66 Diesel Monitoring Systems Inc.
4900 Mill Street
Building A-4
Norway Reno, Nevada 89511
Maxeta A/ S Phone-no.: ++1 - 7 02 - 8 26 20 03
Porsgrunnsveien 225 Telefax-no.: ++1 - 7 02 - 8 26 20 04
3901 Porsgrunn
Phone-no.: ++47 - 35 - 59 77 55
Telefax-no.: ++47 - 35 - 59 79 40 United Kingdom
Bond Instrumentation
& Process Control Ltd.
Poland Drakes Lane, Industrial Estate
P.P.H. Gdanpol Boreham/ Chelmsford
Al. Niepodleglosci 739 A Essex CM3 3BE
80967 Sopot 1 Phone-no.: ++44 - 2 45 - 36 01 91
Phone-no.: ++48 - 58 - 51 72 41 Telefax-no.: ++44 - 2 45 - 36 22 48
Telefax-no.: ++48 - 58 - 51 08 55 Telex-no.: 99 51 15
12. 95
X
I I
1
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Brochures, Leaflets, etc.
12.95
I*
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&*■
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• • • 10. 01
General Information
Recycling
Forms:
Error descriptions
12.95
SCHALLER - AUTOMATION
IndustriGHe
<D
Aucomatlonstechnlk KG
Bs-a-oa Blieskastel, Industriening 1 -a
Tel. :tOBS-a21 50S-0. Fax CQBB-aB) SOB-BBO
1
XX i_i I u IV /\ I lu rsi
Why do you declare this unit faulty ?
Please fill out this form sheet when replacing electronic card, measuring head or complete OMD
and add the issued sheet to the unit when shipping it to SCHALLER Automation or Repesentative.
Thanks in advance !
You can send this information sheet also by Fax or mall in case the VISATRON oil mist detector is
malfunctioning. We will reply immediately giving you technical advice. Pleas write us particulars.
Name: You have on hand:
Vessel/plant: □
Fax: Manual, Art. No 10024
Phone : Service Box, Art. No. 10055 □
Telex: Installation instructions
Art. No. 10055 □
1.) Ready LED OFF Yes □ No □ '
If Yes mark with a cross which LED on the LED chain (red LED’s from 1 to 14) is blinking:
No % Please insert data to enable identification:

Alarm 14 7
Oil Mist Detector Type: VN 115 / 87 □ , VN 116 / 87 □ , VN 215/87 0
o _ 5
10 ~
Serial No. : (At label of measuring head ) example: IIS-11111
Test 1
o ^ Hl06
numbers, 1 alphabetical letter, dash(-), 5 numbers)
4 Uh
Ready —, |0.3
a 1 bo Oil Mist Detector is installed at:
Main Engine □ Aux. Engine D
VN21»/«r
Engine manufacturer:
Engine type:_______
1.1) In case No 14 is blinking:

LED No 14 Is blinking
Replace Sintered bronze filter
1
Clean fresh air bores( on both sides)
a w Check / adjust suction pressure (60-80 mm water column)
Replace 4.
dirty air
filters
2. Adjust air pressure
dirt
needle*^' y/
(maxlenght ^
11mm)
Clean both fresh air bores Measure air vacuum at detector
Malfunction still present Yes □ NoD
121 In case LED No. 13 is blinking:

Clean the infrared filter glasses on both sides with cotton sticks and alcohol or detergent.
3. LED No. 13 is blinking
Malfunction still present YesD NoD
Clean glasses
Above described procedures performed
Yes D No □
If "no", due to the lack of:
spares □, tools □, time □
Please turn page
5CMAI-I-ER
SCHALLER - AUTOMATION
<©
IndustrlellB Automatlonstechnlk KG
Blieskastel, Industrioring
TaI.:COSB-aS3 50S-0, Fax C06B423 5QB-2BO nbj I tJivi/x I luisi
2.) Condition of Reset Button:

Button mechanically damaged: □ No response when button is pressed □
3.) Valve box working properly (if present) Yes □ No □
4.) Condition of cables of device, OK ? Yes □ No □

Yes □ NoD
5.) Condition of plugs , OK ?
Yes □ NoD
6.) No LED is illuminated at all
Check power supply at terminals 1(+) and 2(-) with volt-meter
Minimum is 18 V =
□□v
Maximum is 30 V = Value:
7.) Problems with performance:

Emergency shut downs caused by Oil mist high concentration alarms without obvious reasons.
7.1) Device is giving oil mist alarm occasionally D, or permanently □
During: Engine start □ Warm up

□
increasing load □ decreasing load
□
shut down □ various condition
□
7.1.2) Engine crankcase checked Yes □ No □
If Yes damages found Yes □ No □
water leakage found Yes □ No □
condensed water found Yes □ No □

7.1.3) Suction pipes and pipe connection box / valve box of device checked
Yes □ NoD
Yes □ NoD
If Yes: lots of oil found
Yes □ NoD
condensed water found
7.1.4) Open control cover and check inside
Yes □ NoD
lots of oil found
condensed water found Yes □ NoD
7.1.5) Check suction pressure with U-Tube Manometer (see previous page)
□□□ mm WC ( normal: 60-80 mm Water column)
Measured value:
7.1.6) Position of Alarm level Switch SI (At display)

□
Your additional Comments:
Yours truly
Schaller Automation
Please turn page
I
• r .
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It
I
/ Notes
' ■
11. 01
12.95
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Notes
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12. 01
Options
List of Options for VN 87
As an option, the following device extensions can be supplied for
the oil mist detectors of series 87:
Item Description Article No.
1 Protecting cover 10015

2 Pressure control unit with input throttle 10001
3 Typhoon filter 10632
4 Measuring head heating system 10671
5 Pressurised air scavenging 10752
6 Analog opacity indicator 10058
7 Siphon block assembly systems
Description of the individual items
Itemi, Protecting cover

The protecting cover can easily be mounted on the four provided threads on the
base plate of the VN device. It serves to protect the device against mechanical
damage and contamination.
Item 2, Pressure regulator unit
The pressure reducer unit consists of a pressure reducer and a throttle block.
Both parts are mounted together on a frame which is fastened by 3 screws, M8.
The pressure reducer device is especially designed to supply the draft air to the
VISATRON ( VN ) device. The throttle block ensures that the negative pressure
.1
in the VN is limited and does not surpass 25% above of the calibrated negative
pressure, should a failure occur in the pressure reducer ( e. g. rupture of the
diaphragm, etc.).
In addition, the throttle block is equipped with a filter to retain impurities

from the plant air supply.
12.95
12. 02
Item 3, Typhoon filter
The typhoon filter serves as a pre- filter for supplying fresh air to the scavenging
air chambers of the VN device.

The typhoon filter is laterally affixed to the protecting cover of the VN device.
The filter outlet and is joined to the air inlet at the inspection cover of the VN device
by means of a flexible hose.
The typhoon filter considerably increases the service life of the fresh air filter
(sinter bronze ), in particular, if the power plant is operated under contaminated
ambient air conditions, such as dusty air, or if the plant is operated in regions
where the air humidity is high. The typhoon filter is furnished with a filter cartridge
which can be cleaned with compressed air ( blowing from inside outwards )
or, if required, be replaced with by unscrewing the top cover.
The typhoon filter consists of:

- a complete filter
- a special inspection cover for the measuring head
- a connecting hose
Item 4, Measuring head heating system
A standard heating element is installed in all the VN 87 series, in the base plate.
This heating unit might not be sufficient to cover all cases ( cases of extreme
humidity in the crankcase, higher water content in the lubricating oil or lower than
normal ambient temperatures).
The measuring head heating system serves to warm up the top of the measuring
head and the crankcase gas flowing through the VN device, in order to avoid
condensation of water, especially in climatic zones with high humidity or low
temperatures. Condensation of water may trigger a false high oil mist alarm when
small droplets of water are detected by the optical measuring track and shut down
the engine.
The measuring head heating system can be mounted on top of the measuring
head and replaces the heating system in the base plate. The power supply is
connected in the same way as the heating system of the base plate by means of a
plug under the main Harting plug on the base plate.
12.95
12. 03
item 5, Pressurised air scavenging
By means of driving air scavenging it is possible to provide filtered air to the
scavenging air chambers independent of the ambient air.

This option is recommended to prevent false alarms with consequential
engine shut downs due to a fire with smoke development in the engine room.
The smoke may reach the VN device, entering through the fresh air slots in the
inspection cover, passing through the fresh air filters ( sinter bronze filters ) to the
optical measuring track, triggering a high oil mist alarm. The pressurised air
scavening receives the air through the nozzle of the draft pump which is connected
with a hose to the special inspection cover on the measuring head. The air flow is
metered by special jets located in the nozzle and inspection cover.
Item 6, Analogue opacity indicator

The analogue square shaped opacity indicator may be utilised for all VN 87 devices.
Its dimensions are 96 x 96 mm and it is appropriate for the installation into

switchboards or panels. The analogue opacity indicator is connected to the
terminals 9 (+) and 10 (-) of the VN 87 device. The relative distance to the adjusted
alarm level is indicated on a scale from 0 to 1, meaning 0% to 100% beeing away
from the alarm level.
Example: If the measured opacity has reached a value corresponding to 50%
of the adjusted alarm level, the analogue opacity indicator will display the value 0.5.
Item 7, Siphon block assembly systems
Siphon blocks are devices which enable to drain the accumulated oil, from the oil
mist suction pipes, directly back to the engine crankcase. The siphon blocks allow
a horizontal suction pipe installation, from compartment to compartment.
Conventional suction pipe systems, without siphon blocks, require to be installed
with a gradient of 2% to 4% ascending to the VN device, in order to drain the
precipitated oil back to the engine.

It is imperative to drain the oil to the crankcase and avoid potential clogging.
Special engine-oriented assembly systems in modular design are available for

VISATRON Oil Mist Detectors for a large number of two- and four- stroke engine
types of various manufacturers.
12.95
5
36618E
WOODWARD
PG-200/PG-300
Case, Accumulator,
and Power Cylinder
installation and Operation Manual
Manual 36618E
WARNING
A 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.
The engine, turbine, or other type of prime mover should be equipped with
an overspeed (overtemperature, or overpressure, where applicable)
shutdown device(s), that operates totally independently of the prime mover
control device(s) to protect against runaway or damage to the engine,
turbine, or other type of prime mover with possible personal injury or loss
of life should the mechanical-hydraulic governor(s) or electric control(s),
the actuator(s), fuel control(s), the driving mechanism(s), the linkage(s), or
the controlled device(s) fail.
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.
© 1 D'T? by Woodward Governor Company
Alt Rights Reserved
Manual 36618 PG-200/-300 Case, Accumulator, and Power Cylinder
Contents
CHAPTER 1. GENERAL INFORMATION ............. 1

Description .................................................................. 1
Optional Accessories.................................................. 2
PG Governor Heat Exchanger (Remote Only) 2
Booster Servomotor........................................... 2
References.................................................................. 3
CHAPTER 2. INSTALLATION ......... 7

Receiving............................................. 7
Storage................................................. 7
Installation Requirements.................. 8
Installation ........................................... 8
Fuel System Linkage.......................... 8
Hydraulic and Electrical Connections 8
Booster Servomotor ........................... 9
Heat Exchanger.................................. 9
Oil Supply ............................................ 9
Oils for Hydraulic Controls................. 9
CHAPTER 3. OPERATION AND ADJUSTMENT 13

Initial Operation ........................................................ 13
Adjustments............................................................... 13
Compensation Needle Valve Adjustments........... 13
Pressure ..................................................................... 14
CHAPTER 4. PRINCIPLES OF OPERATION 15

Introduction......................................................... 15
Amplifier Section ................................................ 15
Oil Pump and Accumulator....................... 15
Power Servo .............................................. 16
Governor Section ............................................... 16
Pressure Reducing Valve ........................ 16
Governing Section ..................................... 18
PG-200/PG-300 ......................................... 19
Increase of Speed Setting or Load......... 19
Decrease of Speed Setting or Load ....... 20
Compensation Cutoff................................ 20
CHAPTER 5. MAINTENANCE 21
Governor Oil ............................. 21
Troubleshooting....................... 21
Repair and Disassembly ........ 22
Woodward
PG“200/-300 Case, Accumulator, and Power Cylinder Manual 36618
Contents
CHAPTER 6. PARTS INFORMATION 23

Parts Replacement Information.......... 23
Parts List for Figure 6-1 ...................... 23
Parts List for Figure 6-2...................... 25
CHAPTER 7. SERVICE OPTIONS ..................... 35

Product Service Options...................................... 35
Replacement/Exchange .............................. 35
Flat Rate Repair............................................ 36
Flat Rate Remanufacture ............................ 36
Returning Equipment for Repair.......................... 36
Packing a Control ......................................... 37
Additional Instructions.................................. 37
Replacement Parts Information........................... 37
How to Contact Woodward.................................. 37
Other Service Facilities......................................... 38
Additional Aftermarket Product Support Services 38
Technical Assistance............................................ 40
Illustrations and Tables
1-1. Right Front View of PGA-200/300................................................. 4

1-2. Lifting Sling for PG-200/300 Governor......................................... 5
1-3. Outline Drawing of PG-200/300 Governor................................... 6
2-1. Viscosity and Operating Temperature of Oils.............................. 12
2-2. Equivalent Viscosities for Lubricating Oils................................... 12
4-1. Schematic of PG-200/PG-300 ..................................................... 17
6-1. Parts for PG-200 Case, Accumulator, and Power Cylinder....... 24
6-2. Parts for Power Piston Assembly and Pilot Valve Assembly..... 25
6-3. Parts for Output Assembly and Reducing Valve Assembly....... 26
6-4. Parts for Servo Assembly ............................................................. 27
6-5. Parts for Accumulator Assembly (old style)................................. 28
6-6. Parts for Vibration Resistant Accumulator Assembly (new style) 29
6-7. Drive Shaft Assembly.................................................................... 31/34
II Woodward
Chapter 1
General Information
This manual describes the PG-200/PG-300 case, accumulator, and power

cylinder operation. Infomiation is provided on governor installation,
adjustments, and maintenance.
This manual only gives information pertaining to the PGA/PGG-200 and -300,
not to any ot the combined PGA-EG/PGG-EG units. Refer to manual 36637 for
more information.
Description
The PG-200/PG-3(X) assembly is a PG type governor and an integral, hydraulic
amplifier unit. The large accumulator and oil pump supply high pressure oil
(1379 or 2482 kPa/200 or 360 psi) to the power servo. The power servo is
differential in operation, needing oil pressure to move it in either the increase-
fuel or decrease-fuel direction. To control the governor output position of the
power servo, oil How to or from the power servo is controlled by a relay pilot
valve. The relay pilot valve consists of a pilot valve bushing and pilot valve
plunger.
A pressure reducing valve reduces the high pressure oil (1379 or 2482 kPa/200
or 360 psi) to a lower pressure (758 or 827 kPa/110 or 120 psi) for operation of
the control section of the PG governor.
In operation, a centrifugal flyweight head and pilot valve assembly senses speed
changes and controls the flow of governor oil to a relay cylinder. The relay
cylinder(a 16.3 J/12 ft-lb single-acting piston) positions the relay pilot valve to
control the power piston output position.
A compensating system gives stability to the governing system. It includes the

compensation needle valve, the compensation land of the pilot valve plunger, a
buffer piston, and two buffer springs.
A short description of the setting of governor speed is given in this manual to aid
in the understanding of the basic operation.
PG-200 PG-300
accumulator pressure 1379 kPa/200 psi 2482 kPa/360 psi
output shaft diameter 1.125-48 serrated 1.500-60 serrated
Woodward 1
PG-200/-300 Case, Accumulator, and Power Cylinder Manual 36618
Optional Accessories
The PG-200/PG-300 is designed for the PGE, PGA, PGPL, PGG, PGL, and PGD
column assemblies to meet a variety of customer requirements. Different
methods of setting speeds and optional auxiliary equipment are available on the
column assembly for use. by themselves or in combination, with the PG-200/PG-
300. The auxiliary equipment performs a secondary function such as limiting
engine load, controlling engine load to maintain constant power output for each
speed adjustment, starting fuel limiting, permitting temporary overloads, etc.
Optional accessories used on the PG-200/PG-300 case assembly include:
PG Governor Heat Exchanger (Remote Only)

The heat exchanger is used to lower governor oil temperature when the governor
operates in high ambient temperatures. It should be used whenever the governor
will go above 93 ®C (200 °F) maximum operating temperature. When a governor
heat exchanger is needed, it can be added without change or conversion to the
PG-200/PG-300.
NOTE
Some PG-200/PG-300 governors (manufactured before 1979) have a
pressurizing valve which may have been disabled. If a heat
exchanger Is added to one of these governors, the pressurizing valve
(Figure 6-1, #4) should be disassembled and checked to be sure that
it has not been disabled with a cotter pin. If a cotter pin is present, it
must be removed before the pressurizing valve is replaced in the
governor.
Booster Servomotor
The booster servomotor is used with the governor to help the prime mover start
quickly by moving the governor output toward the maximum fuel position at
startup. A high output booster having a 1:1 or higher pressure ratio is necessary
when used with the PG-200/PG-300 governor. A fuel limiter, an option on the
PG column assemblies, is sometimes necessary when the booster servomotor is
used.
2 Woodward
References
This manual is one of several lhal must be used to describe a model of the
PG-200/PG-300 governor. For help in selecting optional features of the
governor, or if field conversion is necessary, write or call one of the Woodward
offices shown on the back of this manual.
Manual Title
25071 Oils for Hydraulic Controls
25075 Commercial Preservation Packaging for Storage of Mechanical-
Hydraulic Controls
36036 Starting Fuel Limiter for PG Governors
36052 Magnetic Speed Pickups for PG, UG8 and UG-40 Governors
36404 Analysis and Correction of PG Governing Troubles
36601 Absolute Manifold Pressure Bias Load Control and Fuel Limiter
36604 PGA Marine Governor
36614 PG Governor Dial Type Speed Setting
36615 PG Governor Lever Type Speed Setting
36621 PG Governor Speed Droop Linkage
36627 PGG Governor
36630 Basic Load Control System for PG Governors
36637 Integral EG Actuator for PG Governors
36640 Extensible Tailrod for PG Governors
36641 Governor Oil Heat Exchanger
36650 Solenoid Operated Shutdown Assembly
36651 Pressure Actuated Shutdown Assembly
36652 Automatic Safety Shutdowns and Alarms
36653 Pressure Actuated Shutdown for PGD and PGL Governors
36661 Manifold Gauge Pressure Fuel Limiter
36662 Torque Limit Control with Speed Droop
36684 Booster Servomotor
36685 PG Shutdown Solenoid
36686 Pneumatic Load Balance System for PGA Governors
36691 Electronic Speed Setting for PG Governors (PG-TR)
36694 PG-PL Governors
36695 Manifold Air Pressure Bias Fuel Limiter (Single Barrel Model)
Woodward 3
COLUMN AND
COVER ASSEMBLY
DIP STICK
ACCUMULATOR
INDICATOR SCALE
(EITHER SIDE)
OUTPUT SHAFT
MOUNTING BASE ' (BOTH SIDES)
Figure 1-1. Right Front View of PGA-200/300
4 Woodward
I
t
NYLON WEB SLINO. APPROXIMATELY

9 1/2 FEET LONG.
APPROXIMATE WEIGHT
OF THE PG200 IS
157.S K (350 LBS.)
3e<CÂ-29l
Figure 1-2. Lifting Sling for PG-200/300 Governor
Woodward 5
PG-200A300 Case, Accumulator, and Power Cylinder Manual 36618
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Figure 1 -3. Outline Drawing of PG-200/300 Governor
6 Woodward
Chapter 2
Installation
This chapter covers receiving, storage, and installation requirements for the
PG-200/PG-300 governor (see outline drawing. Figure I-3).
WARNING
A The engine, turbine, or other type of prime mover should be equipped
with an overspeed (overtemperature, or overpressure, where
applicable) shutdown device(s), that operates totally independent of
the prime mover control device(s) to protect against runaway or
damage to the engine, turbine, or other type of prime mover with
possible personal injury or loss of life should the mechanical-
hydraulic governor(s) or electric control(s), the actuator(s), fuel
control(s), the driving mechanism(s), the llnkage(s), or the controlled
device(s) fail.
Be careful when handling and installing the governor. Do not hit the drive shaft
or output shaft. Rough handling can cause damage to seals, parts and
adjustments.
Receiving
The PG-200/PG-300 governor is shipped from the factory in a vertical position,
bolted to a wood platform. The governor has been calibrated at the factory to
exact specifications, then drained of oil. A light film of oil covers the internal
parts to help prevent rust. Calibration or internal cleaning is not needed before
installation and operation. The drive shaft and output shafts are covered with a
light film of oil, and a soft seal preservative can be applied at the customer's
request. The seal preservative is removed before installation with a cloth and
mineral spirits.
storage
If the PG-2(X)/PG-300 governor is to be in storage for a period of lime, see the
Woodward specification procedure, 25075, Commerciol Preservation Packaging
for Storage of Mechanical-Hydraulic Controls.
Woodward 7
Installation Requirements
See Figure 1-3 for overall dimensions, location of installation holes, hydraulic
fitting sizes, output and drive shaft dimensions, and adjustment locations.
Enough clearance must be allowed for installation, removal, and servicing of the
governor. The governor oil drain should be easily accessible.
Installation
Install the PG-200/PG-300 governor on the engine accessory drive pad. The
drive shaft must slip into the accessory drive or mating coupling without force.
Be careful not to push the drive shaft into the governor. Improper alignment or
too light a fit between any of the parts can result in wear or seizure. It can also
cause Jiggle in the governor output.
CAUTION
A Damage to the drive shaft, drive shaft seal, or other parts of the
governor may occur if the governor is dropped or set on the drive
shaft or drive coupling.
Fuel System Linkage

Correctly align and install the linkage between the fuel system and the
PG-200/PG-300 governor. The linkage must move freely and not have excessive
backlash. Use approximately 2/3 governor output travel (26®) between idle and
full fuel. Permit enough overtravel (typically 7°) so the governor can cause
complete shutdown and give full fuel at full load. The governor output travel
between shutdown position and idle speed must never be less than 5°. Many
governors include an optional compensation cutoff and since this option cannot
be seen without disassembly of the governor, this caution must be followed:
CAUTION
A Due to the location of the compensation cutoff port In the relay servo
wall, it is necessary to adjust the governor output linkage to use no
less than 5° travel between shutdown and Idle.
Compensation cutoff is more completely described in Chapter 4, Principles of

Operation.
Hydraulic and Electrical Connections

Make all other hydraulic and electrical connections, if any, for the particular
model PG-2(X)/PG-300 being installed. Use the correct Woodward manuals.
8 Woodward
Booster Servomotor
The boosler servomotor is remotely located from the governor. Make all
hydraulic connections from the booster to the governor (see Manual 36684,
Booster Sen'oniotor). The booster servomotor is actuated by a starting air
pressure of 1034 to 1379 kPa (150 to 200 psi), and pressure oil from the booster
moves the servo piston to the maximum fuel position. Make the starling air
connection to the booster at the optional air supply inlet (the orificed inlet). Plug
the other inlet. The governor fuel position during startup can be controlled by the
fuel limiter (if available). Because of the large volume of oil needed to move the
PG-200/PG-300 servo, the boosler limit screw should be adjusted to permit
maximum booster servo output.
Heat Exchanger
The heat exchanger is remotely located from the governor. Make all hydraulic
connections for the heat exchanger to the governor (see manual 36641, Governor
Oil Heat Exchanger). If a heat exchanger is added to a governor manufactured
before 1979, the pressurizing valve (Figure 6-1, #4) should be removed and
checked to be sure that it has not been disabled with a cotter pin. If a cotter pin is
present it must be removed before the valve is replaced in the governor.
If a heat exchanger is added to a governor that does not have a pressurizing

valve, a pressurizing valve must be installed.
Oil Supply
Until the governor has been run and the accumulator filled, approximately four
liters/quarts of oil will fill the governor. Governor oil capacity is 7.1 liters (7.5
quarts), and it is necessary to add oil after the governor is first started in order to
restore oil to the full level mark on the dipstick. Check the oil level with the
governor running.
Oils for Hydraulic Controls

This information is provided as a guide in the selection of lubricaling/hydraulic
oil for governor use. Oil grade selection is based on viscosity change over the
temperature range of the governor. The information also provides an aid in
recognizing and correcting common problems associated with oil used in
products manufactured by Woodward. It is not intended to suggest the selection
of lubrication oil for the engine, turbine, or other type of prime mover being
controlled.
Woodward 9
Governor oil lubricates and provides hydraulic power. The oil must have a
viscosity index that allows it to perform over the operating temperature range
and it must have the proper blending of additives to cause it to remain stable and
predictable over this range. Governor fluid must be compatible with seal
materials, (i.e., nitrile, polyacrylic and fluorocarbon). Many automotive and gas
engine oils, industrial lubricating oils, and other oils of mineral or synthetic
origin meet these requirements. Woodward governors are designed to give stable
operation with most oils, if the fluid viscosity at the operating temperature span
is within a 50 to 3000 SUS (Sayboll Universal Seconds) range. Ideally, at the
normal operating temperature, viscosity should be between 100 and 300 SUS.
Poor governor response or instability usually is an indication that the oil is loo
thick or too thin.
Excessive component wear or seizure in a governor indicates the possibility of:
1. Insufficient lubrication caused by:

A. An oil that flows slowly either when it is cold or during startup.
B. An oil line restriction, obstructions within or bends in the line.
C. No oil in the governor or governor oil level too low.
2. Contaminated oil caused by:
A. Dirty oil containers
B. A governor exposed to heating and cooling cycles, creating
condensation of water in the oil.
3. Oil not suitable for the operating conditions.
4. An improper oil level which creates foamy, aerated oil.
Operating a governor continuously beyond the high limit temperature of the oil
will result in oil oxidation, identified by varnish or sludge deposits on the
governor parts. To reduce oil oxidation, lower the governor operating
temperature with a heat exchanger or other means, or change to an oil more
oxidation resistant at the operating temperatures.
WARNING
A A loss of stable governor control and possible Prime Mover
overspeed may result if the viscosity exceeds the 50 to 3000 SUS
range. Overspeed can damage the engine and cause personal injury
or death.
Specific oil viscosity recommendations are given in the chart. Select a readily
available good brand of oil, either mineral or synthetic, and continue using it. Do
not mix the different classes of oils. Oil that meets the API (American Petroleum
Institute) engine service classification in either the “S” group or the “C” group,
starting with “SA” and “CA” through “SF’ and “CD” is suitable for governor
service. Oils meeting performance requirements of the following specifications
are also suitable: MIL-L-2104A, MILL-2104B, MIL-L-2104C, MIL-L-46152,
MIL-L-46152A, MIL-L-46152B, MIL-L-45199B.
10 Woodward
Replace the governor oil if it is contaminated, or if it is suspected of contributing
to governor instability. Drain the oil while hot and agitated; and Hush the
governor with a clean solvent having some lubricity before refilling with new oil.
If drain time is insufficient for the solvent to completely drain or evaporate, flush
the governor with the same oil it is to be refilled with to avoid dilution and
possible contamination of the new oil. To avoid contamination, replacement oil
should be free of dirt, water, and other foreign material. Use clean containers to
store and transfer oil.
Oil that has been carefully selected to match the operating conditions and is
compatible with governor components should give long service between oil
changes. Under ideal conditions (minimum exposure to dust and water and
within the temperature limits of the oil), changes can be extended. A regularly
scheduled oil analysis is helpful in determining the frequency of oil changes.
Any persistent or recurring oil problems should be referred to a qualified oil

specialist for solution.
The recommended continuous operating temperature of the oil is 60 to 93 °C

(140 to 200 ®F). Measure the temperature of the governor or actuator on the
outside lower part of the case. The actual oil temperature will be warmer by
aboul6°C(10 °F).
Woodward 11
RECOMMENDED RECOMMENDED
UPPER UU'T UPPER LIMIT
OF PETROLEUM OF SYNTHETIC
ANY OIL LISTED IS C-NLY A SUGGESTION USE THE 'OIL OtL IS 20CT OIL IS 250T
OF YOUR CHOICE WITH THE CORRECT VISCOSITY AS
INDICATED IN THE CHART
T
COV OH OFERATINC i -40T I20T I60T 200T 240T
TEMPEFATURE -40X
OT
-15X 40Y oOT
27-C 4j‘C 71-C ne-C
^■c 53T
SAE 40
Z:2A
POOF PO^NT msEM SAE 30
T
SAE 20
jU.
FETSOLEUM
577 SAE 10
SC SUS LIMIT
(7 5 CST)
OHS
SAE 10WK' ■E
'4^ V/A,,
SAE I0«40
z SaE 2CW4C
SAE ISlVAO
AUTO TRANS.
FLUID
7/ TYPE A-F
DEXRQN II CL
WMmWMyA ALL PROOF lOWSC
AUSOIt 10W40
SyntmE T)C
ZjU. ON 600
V.
OILS
MOBILE I
i4w.i>«ii«c wTQ»oe»Atc»i)
DElVAC i I
»'P»OC*P*OMS;!
wmmm
LIMITED OPEPATION AT IDEAL OPERATING LIMITED OPERATION AT
( FOUR POINT
LOW TEMPERATURE range HIGH TEMPERATURE
* V \s.
LEGEND
3000 SUS 300 SUS TOO SUS 50 SUS

(6£0 CST) (65 CSTj (20 CST) (7 5 CST)
RECOMMENDED
UPPER
ACCEPTABLE OPERATING RANGE TEMPEPATURE
LIMITS
250-07SH
Figure 2-1. Viscosity and Operating Temperature of Oils
VISCOSITY COMPARISONS
CENTISTOKES SAYBOLT UNIVERSAL SAE MOTOR SAE GEAR
(CST. CS. OR CTS) SECONDS (SUS) NOMINAL (APPROXIMATE) (APPROXIMATE) ISO
60 5W 15
106 5W
22 22
32 151 75 32
10W
46 214 75 46
10
310
6e 20 se es
IOC 463 30 SO 100
150 696 40 65 150
220 1020 50 90 220
32C 60 115 320

14S3
46C 70 140 460
2133
250-067
97_n-0< si«
Figure 2-2. Equivalent Viscosities for Lubricating Oils
12 Woodward
Chapter 3
Operation and Adjustment
This section describes the first startup and the basic adjustments of the
PG-2(K)/PG-300 assembly.
Initial Operation
Before the first startup of the PG-200/PG-300, be sure that all steps in Chapter 2
have been done and are correct.
WARNING
A TO PROTECT AGAINST POSSIBLE PERSONAL INJURY, LOSS OF
LIFE and/or PROPERTY DAMAGE WHEN STARTING the engine,
turbine or other type of prime mover, BE PREPARED TO INITIATE AN
EMERGENCY SHUTDOWN to protect against runaway or overspeed
should the mechanical-hydraulic governor(s) or electric control(s),
the actuator(s), fuel control(s), the driving mechanism(s), the
linkage(s), or the controlled devices fail.
Adjustments
Normally, the only requirements for putting a new or repaired and calibrated
governor into service are filling the governor with oil and adjusting the
compensation needle valve to get maximum stability. All other operating
adjustments are made during factory calibration to manufacturer’s specifications.
Further adjustment should not be needed. Do not make an internal adjustment of
the governor unless completely familiar with the correct procedure.
Compensation Needle Valve Adjustments

The compensation needle valve is an adjustable part of the compensation system.
Its setting, which affects governor stability, is made according to the individual
characteristics of the prime mover (see Figure 6-1, #12).
Woodward 13
To Adjust The Needle Valve:
1 With the prime mover operating at IDLE speed, open the compensation
needle valve until the governor begins to hunt. Let the governor hunt several
minutes to remove trapped air in the hydraulic circuits.
NOTE
It may be necessary to upset the governor speed momentarily to
cause the governor to hunt.
2. Close the compensation needle valve slowly until hunting just stops. Keep
the needle valve open as far as possible to prevent slow governor response.
The needle valve setting can be from 1/16 to 2 turns open. Do not close the
needle valve tight. The governor cannot operate correctly in this condition.
3. Check the governor stability by manually disturbing the governor speed

setting. The compensation adjustment is satisfactory when the governor
returns to speed with only a small overshoot or undershoot. Once the needle
valve adjustment is correct, it is not necessary to change the setting unless
there is a large permanent change in temperature that will change oil
viscosity. Additional adjustment may be necessary if stability problems
exist at full speed/full load conditions.
Pressure
Oil pump pressure in the PG-200 model should exceed 1379 kPa (200 psi) at
operating speed. Pressure in the PG-3(X) model should exceed 2068 (300 psi) at
operating speed. To check the internal pressure, attach a pressure gauge in the
.562-18 straight-thread port indicated as oil from booster outlet number 1 in
Figure i-3 of this manual.
14 Woodward
Chapter 4
Principles of Operation
Introduction
This chapter describes the operation of the basic elements of the PG-200/PG-300
case, accumulator, and power cylinder assembly. A schematic drawing (Figure 4-
1) shows the working relationship of the various parts. The speed selling is in the
column assembly of the PG-200/PG-300 governor, and only a short description
is given to aid in understanding the basic operation.
The description of operation is separated into two parts:

• Amplifier section
• Governor section
Amplifier Section
Oil Pump and Accumulator

The PG-2()()/PG-300 has its own oil sump and oil pump. The drive shaft is driven
at a speed proportional to the engine speed by a mechanical connection to the
engine, and rotates the pump drive gear and the rotating bushing. As the inner
pump drive gear turns the outer gear, oil from the sump is drawn by the gear
teeth to the discharge side of the pump. Oil is pushed from the spaces between
the gear teeth as the two gears mesh.
Four check valves, two on the suction and two on the discharge side of the pump,
permit the drive shaft to rotate in either direction without changing the PG-
200/PG-300 operation. If the pump gears were rotated in the opposite direction,
the open check valves would close and the closed check valves would open.
Oil on the discharge side of the pump pushes the accumulator piston against the
accumulator spring. When piston movement uncovers the bypass port, excess
pressure oil from the pump is returned to the sump through the pressurizing
valve or heal exchanger. The accumulator is a reservoir for pressure oil and
operates as a relief valve to limit maximum pressure in this part of the hydraulic
circuit. Pressure is held at a minimum of 1379 kPa (200 psi) in the PG-200, and
2482 kPa (360 psi) in the PG-300.
When the PG-200/PG-300 is used with the optional heal exchanger, oil flows
through the heat exchanger from the accumulator bypass. If the oil flow through
the exchanger becomes restricted, and the pressure reaches 172 kPa (25 psi), the
pressurizing valve opens and directs bypass oil back to sump.
A newer accumulator that is more vibration resistant is available if needed.
Woodward 15
Power Servo
The relay pilot valve controls the flow of 1379 or 2482 kPa (200 or 360 psi) oil
to the power servo assembly. The power piston, working through connecting
linkage, controls the engine or turbine.
The power piston operates as a differential type, requiring pressure oil to move
in either increase fuel or decrease fuel direction. The differential piston has
pressure oil continually directed to the small area side. The constant pressure
tries to move the piston in the decrease fuel direction, but the piston cannot move
to decrease fuel until oil in the passages between the relay piston and the large
area side of the servo piston is released to sump. Oil is connected to the sump
only when the relay pilot valve plunger is below its centered position.
If the relay pilot valve plunger is above the centered position, oil flows to the
control (large area) side of the servo piston. The force that results from oil
pushing on the large surface area which is greater than the constant force on the
loading (small area) side, moves the piston in the increase fuel direction.
NOTE
The power piston can move only when the relay pilot valve is
uncentered and permits oil to flow.
Governor Section
The governing section of the PG-200/PG-3(X) has a pressure reducing valve, a
ballhead, pilot valve plunger, rotating bushing, a compensating system, and a
relay servo.
Pressure Reducing Valve

The pressure reducing valve receives the full output of the oil pump and supplies
690 kPa (100 psi) oil to the governing section and additional speed setting and
auxiliary features included in the column assembly. Oil at 1379 or 2482 kPa (200
or 360 psi) enters the pressure reducing valve at the metering piston, where its
flow is controlled by movement of the metering piston. Pressure on the metering
piston that is greater than 690 kPa/lOO psi causes it to move left against a
reference spring, closing the pressure reducer to restrict oil flow. Pressure lower
than 690 kPa/100 psi permits the reference spring to move the metering piston to
enlarge the inlet.
16 Woodward
Manual 36618 PG-200A300 Case, Accumulator, and Power Cylinder
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Figure 4-1. Schematic of PG-200/PG-300
Woodward 17
PG-200/-300 Case, Accumulator, and Power Cylinder Manual 36618 V,.
Governing Section
The upper end of the rotating bushing holds the ballhcad assembly, giving a
direct drive from the prime mover to the flyweights. The thrust bearing on top of
the flyweight toes pennits the pilot valve plunger to remain stationary while the
bushing rotates. This reduces friction between the bushing and plunger.
A spring driven, oil dampened ballhead can be used to filter objectionable input
torsionals which could be transferred to the governor control output. These
ballheads are more completely described in the Woodward Service Bulletin
50001.
As the ballhead rotates, centrifugal force developed by the flyweights tries to lift
the pilot valve plunger and is opposed by the force of the speeder spring pushing
down. The greater of the two forces moves the pilot valve plunger.
When the prime mover is on speed at any speed setting, these forces are equal
and the flyweights are in a vertical position. In this position the control land on
the pilot valve plunger is centered over the control port in the rotating bushing.
No oil, other than normal leakage, flows to or from the buffer compensation
system or the relay servo.
A change in either of these two forces moves the plunger from its centered
position. The plunger is lowered (1) when the governor speed setting is
unchanged but additional load slows the prime mover and governor (decreasing
flyweight centrifugal force), or (2) when prime mover speed is not changed but
speeder spring force is increased to raise the governor speed setting. In a similar
way, the pilot valve plunger is raised (1) when governor speed setting is not
changed but load is removed from the prime mover causing an increase in speed
(hence an increase in flyweight centrifugal force), or (2) where prime mover
speed is not changed but speeder spring force is reduced to lower the governor
speed setting.
When there is an underspeed condition, the plunger is lowered and pressure oil is
directed into the buffer and compensation sy.stem and relay servo to raise the
relay pilot valve plunger and cause the power piston to move to increase fuel. In
an overspeed condition, the plunger is lifted permitting oil to drain from these
areas to the sump. A return spring moves the relay piston to decrease and also
lowers the relay pilot valve plunger, releasing oil from the left side of the power
servo, allowing movement toward decrease fuel.
A buffer piston-needle valve compensation system which anticipates the inherent

lag in acceleration or deceleration between throttle setting and final speed is
provided in the PG-200/PG-300 control system.
With the governor acting directly on the fuel setting but sensing only actual
engine or turbine speed, extensive overspeed or underspeed would occur at each
speed change were it not for the buffer compensation system. The buffer piston,
springs, and needle valve in the hydraulic circuit between the pilot valve plunger
and the relay servo make up the system.
18 Woodward
Manual 36618 PG‘200/-300 Case, Accumulator, and Power Cylinder
When ihc flyweights move the pilot valve off the centered position, oil flow to or
from ihc small power piston causes a pressure differential across the buffer
piston and needle valve.
The restriction of flow through the needle valve causes oil to flow through the
path that houses the buffer piston and springs and causes the buffer piston to
move against the buffer spring on the low pressure side of the piston. The
amount of pressure differential across this system is controlled by the
combination of needle valve opening and buffer spring scale.
This pressure differential is sensed by the compensation land on the pilot valve,
applying a force tending to oppose the change in force of the flyweights and
move the pilot valve back to the centered position before the set speed is
reached. This negative feedback (droop) reduces overshoot of the set speed and
increases the stability of the control loop. The pressure differential gradually
equalizes through the needle valve and the negative feedback dissipates,
returning speed to the set point.
The rate at which this happens is controlled by the needle valve opening and by
buffer spring scale. Stronger buffer springs increase the effect, or gain, of the
compensation, and the needle valve opening determines the recovery time. The
smaller the opening, the slower the recovery to set speed. The buffer spring scale
is predetermined and specified by the prime mover manufacturer or by
Woodward.
PG-200/PG-300
The following two examples show the sequence of events during a speed setting
change or load change. The sequence occurs within the governor almost
simultaneously rather than the step-by-step method de,scribed.
Increase of Speed Setting or Load

Increasing speed setting or increasing load on the prime mover operating at any
given speed has an identical effect for the purpose of description. In either of
these conditions, the rotating tlyweights move in due to an increase in speeder
spring force, or by the decrease in centrifugal force caused by the decrease in
prime mover speed as load is added. When the flyweights move in, the pilot
valve plunger moves down and directs pressure oil into the compensation
system, causing the buffer piston to move to the right and forcing the relay servo
to move in the increase direction.
As the prime mover accelerates to the set speed, the compensation force
gradually reduces to offset the increasing Hyweighl force. This is done each time
by balancing the pressures on both sides of the compensation land through the
needle valve. This reduces overshoot to quickly establish stable, on-speed
operation.
Woodward 19
When large changes in speed setting or load arc made, the buffer piston moves
far enough to open a bypass port in the buffer cylinder. This permits oil to flow
directly to the relay servo and lets the governor respond quickly to large changes
in speed setting or load.
Decrease Of Speed Setting Or Load

The results of decreasing the speed setting or load on the prime mover are the
same, and cause an action in the reverse of that described above. The flyweights
move out, lifting the pilot valve plunger, permitting oil to drain from the
compensating system and under the relay servo. The return spring causes the
relay piston to move to decrease. The pressure differential across the
compensation land this time causes a force down to help the speeder spring
center the pilot valve plunger just before the prime mover has completely
decelerated. This stops movement of the relay piston when the correct position is
reached for the new lower speed setting or load.
Compensation Cutoff
With large decreases in speed setting or large load decreases, the small power
piston moves to the minimum fuel position and covers the compensation oil
passage between the small servo and the needle valve to prevent normal
balancing of the compensation pressures. This holds the buffer piston to the left
of center and increases the level of the pressure sent to the upper side of the
compensation land.
The increased pressure differential, added to the compression of the speeder

spring, temporarily increases the governor speed setting. The governor begins
correcting as soon as the engine speed drops below this temporary speed setting
and starts the relay piston restoring the fuel supply in time to prevent a large
underspeed transient. This action is called compensation cut off. When the relay
piston moves up and uncovers the compensation oil passage, normal
compensation is again available and the engine keeps steady-state speed at the
set speed of the governor.
20 Woodward
Chapter 5
Maintenance
Governor Oil
Use NEW OIL to fill the governor. Be sure that all containers used for governor
oil storage are clean. Contaminated governor oil will cause early wear of
plungers, bushings, gears, bearings, etc., and can cause rust and corrosion on
springs and other internal parts.
Under normal operating conditions, oil should be changed every 12 months. Oil
must be changed more often if the unit operates under unusual temperature or
dirt conditions.
After the governor is put in service, the oil condition should be carefully
monitored until a length of service can be established. A careful check of oil
condition is suggested at least every three months until length of service is
established. Any time the oil looks dirty or appears to be breaking down from
contamination or high temperature, drain the governor oil while it is hot, flush
with the lightest grade of the same oil. and refill the governor with new oil of the
correct viscosity. (Sec oil viscosity table. Figure 2-1, or refer to Woodward
manual 25071 A, Recommended Oils for Governors, Actuators.)
Troubleshooting
While a governor problem can show up as speed variations of the prime mover,
not all speed variations of the prime mover are caused by a malfunction of the
governor. When there is a problem, follow these procedures:
1. Check that the load is not beyond the load limit of the prime mover.
2. Be sure the engine cylinders are firing and the fuel injectors are operating
and correctly calibrated.
3. Check the linkage from the governor output to the fuel control. There must
be no binding and a minimum amount of backlash.
4. Check for fuel or steam pressure changes.
5. Be sure the compensating needle valve is set correctly.
6. Check the governor external speed adjusting devices.
7. Check governor oil pressure at the booster outlet port on the PG-200/
PG-300 case. Pressure in the PG-200 should be 1379 kPa (200 psi).
Pressure in the PG-300 should be 2482 kPa (360 psi). Check at operating
temperature and speed.
Woodward 21
PG-200/-300 Case. Accumulator, and Power Cylinder Manual 36618
8. Check the governor oil and replace it if it is dirty. Sometimes the
malfunction of the governor can be corrected by flushing the governor with
fuel oil or kerosene while the governor is operated through a cycle.
9. Check the drive to the governor for any evidence of the governor not being
aligned correctly on the installation pad, rough gears, or backlash.
10. Manual number 36404, Analysis and Correction of PG Governing Troubles,

covers governor malfunctioning and possible causes and corrective actions.
Repair and Disassembly

A governor can operate several years before it will need an overhaul if the oil is
kept clean and the drive from the prime mover is smooth and does not have
torsional vibration.
If disassembly and repair become necessary, the work must be done by personnel
trained in the correct repair procedures.
WARNING
A The accumulator spring (#205 in Figures 6-5 and 6-6) is compressed
and held in the accumulator assembly. In old style accumulators
(Figure 6-5), careless disassembly of the unit can result in injury to
person or damage to equipment. Place the accumulator assembly in
an arbor press to permit a controlled rate of spring expansion. This
does not apply to the newer-style accumulator (Figure 6-6). If in
doubt over which type you have, please check the actual build with
the versions depicted in Figures 6-5 and 6-6.
22 Woodward
Chapter 6
Parts Information
Parts Replacement Information

When ordering governor replacement parts, it is essential that the following
information be given.
1. Governor serial number and part number as given on the nameplate.
2. Manual number (this is manual 36618).
3. Part reference number as given in the part list, name of part, or description
of part.
Parts List for Figure 6-1

Ref. No. Part Name........................................ Qty
36618-1 Relief valve plunger......................... 1
36618-2 Relief valve spring............................ 1
36618-3 Preformed packing .801 I.D. x .070 1
36618-4 Relief valve plug............................... 1
36618-5 Retaining ring -1.111 diameter...... 1
36618-6 Housing............................................. 1
36618-7 Preformed packing........................... 4
36618-8 Plug-.438-20 UNF 2A..................... 4
36618-9 Washer- .500 I D.............................. 4
36618-10 Screw - .500-13 X 2.500.................. 4
36618-11 Oil level gauge assembly................ 1
36618-12 Needle valve..................................... 1
36618-14 Plug-.562-18 UNF 2A..................... 2
36618-15 Preformed packing .468 I.D. x.078 . 2
36618-16 Screw .500-13 x 2.000 (screw, washers come from inside part 6).... 2
36618-17 Washer.500 I.D................................. 2
36618-18 Washer, split lock............................. 2
36618-19 Dowel pin, .3742 dia. x .625............ 2
36618-20 Gasket................................................ 1
36618-21 Case................................................... 1
36618-22 Plug - .062 pipe................................ 1
36618-23 Plug - .750......................................... 1
36618-24 Plug-.875-14 UNF 2A..................... 2
36618-26 Plug-.125......................................... 4
36618-27 Pin 2
Woodward 23
-2()0 Case, Accumulator, and Power Cylinder
24 Woodward

Ref. No. Part Name.......................................... Qty
36618-75 Screw - .250-28 X .500....................... 2
36618-76 Washer - .250..................................... 2
36618-77 Washer- .750 O.D. x .266 l.D............ 2
36618-78 Spring cover........................................ 1
36618-79 Preformed packing 1.239 l.D. x .070 1
36618-80 Loading spring.................................... 1
36618-81 Spring seat.......................................... 1
36618-82 Pilot valve sleeve............................... 1
36618-83 Pilot valve spring seat........................ 1
36618-84 Pilot valve plunger adjuster............... 1
36618-85 Pilot valve lever assembly................. 1
36618-86 Cotter pin .062 dia. x .375................. 2
36618-87 Pin - .1862 dia. x .900........................ 1
36618-88 Pin - .1871 dia. x .531........................ 1
36618-89 Power piston assembly..................... 1
36618-90 Tail rod lift nut..................................... 1
36618-91 Washer............................................... 1
36618-92 Not used
36618-93 Pilot valve spring................................ 1
36618-94 Pilot valve plunger assembly............ 1
89
Figure 6-2. Parts for Power Piston Assembly and Pilot Valve Assembly
Woodward 25

Ref. No. Part Name................. Qty
36618-100 Oil seal 1.125 x 1.562
36618-101 Bearing
36618-102 Gasket
36618-103 Screw - .500-13 x 2.500,
36618-104 Washer - .500
36618-105 Output lever
36618-106 Output shaft
36618-107 Cover
36618-108 Screw - .312-18 x 1.500.
36618-109 Washer-.312 I.D.
36618-110 Drive screw
36618-111 Scale.
36618-112 Indicator,
36618-113 Screw - .500-13 x 1.250,
36618-114 Retaining ring .971
36618-115 Pin - 3.750 x .874
36618-116 Retaining ring -.971
36618-117 Plug
36618-118 Preformed packing .614 I.D. x .070
36618-119 Retaining ring - .620
36618-120 Spring seat
36618-121 Spring
36618-122 Retaining ring-.207
36618-123 Reducing valve plunger
36618-124 Reducing valve sleeve
36618-125 Washer, flat
SHOWN ENLARGED
Figure 6-3. Parts for Output Assembly and Reducing Valve Assembly
26 Woodward

Ref. No. Part Name................ ................ Qty
36618-175 Preformed packing...................... 4
36618-176 Check valve assembly............... 4
36618-177 Retaining ring - 1.526.................. 4
36618-178 Pin - 3.188 X .875........................ 1
36618-179 Gasket.......................................... 1
36618-180 Washer .500................................ 7
36618-181 Screw - .500-13 X 2.000............. 7
36618-182 Servo cover.................................. 1
36618-183 Servo piston................................. 1
36618-184 Connecting rod............................ 1
36618-185 Retaining ring 1.804.................... 1
36618-186 Buffer plug.................................... 1
36618-187 Preformed packing 1.296 x .139 1
36618-188 Buffer spring................................. 2
36618-189 Butter piston................................. 1
36618-190 Buffer spring seat........................ 1
36618-191 Retaining ring.............................. 2
Figure 6-4. Parts for Servo Assembly
Woodward 27

Ref. No. Part Name Qty
36618-201 Preformed packing 1.114 I.D. x .070
36618-202 Accumulator plate
36618-203 Stud- 13.000 X.500
36618-204 Accumulator cylinder
36618-205 Accumulator spring
36618-206 Accumulator tube.
36618-207 Preformed packing
36618-208 Accumulator end
36618-209 Washer - .500
36618-210 Nut
36618-211 Plug - .750
36618-212 Warning plate
36618-213 Drive screw - #2 x .125
36618-214 Plug-.562-18 UNF2A
36618-215 Preformed packing .468 x .074
36618-216 Stud - 14.000 X .500
Figure 6-5. Parts for Accumulator Assembly (old style)
28 Woodward

Ref. No. Part Name.................................. Qty
36618-201 Preformed packing.....................
36618-204 Accumulator cylinder..................
36618-205 Accumulator spring....................
36618-211 Plug..............................................
36618-211A Preformed packing.....................
36618-214 Plug..............................................
36618-226 Accumulator plate......................
36618-227 Flat washer.................................
36618-228 Bolt. .500-13 X 8.8 inches.........
36618-229 Soc. hd. screw, .500-13 x 1.750,
36618-230 Accumulator housing.................
Figure 6-6. Parts for Vibration Resistant Accumulator Assembly (new style)
Woodward 29

Ref. No. Part Name........................................... Qty
36618-301 Key, PG drive..................................... 1
36618-302 Pilot, base............................................ 1
36618-303 Bearing, needle.................................. 1
36618-304 Washer, thrust.................................... 2
36618-305 Bearing, thrust, needle...................... 2
36618-306 Oil Seal................................................ 1
36618-307 Shaft, PG200 drive, serrated............ 1
36618-308 Washer, flat........................................ 1
36618-309 Ring, external retaining...................... 1
36618-310 Coupling, 3199 PG drive................... 1
36618-311 Ring, internal retaining....................... 1
36618-312 Retainer seal...................................... 1
36618-313 O-ring, Viton....................................... 1
36618-314 O-ring, Viton....................................... 1
36618-315 Pump. Gerotor.................................... 1
36618-316 Screw, socket head cap (not shown) 4
36618-317 Shaft. PG200 drive, keyed................ 1
36618-318 Spacer................................................. 1
36618-319 Sleeve, shipping (not shown)........... 1
36618-320 Nut, .625-18 castellated (not shown) 1
36618-321 Key (not shown)................................... 1
36618-322 Cotter pin (not shown)....................... 1
36618-323 Key, PG200 pump.............................. 1
36618-324 Pilot base............................................. 1
36618-325 Pump, Gerotor.................................... 1
30 Woodward
DRIVE COUPLING
\ I a. \
v: M \ ^ \
A /I \ \
M \ \ \
K s\
\
313
309
308-
NOT SHOWN: 366-547
99-03-25 skw
316
Figure 6-7a. Drive Shaft Assembly, Serrated Drive (PG-200/-300/-500)
Woodward 31
PG-200/-300 Case. Accumulator, and Power Cylinder Manual 36618
DRIVE COUPLING
Nj
k'
4
NOT CHOWN:
316
319
3c0
321
322
366-548
99-03-55 skw
Figure 6-7b. Drive Shaft Assembly, Keyed Drive (PG-200/-300/-500)
32 Woodward
/I DRIVE CDUFLING
rm: \
trz
t
0
MPT SHOWN-
j16
366-5^9
99-03-25 skw
Figure 6-7c. Drive Shaft Assembly, Serrated Drive (PG-200/-300)
Woodward 33
PG-200/-300 Case, Accumulator, and Power Cylinder Manual 36618 »
M DRIVE COUPLING
M N
V
N
y NOT SHQVN:
316
. \. ■; 319
383 \
N 320
\
321
322
\
\ ^ N ^
s
317
366-550
99-03-25 sUw
Figure 6-7d. Drive Shaft Assembly, Keyed Drive (PG-200/-300)
34 Woodward
Chapter 7
Service Options
Product Service Options

The following are the factory options available for the service of Woodward
equipment under Woodward's standard Product and Service Warranty (25222),
in effect at the lime the product is sold from Woodward or the service is
performed:
• Replaccment/Exchange (24-hour service)
• Flat Rale Repair
• Flat Rate Remanufaclure
If you are experiencing problems with installation or unsatisfactory performance

of an installed system, the following options are available:
• Consult the system troubleshooting guide in the manual.
• Contact Woodward technical assistance (see “How to Contact Woodward”
later in this chapter) and discuss your problem. In most cases, your problem
can be resolved over the phone. If not, you can select which course of action
you wish to pursue based on the available services listed in this section.
Replacement/Exchange
Replacemenl/Exchange is a premium program designed for the user who is in
need of immediate service. It allows the user to request and receive a like-new
replacement unit in minimum lime (usually within 24 hours of the request),
providing a suitable unit is available at the lime of the request, thereby
minimizing costly downtime. This is also a Flat Rate structured program and
includes the full standard Woodward product warranty, pursuant to Woodward’s
Product and Service Warranty (25222).
This option allows customers to call in advance of a scheduled outage or an

unexpected outage and request a replacement control unit. If the unit is available
at the lime of the call, it can usually be shipped out within 24 hours. The
customer replaces his field control unit with the like-new replacement and
returns the field unit to the Woodward facility as explained later in this chapter.
Charges for the Replacemenl/Exchange service are based on a flat rate plus
shipping expenses. The customer is invoiced the flat rate replacemeni/exchange
charge plus a core charge at the lime the replacement unit is shipped. If the core
(field unit) is returned to Woodward within 60 days. Woodward will issue a
credit for the core charge. [The core charge is the average difference between the
flat rate replacement/exchange charge and the current list price of a new unit.]
Woodward 35
Return Shipment Authorization Label. To ensure prompt receipt of the core,
and avoid additional charges, the package must be properly marked. A return
authorization label is included with every Replacemcnt/Exchange unit that
leaves Woodward. The core should be repackaged and the return authorization
label affixed to the outside of the package. Without the authorization label,
receipt of the returned core could be delayed and cause additional charges to be
applied.
Flat Rate Repair

Flat Rate Repair is available for the majority of standard products in the field.
This program offers the user repair service for their products with the advantage
of knowing in advance what the cost will be. All repair work carries the standard
Woodward service warranty, pursuant to Woodward’s Product and Service
Warranty (25222) on replaced parts and labor.
Flat Rate Remanufacture

Flat Rate Remanufacture is very similar to the Flat Rate Repair option with the
exception that the unit will be returned to the user in “like new” condition and
carry with it the full standard Woodward product warranty, pursuant to
Woodward's Product and Service Warranty (25222). This option is applicable to
mechanical products only.
Returning Equipment for Repair

When returning equipment to Woodward, please telephone and ask for the
Customer Service Department [(1)(800) 835-5182 in North America or
(1)(970) 498-5811]. They will help expedite the processing of your order
through our distributors or local service facility. To expedite the repair process,
contact Woodward in advance to obtain a Return Authorization Number, and
arrange for issue of a purchase order for the item(s) to be repaired. No work can
be started until a purchase order is received.
NOTE
We highly recommend you make arrangement in advance for return
shipments. Contact a Woodward customer service representative at
(1)(800) 835-5182 in North America or (1)(970) 498-5811 for
instructions and for a Return Authorization Number.
36 Woodward
Replacement Parts Information

When ordering replacement parts for electronic controls, include the following
information:
• the part number(s) (XXXX-XXX) that is on the enclosure nameplate;
• the unit serial number, which is also on the nameplate.
How to Contact Woodward

In North America use the following address when shipping or corresponding:
Woodward Governor Company
POBox 1519
1000 East Drake Rd
Eon Collins CO 80522-1519, USA
TELEPHONE: (1)(970) 498-511 (24 hours a day)

TOLL-FREE PHONE (in North America): (1)(800) 835-5182
FAX: (1)(970) 498-3058
For assistance outside North America, call one of the following international
Woodward facilities to obtain tbe address and phone number of the facility
nearest your location where you will be able to receive information and service.
FACILITY PHONE NUMBER

Australia (61)(2) 9758 2322
Brazil (55)(19) 708 4800
England (44)(118) 9752727
India (9I)()29) 230419
Japan (81)(476) 93-4661
The Netherlands (31)(23)56 6I111
Singapore (65)270-0081
There is also information and e-mail addresses on Woodward’s Internet (World

Wide Web) home page:
http://www.woodward.com
other Service Facilities

Contact the Woodward Customer Service Department or consult our worldwide
directory on the Internet:
http://www.woodward.com/lndustrial/address.htm
for the name of your nearest Woodward distributor or service facility.
Woodward 37
Additional Aftermarket Product Support Services

Woodward Aftermarket Services offers the following after-sale support for all
Woodward products:
• Customer Training
• Technical Assistance
• Field Service
• Specialised Services
Customer Training is offered at our facility in Loveland, Colorado, or at the

customer's site. This training, conducted by experienced trainers, will assure that
customer personnel will be able to maintain system reliability and availability.
For information concerning training available, call the number above and ask for
customer training.
Technical Assistance is available using the Woodward toll-free number. The

Aftermarket application engineering group is available to assist customers with
technical questions or problem solving during normal business hours or as
emergency support 24 hours a day. This group can also provide engineering
support for changes or enhancements after the commissioning of your system.
For technical engineering a.ssistance. call the number above and ask for technical
assistance.
Field Service engineers are dispatched from the Woodward facility in Colorado,
or from one of many regional or worldwide offices located near the customer to
provide prompt response. Woodward field engineers are experienced and are
continually updated on all Woodward products as well as much of the non-
Woodward equipment they interface with. The field engineers ensure that all
documentation is updated, and all field engineers are well informed as to new
problems which might arise. Woodward field service engineers are on-call 24
hours a day. Call the number above and ask for field service.
Specialized Services can be tailored to the specific needs of the customer. These
services can be based on a particular aspect of a single service or a combination
of services and are covered under one low-cost service contract. A contract may
be for regularly scheduled training courses or possibly to have a field engineer
visit the customer site at pre-determined intervals to provide a system analysis,
verify proper operation, and make recommendations for maintenance
improvements, enhancements, or other needs. These contracts are usually
custom-designed and structured to allow ultimate flexibility, thereby allowing
the customer to plan and budget more accurately. For more details, contact the
Woodward sales representative, or call the number above and ask for sales
support to discuss specific needs.
38 Woodward
Technical Assistance
If you need lo telephone for technical assistance, you will need to provide the following information.
Please write it down here before phoning:
General
Your Name___
Site Location_
Phone Number
Fax Number
Prime Mover Information

Engine/Turbine Model Number______
Manufacturer_____________________
Number of Cylinders (if applicable)__
Type of Fuel (gas, gaseous, steam, etc)
Rating___________________________
Application_______________________
Governor Information
Please list all Woodward governors, actuators, and electronic controls in your system:
Woodward Part Number and Revision Letter
Control Description or Governor Type
Serial Number
Serial Number
Serial Number
If you have an electronic or programmable control, please have the adjustment setting positions or
the menu settings written dow'n and with you at the time of the call.
Woodward 39
We appreciate your comments about the content of our publications.
Please send comments to:
Attention: Technical Publications
PO Box 1519
Fort Collins CO 80522-1519, USA
Please include the manual number from the front cover of this publication.
WOODWARD
Industrial Controls
Woodward Governor Company, PO Box 1519 (1000 East Drake Road), Fort Collins CO 80522-1519, USA
Phone (1)(970) 482-5811 • Fax (1)(970) 498-3058
Global Services
Woodward Governor Company, PO Box 3800 (3800 North Wilson Avenue), Loveland CO 80539-3800, USA
Phone (1)(970) 663-3900 • Fax (1)(970) 962-7050
E-mail and World Wide Web Home Page—http://www.woodward.com
Registered Firm
ISO 9001:1994/09001-1994
Certificate QSR-36 DUTCH COUNCIL
FOR CERTIFICATION
PLANTS & SUBSIDIARIES BRANCH/REGIONAL OFFICES DISTRIBUTORS/REPRESENTATIVES

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Germany (Aken/Elbe) Korea (Pusan) Italy (Genoa)
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Japan (Tomisato & Kobe) New Zealand (Christchurch) Netherlands Antilles (Curasao)
Netherlands (Hoofddorp & Rotterdam) Poland (Warsaw) Spain (Cadiz)
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United Kingdom (Reading, England, & United Kingdom (Dundee, Scotland) United States (California, Delaware,
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United States (Colorado. Illinois. Illinois, Pennsylvania, Texas, Rico, Texas, Washington)
Michigan, New York. South Carolina, Washington) Venezuela (Caracas)
Tennessee)
plus Authorized Facilities throughout the world
Complete address/phone/fax/e*mail information for all locations is available on the Internet at:
http://wvhrw.woodward.com/industrial/address.htm
99/8/F
6
36637D
WOODWARD
Integral EG Actuator
for PG Governors
Installation, Operation, and Calibration Manual
Manual 36637D
WARNING
A 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.
The engine, turbine, or other type of prime mover should be equipped with
an overspeed (overtemperature, or overpressure, where applicable)
shutdown device(s), that operates totally independently of the prime mover
control device(s) to protect against runaway or damage to the engine,
turbine, or other type of prime mover with possible personal injury or loss
of life should the mechanical-hydraulic governor(s) or electric control(s),
the actuator(s), fuel control(s), the driving mechanism(s), the linkage(s), or
the controlled device(s) fail.
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.
© 1995 by Woodward Governor Company
All Rights Reserved
Manual 36637 Integral EG Actuator for PG Governors
Contents
CHAPTER 1. GENERAL INFORMATION 1

Introduction................................................. 1
Description................................................. 1
Reverse or Direct Acting........................... 1
Vibration Resistance................................. 1
CHAPTER 2. INSTALLATION...... 7
Receiving......................................... 7
Storage............................................ 7
Mounting Requirements................ 7
Linkage............................................ 8
Electric and Hydraulic Connections 8
Clearances..................................... 9
Governor Oil................................... 9
Oil Problems................................... 10
Governor Oil Service...................... 11
CHAPTER 3. PRINCIPLES OF OPERATION 13

Flapper Nozzle Systems.................................. 13
Torque-motor System...................................... 13
Direct and Reverse Acting............................... 14
CHAPTER 4. OPERATION AND ADJUSTMENTS 19

Introduction............................................................... 19
Centering Adjustment............................................... 19
Parts List for Figure 4-1............................................ 21
Parts List for Figure 4-2............................................ 23
Adjustment of the Anti-rotation Device.................... 24
Mode Select Valve and Mode Indicating Switch..... 24
Mode Indicating Pressure Switch.................... 24
No Mode Select Block..................................... 24
Mode Select Block............................................ 25
Mode Select Valve............................................ 25
Maintenance..................................................... 26
Applications...................................................... 26
Parts List tor Figure 4-3............................................ 29
CHAPTER 5. SERVICE OPTIONS...................... 31

Product Service Options........................................ 31
Replacement/Exchange............................... 31
Flat Rate Repair............................................ 32
Flat Rate Remanufacture............................. 32
Returning Equipment for Repair........................... 32
Packing a Control.......................................... 33
Return Authorization Number....................... 33
Replacement Parts Information............................ 33
How to Contact Woodward................................... 33
Additional Aftermarket Product Support Services 34
Technical Assistance............................................. 36
Woodward
Integral EG Actuator for PG Governors Manual 36637
Illustrations and Tables
1-1. PG-EG Actuator Connections............................................................ 2

1-2. PGA/PGG-EG Governor Connections (without mode select block) 3
1-3. PGA/PGG-EG Governor Connections {with mode select block).... 4
1-4. PGA-EG 200/300 Outline Drawing................................................... 5
2-1. Governor Travel.................................................................................. 9
3-1. Schematic of Pilot Valve and Pressure Regulator Section.............. 12
3-2. PG-EG Schematic, without Mode Select Valve............................... 15
3-3. PG-EG Schematic, with Mode Select Valve, Controlling on PG..... 16
3-4. PG-EG Schematic, with Mode Select Valve, Controlling on EG..... 17
3-5. EG Actuator Schematic. No Ballhead Backup................................. 18
4-1. Torque Motor Exploded View............................................................. 20
4-2. Mode Select Block Exploded View................................................... 22
4-3. Assembly and Tubing Exploded View............................................... 28
II Woodward
Chapter 1
General Information
Introduction
This manual contains infonnation about the Woodward Integral EG Actuator for
PG governors as an add-on unit:
• to form the PG-EG actuator (no ballhead) or
• to create a ballhead backup governor {PGA-EG or PGG-EG) from the PGA
or PGG governor.
In this manual. PG-EG refers to any of these three governor types.
This manual covers the EG. governor components affected by the EG. and
information pertaining to the PG-EG. For more general governor information,
refer to the PGA governor manual (36604) or the PGG governor manual
(36627).
Description
The EG is an electro-hydraulically controlled actuator that accepts a 0-200 mA
signal, and outputs on a standard PG servo proportional to the mA signal.
Reverse or Direct Acting

The actuator is available for use with either direct- or reverse-acting electronic
controls. Direct-acting units assume an increasing fuel as the current level
increases. Reverse-acting units assume a decreasing fuel position as the current
level increases.
Reverse-acting EG actuators are normally used on ballhead governors to provide

an automatic ballhead back-up in case the electrical control signal is lost or
interrupted.
Direct-acting EG actuators will cause shutdown if the electrical current to the

actuator is lost or Interrupted.
Direct-acting Reverse-acting
Fuel Rack Position 0.050-0.950" TR 0.050-0.950" TR
Control Current 20-160 mA 160-20 mA
Vibration Resistance
The EG actuator is in itself resistant against vibration due to the torque motor
beam being mass-stabilized in all three axes. As a consequence, vibrations have
minimal influence on the position of the beam.
Woodward 1
integral EG Actuator for PG Governors Manual 36637
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Figure 1-1. PG-EG Actuator Connections
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2 Woodward
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Figure 1-2. PGA/PGG-EG Governor Connections (without mode select block)
Woodward 3
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4 Woodward
(OPPOSITE SIDE)
OIL FROM BOOSTER OUTLET NO 3
f— 438-20 (INCH) UNjF-28
/ STRAIGHT THREAD PORT (-4)
(REF MS 16142).
/
OIL FROM BOOSTER OUTLET NO 1
S62-18 (INCH) UNJF-2B STRAIGHT I
THREAD PORT (-6) (REF MS 16142).
A
t /
/
/
/
n I
3 OIL LEVEL DIPSTICK

(FILL PORT)
OIL COOLER TO GOVERNOR

PC 200/300 .7S0 (INCH) COMPENSATION NEEDLE VALVE
NPTF CONNECTION
PG500- 87S (INCH)
UNJF-2B STRAIGHT THREAD
PORT (-10) (REF MS 16142).
GOVERNOR OIL DRAIN OR OIL TO
BOOSTER INLET 562-18 (INCH) UNJF-2B
PG-EG 200. 300. SOO FT-LB STRAIGHT THREAD PORT (-6) (REF MS 16142).
GOVERNOR/ACTUATORS CAN USE
ANY STANDARD PG DRIVE SHAFT.
4
1
TERMINAL SHAFT SERVO HOUSING

PG200 -1 1/8- 48 SERRATION DRAIN
PG300/500 - /2 - 60 SERRATION 5«000 B-31-2
(Do Not Use for Construction)

Figure 1-4. PGA-EG 200/300 Outline Drawing
Woodward 5
6 Woodward
Chapter 2
Installation
Receiving
Your PG governor is shipped from the factory boiled to a wooden platform in a
vertical position. After being tested at the factory, the governor is drained of oil.
This leaves a light film of oil covering the internal parts, preventing rust. No
internal cleaning is required.
CAUTION
A Use care in handling the governor. Be particularly careful to avoid
striking the drive shaft. Do not drop or rest the governor on its drive
shaft. Such treatment could damage the gears and bearings in the
governor oil pump.
Most PG governors lift from an eye-bolt threaded into a 0.375-16 (inch) hole in
the center of the cover. PG-200. PG-300. and PG-500 governors must be lifted
with a sling. Some PG governors have split covers which need to be lifted with a
sling as well.
storage
The governor may be stored for up to a year as received from the factory. Store
the governor in a vertical position. Fill completely with oil if extended storage is
necessary.
Mounting Requirements
A gasket must be used between the governor and the accessory mounting pad. A
0.032 inch thick (0.81 mm) gasket is recommended for this purpose. The gasket
is used to absorb imperfections between the governor base and the mounting pad,
and to avoid oil leakage between the governor and the drive portion of the
engine.
Install the governor square on the accessory pad, using the correct length of
coupling between the governor and the drive. Make sure the driveshafl does not
bind, and that there is no excessive side load on the driveshafl assembly. Make
sure the coupling is tight, and do not use force when installing the drive shaft
into the coupling. The governor must be installed in a vertical position.
A rough or non-concentric drive can prevent smooth governor operation and
shorten governor life. The drive should be as smooth as possible. Poor drive
dynamics can damage governor seals and bearings.
CAUTION
A Rotation direction is factory set for some governors. Damage will
result if the governor is installed on a drive which rotates in the
Woodward 7
wrong direction. Specifications for individual governors indicate if
the unit has been plugged to limit rotation to one direction only.
Many PG governors are equipped with check valves in the pump,
allowing rotation in both clockwise and counterclockwise directions.
Linkage
Align the linkage from the governor to the fuel pumps or valves to eliminate
binding and excessive backlash. The relationship of governor/terminal shaft
angular position to the fuel control position must be adjusted in accordance with
the engine manufacturer’s specifications. The linkage must not limit the
governor's ability to call for maximum fuel or to shut down the engine.
Linkage must not give during major transients and must not be so heavy that it
hinders accurate governor response. Linkage must be designed to resist wear.
Linkage is responsible for many apparent “governor problems”, and proper

design and installation of the linkage between the governor output and the engine
is extremely important.
The fuel-control linkage must be adjusted so at least 15% of the governor travel
(output) from minimum position has been used when the fuel control is at idle
no-load (A and D; see Figure 2-1). This minimum setting is required due to the
location of the compensation cut-off port (if so equipped).
Use as much of the governor output travel as possible. Stability is greatly

improved with the use of maximum governor travel. Design linkage so governor
output and resultant power output of the engine are nearly linear.
Electrical and Hydraulic Connections

Make the pneumatic (if applicable), hydraulic, and electrical connections
required for the particular governor. Refer to Figures l-I through 1-3.
Standard electrical connections are made to the four-pin connector on the side of
the column (see figures). Optionally, the EG actuator may be wired to the
connector on the receiver bracket through an internal mounting bracket.
Instead of a connector, the governor may be equipped with a flying lead, leaving
the governor on the side of the column. This option is used mostly on governors
in a high-vibration environment.
8 Woodward
F'JU GOVEFilOP TS>AVEu
• FCIME WOVEF STOP ----

NO LOAD rutL LOAD —
C
0 B
ICO*
0
GOvCPfÔf?
L PRIME ,
travelUOvCff
E /
/
/ . \
//■ /
PPivE MOVER PP'UE MCvEP
;»OP
'n \ . \
STOP
■V//'
A - O/EPTfiAVE. TO INSURE PPIVE MOVER STOPS APE PEACHED
e - NO LOAD TO Full load travel - nofmallt i/3 or full

CO-/ERNOP TRAVEL IS FECOVUEMOEO
C - TRAVEL PEOL'«ED TC ACCElEPaTE The ppimE MOVER
TFA<EL FEOOIPED TO DECELERATE OR Shut DOWN

0 PRIME MOVER
Figure 2-1. Governor Travel
Clearances
Leave adequate clearance to connect the linkage, to fill the governor with oil,
and to remove the cover (if necessary).
Governor Oil
Governor oil must have lubricating and hydraulic properties. The oil must have a
viscosity index that allows it to perform over the operating temperature range of
the governor. The oil must have additives that allow it to remain stable and
predictable over the operating temperature range of the governor. The oil used in
the governor must be compatible with the nitrile, polyacrylic, and fluorocarbon
seals used in the governor.
Many oils and synthetic lubricating fluids used in the engines controlled by PG
governors meet these specifications. When possible use the same grade and
weight of oil used in the engine. Information in this manual is intended to be
used only in the selection of the governor lubricating oil, not for selecting engine
lube oil. USE ONLY NEW, CLEAN OIL. DO NOT USE USED ENGINE OIL
IN THE GOVERNOR.
Woodward governors and actuators are designed to give stable operation with
oils which provide 50 to 30(X) SUS (Saybolt Universal Seconds) of viscosity
throughout the operating temperature range. Ideally the viscosity at the normal
operating temperature should be between 100 and 300 SUS. Poor governor
response or instability is often an indication that the oil being used is too thick or
too thin.
Woodward 9
For more detailed information on the choice of governor oil refer to manual
25071, Oils for Hydraulic Controls.
The recommended oil temperature for continuous governor operation is 60 to 93

®C (140 to 200 ®F). Measure the oil temperature of the governor or actuator on
the outside lower part of the power case. The actual oil temperature will be about
6 °C (10 ®F) higher. The governor is designed to operate in ambient temperatures
of+29 to +93 (+20 to +200 °F).
Oil Problems
A filter is located between the oil pump and the control pilot valve of the EG
actuator. Should this filler become clogged, it can seriously hinder the ability of
the actuator to control, even on the mechanical ballhead side. Take extra care
with the PG to be sure that oil is clean and that it does not deteriorate due to
heat.
Excessive component wear or seizure in a governor indicates the possibility of

insufficient lubrication caused by:
• An oil that flows slowly when it’s cold or at start-up;
• High or low governor oil level;
• Restrictions in oil lines to boosters or heal exchangers;
• Contaminated oil (usually caused by dirty oil containers used when
transferring oil to the governor);
• A governor exposed to healing and cooling cycles, creating condensation of
water in the oil;
• Oil not suitable for the operating conditions.
Operating a governor continuously beyond the high-limit temperature of the oil
will result in oil oxidation. This is identified by varnish or sludge deposits on
governor parts. To reduce oil oxidation, lower the oil operating temperature with
a heat exchanger or other means, or change to an oil more oxidation resistant at
the operating temperature.
PG-govemors operating with internal oil-pressures in excess of 1655 kPa (240

psi) often require a heal exchanger to protect the oil from damage.
NOTE
Many governor problems are the result of improper selection or
improper maintenance of governor oil. The governor should be
serviced on a routine schedule. Develop the schedule with
consideration to the governor operating temperature and the
cleanliness of the atmosphere in which the governor operates.
WARNING
A A loss of stable governor control and possible engine overspeed may
result if oil viscosity exceeds the 50 to 3000 SUS range.
10 Woodward
Governor Oil Service

Replace the governor oil if it is contaminated or if it is suspected of causing
governor problems. Drain the oil while it is still hot and agitated. Flush the
governor with kerosene or an equivalent solvent. If drain time is insufficient for
the solvent to completely drain or evaporate, flush with the same grade and
weight of oil which will be used to refill the governor. Discard the oil used to
flush out the solvent.
To avoid contamination of the governor, the replacement oil must be free of dirt,
water, or other foreign material. Use clean containers to store and transfer oil.
Refer persistent or recurring oil problems to an oil specialist.
After the oil is selected, fill the governor with new, clean oil, in the volumes
listed here: Type 12/29/58 (1.4 L/1.5 ql). Type 200/300 {6.2 L/6.5 qt), Type 500
(6.6 L/7.0 qt).
While the engine is tiot running, fill the governor to the maximum level
indication. During normal operation, this level should not drop below the
minimum level. Do not add oil when operating the governor.
PG-EG 200, 300, and 500 cases must be filled in two stages. Fill with about 4
liters/quarts before starting, then add the amount needed to bring the oil up to
operating levels after start-up. On these governors, there is an oil level dipstick
inside the fill port cap. On newer types, a small sight gauge glass has been added
onto the terminal shaft housing. Always use the dipstick for accurate oil level
readings. All other PG-EGs have an oil filler cup in the cover and a special long
oil gauge glass on the power case.
To prevent contamination of the flapper nozzle system, an oil filter has been
fitted to the oil feed line going to the EG actuator. Check this filter every time
the oil is changed, and clean if necessary.
Woodward 11
CENTER TORQUE
adjustment MOTOR BEAM
follower type
PILOT VALVE
PLUNGER
DROPPING SUPPLY'
ORIFICE PRESSURE
SERVO control
PRESSURE
PILOT VALVE
□ CONTROL PRESSURE
REGULATED
PRESSURE
SUMP
PRESSURE
REGULATING
□ PRESSURE
VALVE
TO BOTTOM
OF SERVO
PISTON
TO SUMP
620-053 E
91-08-21 MCL
Figure 3-1. Schematic of Pilot Valve and Pressure Regulator Section
12 Woodward
Chapter 3
Princigle^^geration
Flapper Nozzle System

The Happcr nozzle system is basically a hydraulic amplifier which converts the
torque motor beam position through the pilot valve into a servo position. Pump
pressure oil is supplied to the interior of the pilot valve and lowered by the
pressure regulating valve into the regulated pressure at 690 kPa (100 psi). This
flow of 690 kPa oil is then directed onto the bottom of the control land and
through a dropping orifice (giving the pilot valve control pressure) to the top of
the same control land but with a larger surface. At the same lime, pilot valve
control pressure oil is directed through a nozzle and sprays onto the bottom of
the torque motor beam (acting as the flapper).
The balance of these hydraulic pressures and forces positions the pilot valve in
the bushing and causes the pilot valve to follow the position of the torque motor
beam. To center the pilot valve in the bushing in steady state, the gap between
the Happer (the torque motor beam) and the nozzle is adjustable by means of the
center adjustment.
The control land of the pilot valve, balanced between the regulated pressure
below and the pilot valve control pressure above, provides a hydraulic
amplification of the position of the torque-motor beam. This pennits accurate
positioning of the plunger in the bushing without having the bushing rotate to
eliminate static friction as is necessary in the mechanical pilot valve system.
Torque-motor System
The torque-motor system consists of an electromagnetic coil and a beam. On top
of the beam, an armature is mounted which is placed into the electromagnetic
field of the coil. The beam itself is suspended by a torsion spring, allowing a
small degree of rotation of the beam around the center of the torsion spring but
no translations.
The torque-motor beam is balanced between the restoring spring, the level-adjust
spring, and the torque from the torque-motor. With the system in steady state, the
pilot valve of the flapper nozzle system is centered and the servo is stationary.
By changing the current to the coil, the amount of torque on the armature
changes, and thus the torque on the torque-motor beam. This will change the gap
between the beam and the pilot valve, cause the pilot valve to follow the
movement of the beam, and allow oil to flow to or from the servo. The resultant
change in servo position causes the restoring lever to load or unload the restoring
spring, and thus restores the equilibrium of the torque-motor beam at the new
current level. The torque motor beam resumes its original position, and the gap
between the beam and the pilot valve will be restored to its original size with the
pilot valve centered.
Woodward 13
Integral EG Actuator for PG Governors___________ Manual 36637
Direct and Reverse Acting

The same set of springs may be set for either a direct- or reverse-acting actuator.
The only difference is the level to which the level-adjusl spring is set, and the
wires to the torque-motor which are reversed.
14 Woodward
Manual 36637 integral EG Actuator for PG Governors
PG-EG WITHOUT MODE SELECT VALVE
• ^HOWN AT STEADY STATE CONTROLLING ON E G
• BALLHEAD PILOT-valve OPENED
EG ACTUATOR
RESTORING RANGE
signal from LEVER ADJ
ELECTRONIC + pm
GOVERNOR
LEVEL _rPr\ \
adjustment
p
o o
b d
p H
torque BiS-
MOTOR rî SPEED SETTING
I
BEAM bleed m
J VALVE T
,o
ORIFICE a : r-i PG
n BALLHEAD
LOCATION OF SUMP i:
PRESSURE
REGULATING
valve SUMO
L_ SUMP
POV^FP
MODE INDICATOR P'STON
PRESSURE SWITCH
(OPTIONAL)
FILTER
SUMP
.NCREASE
SERVO
OUTPUT
[ ] SUMP
PUMP PRESSURE
rnilll intermediate pressure
V///A CONTROL PRESSURE
liiililil BLEED PRESSURE
TO COLUMN ACCUMULATORS regulated 100 PSl PRESSURE
ACCESSORIES 01 |W 01 UH
E 0. Si* 5tt
PUMP 365-510
PRESSURE 92-5-6 JR
Figure 3-2. PG-EG Schematic, without Mode Select Valve
Woodward 15
PG-EG WITH MODE SELECT VALVE
• SHOWN AT STEADY STATE CONTROLLING ON FG (BALLHEAD)
EG ACTUATOR range
r 1 ADJ
+
signal from
ELECTRIC \ s
GOVERNOR RESTORING
LEVER
A
LEVEL ADJUSTMENT \ vrv.
bio o'd it o o
SPEED SETTING
TOROUE
MOTOR BEAM
i
ORIFICE //
ts n PG
BALLHEAD
SUMP I
* SUMP
I?
a
L SUj^P J di
ill
FILTER ■ PO//ER
MODE
PISTON
IND.PfiESS T^
SWTCH
MODE r-i
SUMP SELECT BLOCK
CONTROL VALVE IsumpI INCREASE
(MANUAL.ELECTRIC =rb=5^ i
OR PNEUMATIC) i
SERVO
SUMP OUTPUT
SUMP
[ ] SUMP
PUMP PRESSURE
HlTTITTl INTERMEDIATE PRESSURE
V///A CONTROL PRESSURE
TO COLUMN ACCUMULATORS
ACCESSORIES SUMP §l ZZ$~9S
C_S 3l_It
SUMP Z>
PUMP K6-SI9
PRESSURE 94-9-9 ANW
Figure 3-3. PG-EG Schematic, with Mode Select Valve, Controlling on PG
16 Woodward
PG-EG WITH MODE SELECT VALVE
• SHOWN AT STEADY STATE CONTROLLING ON EG
• ballhead pilot-valye opened
EG ACTUATOP RANGE
r ■1^". AOJ
S!GNi.L FROM S'
ELECTP'C
GOVEF NOR 1 RESTORING
LEVER
/
LEVEL adjustment 7!^
p
D
u
D
,
,
o
c o b'1
TOPOUE SPEED SETT!NG

MOTOR beam i
Tl^
ORIFICE I: ■r (-1 PG
SUMP sL eallhead
L T
I L
SUMP
a P
L - _
FILTER
9fr,\ _ _SUMP J
I POWER
MODE PISTON
IND PRESS
SWITCH
MODE
SUMP SELECT BLOCK
CONTROL valve !7^ I IZIT-------1 ISUMP
i
■ INCREASE
(MANUAL.ELECTRIC
OR PNEUMATIC) (M o
i_.X SERVO
SUMP OUTPUT
SUMP
I I SUMP
PUMP PRESSURE
(IITinil INTERMEDIATE PRESSURE
\y//A CONTROL PRESSURE
TO COLUMN ACCUMULATORS nUtiil! BLEED PRESSURE

ACCESSORIES SUMP M TQ
3 ca
ffi-.a
pj—Ba X/y/A regulated 100 PSI PRESSURE
SUMP PUMP 366-soa
PRESSURE 92-5-5 Ji
Figure 3-4. PG-EG Schematic, with Mode Select Valve, Controlling on EG
Woodward 17
ACTUATOR VERSION
• NO BALLHEAD back-up
EG ACTUATOR
RESTORING RANGE
signal RROW LEVER ADJ
electronic /
GOVERNOR
/B\ S'
( I
LEVEL I \ /
adjijstment
f°)—I
D O TC
I 3
B5
TORQUE
MOTOR
beam
BLEED
VAL'/E
ORIFICE SUMP BALLHEAO
PLUG
Ir SUMP
>1
k: >1
SUMP
POVSER
MODE INDICATING \^////y//y y.
PISTON
FILTER PRESSURE SWITCH
(OPTIONAL)
a
INCREASE
SERVO
SUMP OUTPUT
[ I SUMP
\yyyA pump pressure
Y///A CONTROL PRESSURE
ACCUMULATORS i}]'}|}}| BLEED PRESSURE

TO COLUMN
ACCESSORIES SUMP =i^ =u [rQ-Q-'J REGULATED 100 PSI PRESSURE
m., .C
SUMP
PUMP 366-509
PRESSURE 82-5-B JR
Figure 3-5. EG Actuator Schematic, No Ballhead Backup
18 Woodward
Chapter 4
Operation and Adjustments
Introduction
Because the PGA-EG and PGG-EG are each a combination of an electric
actuator and a ballhead governor, routine start-up adjustments can be more
complex than on other governors.
When installing or adjusting a PGA-EG/PGG-EG which has been taken off an

engine or has been repaired, make sure to understand if the governor is running
under control of the electronics or on the ballhead. Be sure of electronic control
when setting the dynamics of the electronic control system.
Centering Adjustment
The torquc-motor/pilot valve relationship in the electric actuator is
calibrated at the factory and should not need readjustment unless the
torque motor, the pilot valve plunger, or the pilot valve bushing is replaced.
The adjustment is extremely sensitive and will change all other adjustments.
DO NOT TOUCH any of the calibration adjustments unless thoroughly

familiar with the electrical portions of the control. Complete calibration of
the actuator should not be attempted on the engine as overspeeding or other
dangers may occur during the calibration process.
It is absolutely vital that the armature/torque motor beam combination is

correctly centered between the magnets of the torque motor. If the tools to assist
this action arc not available, do not attempt to do this.
If a torque motor has been disassembled, it may be necessary to re-magnetize the

magnets to ensure the torque motor will have enough power to allow all settings
to be made. Since measuring the amount of magnetism present is very difficult,
do not disassemble the magnet unless you are able to re-magnetize it afterwards.
CAUTION
A Use of the proper tools for the centering adjustment is essential to
proper control operation. These tools are available only in specially-
equipped workshops.
NOTE
DO NOT DISASSEMBLE any part of the torque motor outside a
Woodward plant.
Woodward 19
DO NOT DIS-ASSEMBLE
TAILROD (REF. ONLY)
366 - 520
99-09-02
Figure 4-1. Torque Motor Exploded View
20 Woodward

Ref. No. Part Name......................... Quantity
36637-1 internal retaining ring........ 1
36637-2 bi-metal washer................ 1
36637-5 flat washer......................... 1
36637-6 regulator spring.................. 1
36637-7 regulator............................ 1
36637-8 bushing............................... 1
36637-9 actuator plunger................ 1
36637-10 grommet............................ 1
36637-11 screw 6-32 x .750............. 2
36637-12 torque motor cover........... 1
36637-13 armature stop.................... 1
36637-14 torque motor magnet........ 1
36637-15 reduced nut........................ 2
36637-16 spring adjuster.................. 1
36637-17 trim spring.......................... 2
36637-18 armature............................ 1
36637-19 torsion spring..................... 1
36637-20 flapper spacer.................... 1
36637-21 torque motor beam........... 1
36637-22 not used
36637-23 not used
36637-24 not used
36637-25 not used
36637-26 screw 8-32 x .750............. 1
36637-27 control adjuster................. 1
36637-28 torque motor house.......... 1
36637-29 screw 6-32 X 1.000........... 4
36637-30 washer................................ 4
36637-31 buffer spring....................... 1
36637-32 primary feedback lever.... 1
36637-33 screw 10-32 x .375........... 1
36637-34 range adjustment strap.... 1
36637-35 screw 10-32 x 1.000......... 1
36637-36 tailrod clamp...................... 1
36637-37 secondary feedback lever, 1
36637-38 pivot pin.............................. 2
Woodward 21
Figure 4-2. Mode Select Block Exploded View
22 Woodward
Ref. No. Part Name.................. Quantity

36637-101 O-ring.......................... 1
36637-102 O-ring.......................... 2
36637-103 block- PG-200............ 1
36637-104 screw- .250-20 x 1.50 4
36637-105 washer........................ 4
36637-106 O-ring.......................... 2
36637-107 O-ring.......................... 1
36637-108 block- PG-58.............. 1
36637-109 screw- .312-18 x 2.50 4
36637-110 washer........................ 4
36637-111 O-ring........................... 1
36637-112 O-ring........................... 2
36637-113 O-ring........................... 1
36637-114 pilot valve.................... 1
36637-115 spring........................... 1
36637-116 O-ring........................... 1
36637-117 plug.............................. 1
36637-118 retaining ring.............. 1
36637-119 pressure switch.......... 1
36637-120 elbow........................... 1
numbers 121 to 129 not used
36637-130 screw-.250-20 X 3.00............. 3
36637-131 washer....................................... 3
36637-132 plate- cover............................... 1
36637-133 O-ring......................................... 1
36637-134 seal............................................ 1
36637-135 plunger- driver......................... 1
36637-136 connector.................................. 1
36637-137 block- pneumatic mode select 1
36637-138 decal-PGEG mode select....... 1
36637-150 screw- .250-20 x 1.75........ 3
36637-151 washer................................. 3
36637-152 knob...................................... 1
36637-153 O-ring.................................... 1
36637-154 block- manual mode select. 1
36637-155 retaining ring....................... 1
36637-156 decal- manual mode select 1
36637-170 screw- .250-20x2.00.......... 3
36637-171 washer................................. 3
36637-172 block- electric mode select 1
36637-173 valve 3 way-solenoid......... 1
36637-174 decal- electric mode select 1
Woodward 23
Integral EG Actuator for PG Governors__________________ Manual 36637
Adjustment of the Anti-rotation Device

On the PG-EG actuator with no ballhead, to prevent the feedback lever between
the tailrod and the actuator from becoming dislodged by vibration, an anti
rotation device has been added. It consists of a steel plate mounted on the cover
of the torque motor which guides a pin protruding from the tailrod. Because of
the tolerance of the slot in which the pin moves up and down, and the thickness
of the plate, it is important that pin and plate are perpendicular to each other. To
adjust this, the mounting screws of the plate run through two slots, allowing the
plate to be positioned correctly.
If the guiding plate has been removed, assemble as follows.
1. Install the guiding plate and mount the screws by hand. Do not tighten the
screws but allow small adjustments.
2. First check visually if the plate is set perpendicular to the pin. Adjust this by
moving the plate in its slots until it is.
3. Now run the tailrod up and down. This will set the plate in the correct
position and ensure the slot and the tailrod are exactly parallel. Now tighten
the screws to a torque of 0.7-0.8 N-m (6-7 lb-in).
Mode Select Valve and Mode Indicating Switch
Mode Indicating Pressure Switch

To show the mode the governor is working in, a mode indicating pressure switch
is available.
Two switches are available:

• one for use with 690-896 kPa (100-130 psi) pump pressure governors, with
a switch point of 586 kPa (85 psi);
• one for use with 1379 kPa (200 psi) pump pressure governors, with a switch
point of 1276 kPa (185 psi).
The switch is mounted in one of two locations, depending on whether or not the
governor is equipped with a mode select valve.
No Mode Select Block

When the governor is not equipped with a mode select block, use the switch
mounting position available on the mode select block. For both 690 kPa/100 psi
and 1379 kPa/200 psi pump pressures, the resultant signals are:
• pins A-C closed = pins A-B open = EG-mode;
• pins A-B closed = pins A-C open = PG-mode.
24 Woodward
Mode Select Block
When the govcmor is equipped with a mode select block, use only the position
available on the mode select block. Do not use the switch mounting position on
the connecting block in this case. For both 690 kPa/100 psi and 1379 kPa/200 psi
pump pressures, the resultant signals arc:
• pins A-C closed = pins A-B open = EG-mode;
• pins A-B closed = pins A-C open = PG-mode.
Mode Select Valve

A mode select valve allows the operator to choose and influence the mode the
governor is controlling in. This can be done by means of either a manual,
electrical, or pneumatic signal to the mode select valve.
The valve has two modes:

• Mechanical Control (or PG mode): The oil from the accumulator is routed
through the mode select valve to the ballhead pilot valve/compensation
system and into the servo.
• Electrical Control (or EG mode); The oil from the accumulator is routed
through the mode select valve to the actuator pilot valve, back to the mode
select valve, and through the ballhcad pilot valvc/compensation system into
the servo.
NOTE
In electrical mode, the actuator pilot valve and the ballhead pilot
valve are placed in series. In order for the governor to operate in this
mode, it is necessary to raise the mechanical speed setting over the
electrical speed setting, since this offset will open the ballhead pilot
valve and keep it “out of the way.” This speed difference should
amount to 5-10% of the maximum speed.
For more detail on the additional set-up conditions when used as a PGA-
EG/PGG-EG tracking ballhead with a Woodward control, please refer to
Woodward Application Note 50529, Matching PGA-EG Ballhead Speed to the
507 Speed Setting Signal.
CAUTION
A Under EG mode, the ballhead will still control If the PG speed setting
is lower than the EG.
The mode select valve consists of a pilot valve located in a block which is
mounted onto the side of the governor power case. Internal governor hydraulics
are routed through the block. When the pilot valve is driven against a return
spring, the valve will switch. When the driving force is removed, the spring
returns the pilot valve and the valve switches back. Two pilot valves are
available: a direct-acting one and a reverse-acting one.
Woodward 25
Five different methods are available to drive the mode select valve:
Manual—Turning a knob clockwise directs pressure oil against the end of the
valve plunger and forces the plunger against the return spring to switch into PG
mode. Turning the manual knob counterclockwise connects the operating end of
the mode select valve plunger to drain, allowing the return spring to move the
plunger and switch to EG mode.
Direct Electrical—A 24 Vdc signal moves a solenoid valve to direct pressure

oil against the end of the direct-acting valve plunger and forces it against the
return spring to switch into PG mode. Removal of the electrical signal connects
the operating end of the valve plunger to drain, allowing the return spring to
move the plunger and switch to EG mode.
Reverse Electrical—A 24 Vdc signal moves a solenoid valve to direct pressure

oil against the end of the reverse-acting valve plunger and forces it against the
return spring to switch into EG mode. Loss or removal of the signal connects the
operating end of the valve plunger to drain, allowing the return spring to move
the plunger and switch to PG mode.
Direct Pneumatic—Air pressure drives a plunger which shuttles the direct-

acting mode select valve plunger against the return spring to switch into PG
mode. Removal or loss of air pressure will cause the return spring to move the
plunger back and switch to EG mode.
Reverse Pneumatic—Air pressure drives a plunger which shuttles the reverse

acting mode select valve plunger against the return spring to switch into EG
mode. Removal or loss of air pressure will cause the return spring to move the
plunger back and switch to PG mode.
Maintenance
The mode select valve should require minimal or no maintenance. 0-rings
should be replaced to eliminate possible oil leaks. The pneumatic, electric, or
manual actuator which sets the position of the pilot valve may be removed from
the housing for cleaning or repair.
CAUTION
A Do not attempt to disassemble any portion of the mode select valve
with the governor running. Pressure oil circulates in all parts of the
valve, and the governor will quit operating, and oil will be pumped
out of the governor should any part of the valve be loosened or
removed while the governor is running.
26 Woodward
Applications
The ballhcad governor and ihe electric-inpul actuator operate continually, with
each having its own desired fuel-output position. PGA-EG hydraulics select the
lesser of the two fuel outputs for the actual fuel output.
Setting up for reverse-acting means that the electronics in the control are
programmed for reverse-acting; the actuator must be calibrated to accept this
reverse signal. Loss of electrical signal to the actuator causes the actuator to call
for increased fuel, moving the output to increase until the ballhead lakes over
control (remember that for correct actuator use, the mechanical speed setting
must be raised by 5-10%). This means that the reverse-acting setup of control
and governor results in automatic switching from electrical control to ballhead
control should electronic failure occur, although at a higher speed.
When control and actuator arc set up for direct-acting, loss of electronic signal to
the actuator means that the actuator goes to minimum fuel. Since the ballhead is
set to a speed 5-10% above the electronic maximum speed, it cannot lake over
control.
Woodward 27
LOCATION FOR PRESSURE

MEASUREMENTS OF EG-ACTUATOR
366-522
99-05-02
Figure 4-3. Assembly and Tubing Exploded View
28 Woodward

Ref, No. Part Name................. Quantity
36637-201 0-ring......................... 3
36637-202 connector- elbow...... 1
36637-203 connector- straight.... 2
36637-204 tubing .375 OD......... AR
36637-205 washer....................... 2
36637-206 screw .250-28 x 2.50 2
36637-207 filter............................... 1
36637-208 manifold block........... 1
36637-209 plug .125 NPTF........ 2
36637-210 0-ring......................... 2
36637-211 gasket........................ 1
36637-212 washer....................... 1
36637-213 screw .250-28 X 1.25 1
Woodward 29
30 Woodward
Chapter 5
Service Options
Product Service Options

The following are the factory options available for the service of Woodward
equipment under Woodward’s standard Product and Service Warranty (25222),
in effect at the time the product is sold from Woodward or the service is
performed:
• Replacement/Exchange (24-hour service)
• Flat Rate Repair
• Flat Rate Remanufacture
If you are experiencing problems with installation or unsatisfactory performance

• Consult the troubleshooting guide in the manual.
• Contact Woodward technical assistance (see “How to Contact Woodward”
later in this chapter) and discuss your problem. In most cases, your problem
can be resolved over the phone. If not, you can select which course of action
you wish to pursue based on the available services listed in this section.
Replacement/Exchange
Rcplaccment/Exchange is a premium program designed for the user who is in
need of immediate service. It allows you to request and receive a like-new
replacement unit in minimum lime (usually within 24 hours of the request),
providing a suitable unit is available at the time of the request, thereby
minimizing costly downtime. This is also a Flat Rate structured program and
includes the full standard Woodward product warranty, pursuant to Woodward’s
Product and Service Warranty (25222).
This option allows you to call in advance of a scheduled outage or an unexpected

outage and request a replacement control unit. If the unit is available at the lime
of the call, it can usually be shipped out within 24 hours. You replace your field
control unit with the like-new replacement and return the field unit to the
Woodward facility as explained later in this chapter.
Charges for the Replaccment/Exchange service are based on a flat rate plus
shipping expenses. You are invoiced the flat rate replacement/exchange charge
plus a core charge at the time the replacement unit is shipped. If the core (field
unit) is returned to Woodward within 60 days. Woodward will issue a credit for
the core charge. (The core charge is the average difference between the flat rate
replacement/exchange charge and the current list price of a new unit.]
Woodward 31
authorization label is included with every Replacement/Exchange unit that
leaves Woodward. The core should be repackaged and the return authorization
label affixed to the outside of the package. Without the authorization label,
receipt of the returned core could be delayed and cause additional charges to be
applied.
Flat Rate Repair

Flat Rate Repair is available for the majority of standard products in the field.
This program offers you repair service for your products with the advantage of
knowing in advance what the cost will be. All repair work carries the standard
Woodward service warranty, pursuant to Woodward’s Product and Service
Warranty (25222) on replaced parts and labor.
Flat Rate Remanufacture

Flat Rate Remanufacture is very similar to the Flat Rate Repair option with the
exception that the unit will be returned to you in “like new” condition and carry
with it the full standard Woodward product warranty, pursuant to Woodward’s
Product and Service Warranty (25222). This option is applicable to mechanical
products only.

If a control (or any part of an electronic control) is to be returned to Woodward
for repair, please contact Woodward in advance to obtain a Return Authorization
Number. When shipping the item(s), attach a tag with the following information:
• name and location where the control is installed;
• name and phone number of contact person;
• complete Woodward part number(s) and serial number(s);
• description of the problem;
• instructions describing the desired type of repair.
CAUTION
A 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.
32 Woodward
Packing a Control
Use the following materials when returning a complete control:
• protective caps on any connectors;
• antistatic protective bags on all electronic modules;
• packing materials that will not damage the surface of the unit;
• at least 100 mm (4 inches) of tightly packed, industry-approved packing
material;
• a packing carton with double walls;
• a strong tape around the outside of the carton for increased strength.
Return Authorization Number

When returning equipment to Woodward, please telephone and ask for the
Customer Service Department [(1)(800) 835-5182 in North America or
(1)(970) 498-581!]. They will help expedite the processing of your order
through our distributors or local service facility. To expedite the repair process,
contact Woodward in advance to obtain a Return Authorization Number, and
arrange for issue of a purchase order for the itcm(s) to be repaired. No work can
be started until a purchase order is received.
NOTE
We highly recommend you make arrangement in advance for return
shipments. Contact a Woodward customer service representative at
(1 )(800) 835-5182 in North America or (1 )(970) 498-5811 for
instructions and for a Return Authorization Number.
Replacement Parts
When ordering replacement parts for controls, include the following
information:
How to Contact Woodward

In North America use the following address when shipping or corresponding:
PO Box 1519
1000 East Drake Rd
TELEPHONE: (1)(970) 498-511 (24 hours a day)

TOLL-FREE PHONE (in North America); (1)(800) 835-5182
FAX: (I)(970) 498-3058
Woodward 33
Woodward facilities to obtain the address and phone number of the facility
nearest your location where you will be able to get information and service.

Australia (61)(2) 9758 2322
Brazil (55)(19) 708 4800
England (44)(118) 975 2727
India {91X129) 230419
Japan (81)(476) 93-4661
The Netherlands (31)(23) 5661111
Singapore (65)270-0081
You can also contact the Woodward Customer Service Department or consult
our worldwide directory on Woodward’s Internet website for the name of your
nearest Woodward distributor or service facility:
http://www.woodward.com/industrial/address.htm
[Woodward’s website address is http://www.woodward.com]
Additional Aftermarket Product Support Services

Woodward Aftermarket Services offers the following after-sale support for all
Woodward products:
• Technical Assistance
• Field Service
• Specialized Services
Customer Training is offered at our facility in Loveland, Colorado, or at your

site. This training, conducted by experienced trainers, will assure that customer
personnel will be able to maintain system reliability and availability. For
information concerning training available, call the number above and ask for
customer training.
Technical Assistance is available using the Woodward toll-free number. The

technical questions or problem solving during normal business hours or as
support for changes or enhancements after the commissioning of your system.
For technical engineering assistance, call the number above and ask for technical
assistance.
34 Woodward
Field Service engineers are clispalchecl from the Woodward facility in Colorado,
provide prompt response. Woodward field engineers are experienced and are
documentation is updated, and all field engineers are well infonned as to new
problems which might arise. Woodward field service engineers arc on-call 24
hours a day. Call the number above and ask for field senice.
Specialized Services can be tailored to your specific needs. These services can
be based on a particular aspect of a single service or a combination of services
and are covered under one low-cost service contract. A contract may be for
regularly scheduled training courses or possibly to have a field engineer visit
your site at pre-determined intervals to provide a system analysis, verify proper
operation, and make recommendations for maintenance improvements,
enhancements, or other needs. These contracts arc usually custom-designed and
structured to allow ultimate flexibility, thereby allowing you to plan and budget
more accurately. For more details, contact the Woodward sales representative, or
call the number above and ask for sales support to discuss specific needs.
Woodward 35
Integral EG Actuator for PG Governors_______ Manual 36637
Technical Assistance
If you need to telephone for technical assistance, you will need to provide the following information.
Please write it dow'n here before phoning:
General
Your Name___
Site Localion_
Phone Number
Fax Number
Prime Mover Information

Engine/Turbine Model Number______
Manufacturer______________________
Rating____________________________
Application_______________________
Governor Information
Please list all Woodward governors, actuators, and electronic controls in your system:
Serial Number
Serial Number
Serial Number
If you have an electronic or programmable control, please have the adjustment setting positions or
the menu settings written down and with you at the rime of the call.
36 Woodward
Attention: Technical Publications
PO Box 1519
Please include the manual number from the front cover of this publication.
Industrial Controls
Woodward Governor Company, PO Box 1519 (1000 East Drake Road), Fort Collins CO 80522-1519, USA
Phone (1 )(970) 482-5811 • Fax (1 )(970) 498-3058
Global Services
Woodward Governor Company, PO Box 3800 (3800 North Wilson Avenue), Loveland CO 80539-3800, USA
Phone (1)(970) 663-3900 • Fax (1)(970) 962-7050
E-mail and World Wide Web Home Page—http://www.woodward.com
Registered Firm
ISO 9001:1994/Q9001 -1994
Certificate QSR-36
DUTCH COUNCIL
FOR CERTIFICATION
Woodward has company-owned plants, subsidiaries, and branches,

as well as authorized distributors and other authorized service and sales faciities throughout the world.
Complete address/phone/fax/e-mail information for all locations is available on the Internet at:
99/9/F
7
WOODWARD^
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© A I /tVCM) I
A ©:
P/N’s 8280-505
8280-506
WOODWARD GOVERNOR COMPANY
MANUAL 02845B
WARNING
Read this entire manual and all other publications pertaining to the >vork 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.
The engine, turbine, or other type of prime mover should be equipped with an
overspeed (overtemperature, or overpressure, where applicable) shutdowTi device(s),
that operates totally independently of the prime mover control device(s) to protect
against runaway or damage to the engine, turbine, or other type of prime mover with
possible personal injury or loss of life should the mechanical-hydraulic governor(s) or
electric control(s), the actuator(s), fuel control(s), the driving mechanism(s), the
linkage(s), or the controlled device(s) fail.
CAUTION
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.
CAUTION
Electronic controls contain static-sensitive parts. Observe the following precautions

to prevent damage to these parts.
• Discharge body static before handling the control (with power to the control
turned off, contact a grounded surface and maintain contact while handling the
control).
• Avoid all plastic, vinyl, and styrofoam (except antistatic versions) around
printed circuit boards.
• Do not touch the components or conductors on a printed circuit board with
your hands or with conductive devices.
I Manual revision history can be found on the inside back cover.
Woodward Governor Company reserves the right to update any portion of this publication at any time. Information provided by
Woodward Govemur Company is believed to be correct and reliable. However, no responsibility is assumed by Woodward Governor
Company unless otherwise expressly undertaken.
© 1998 by Woodward Governor Company
CAUTION!!!!
I he coiingnratioii in this Control is set for engine no. 9I36I (1).
If the eontrol is used on other engines, please change eonfinuration according attached Installation Data
Sheet.
GOVERNOR SERVICE, VAASA, FINLAND
WARTSILA
INSTALLATION DATA Controls part no 8280-505 rev. B
Installation name FITM)KR682 Controls CAP CTRL no 5414-170. \V / 9906-619.
I Engine t\ pe 12V46 c: Controls serial no ( s ) 12357520 12357521
Engine rpm. low high 380 / 500 Controls serial no ( s ) 12357522 12357523
Engine no ( s ) '91361 91362 91363 91364 Hand Held part serial no 9907-205 /
Propulsion Control Controls voltage ( VDC ) 24 Drg.no:
ADJUSTMENT OF VALUES IN 723PHj'S FOR PROPULSION INSTALLATIONS
Configure Value List
(-'onfigure Prompt Start \'aluc Final \'aluc / Engine
*PASSCODE* Eng I Eng 2 Eng 3 Eng 4 Eng 5 Eng 6 Ena 7

Enable Conligure 723
' nablc Service 723
•ENGINE SPEED*
Pulses Rev a 1 116

Ma>amum Hz » I 1257
Pulses Rev # 2
U6
Ma.virmim Hz ^ 2 1257
Pulses Rev ■? 1 DIG 116
Pulses Rev a ? DIG 116
SPDANA = F DIG = T WAIIR
Torsional Filter FALSCH
Rated Speed (rpm) 500
Low Setpoint A \ (rpm) 129
0\emde Speed " I (rpni) 181
Minimum Speed a ) (rpm) 207
Low Setpoint « 2 (rpm) 129
Override Speed » 2 (rpni) 181
linimum Speed ^ 2 (rpni) 207
♦FINAL DRIVER*
Actuator Output SEL
2
Reverse Acting? FALSCU
En Mismatch Detect FALSE
Mismatch SD Dela\
(s) 5
♦MODBUS J.3*
MvMlcU=ASai2=RTU) 2
SIu\c Address I
•CONFIGURE*
Enable Calibration F.U.SCH
Tandem Nixie ^ uniq 2 1 1 2
System Nixie ^ uniq 3 4 2
Single Propulsion? FM^cn .sheet I
I
. .'4'-
r.
•J
Configure Value List

|C!onfigure Prompt Start Value Final Value / Engine
•CONTROL OPTIONS* Eng 1 Eng 2 Eng 3 Eng 4 Eng 5 Eng 6 Eng 7
DO 4 y? 3
Open DI « 1 to Run? TRIE
Open DI 4 8 for DIGTL FALSE
Open Dl - 6 for Isoch TRIE
DI 7 Fuel Limiter Shift FALSE
IX) 4 1 NO? FALSE
DO ^ 2 NO? VAISE
00^3 NO? TRIE
LON Svnehrophaser? FALSE TRIE TRIE ERIE TRl E
0\erspecd SD'^ FALSE
AI 4 1?
1
AIfi2?
2
M4 3?
AI 4 4? 5
/ I /
"lutch-In Bias Enable WAIIR
*CONF MODBUS IP’S*

Drot>p Isochronous FALSCH
Didilal .Analogue FALSCU
Start Stop F.VLSCH
Unload FALSCH
Reset FAI.SCH
Increase Decrease FALSCH
( onfitnire Prompt Sen ICC Value List
♦DISPLAY ANALOGUES* Ena 2
__ En2 1 Eng 3 Eng 4 Eng 5 Eng 6 Eng 7
Engine Speed (rpm) Monitor
Speed Reference (rpm) Monitor
Actuator Position (%) Monitor
Hneine Load
(%) Monitor
MW Load (MW) Monitor
.Analogue Reference (rpm) Monitor
Droop Bias (rpm) Monitor
>nchrophaser Bias (rpm) .Monitor
MW Dtck->p Bias (MW) Monitor
Charger Air Pressure (bar) Monitor
System Load
(“o) Monitor
I.oad Share Error
(%) Monitor
Other Analogue Ref (mA) Monitor
Other Speed Ref
(tpnt) Monitor
Assy metric LS Bias
(%) -Monitor
Fuel l.imit Actuator
Cô) Monitor
Fuel Limit Load (®o) .Monitor
Al^ 1 ( mA) Monitor
Al=^2 ( mA) .Monitor
AI=J3 C mA ) Monitor
AI = 4 (mA) Monitor
Other Engine Speed (rpm) .Monitor
Other Engine Load Cô) Monitor I sheet 2
L
I
N I
Service Value List

|Configure Prompt Start Value Final V alue / Engine
'♦DISPLAY BOOLEANS*
Ene ( Eng 2 Eng 3 Eng 4 Eng 5 Eng 6 Eng 7
Load Sharing Monitor
Analogue Selected Monitor
Analogue Active Monitor
Digital Selected Monitor
Digital Active Monitor
Clutch IM Monitor
Sliuldovvn A/anii Monitor
Minor Alarm Monitor
Near Fuel Limit Monitor
Above Max POS.? Monitor
•DYNAMICS 1*
Idle Prop Gain s I
0.22
Rated Prop Gain # I
0.22
lie Int Gain = 1 (1 s) 0.53
aled Int Gain = I (1 s) 0.53
Idle SDR ^ 1 19
Rated SDR = 1
19
.•DYNAMICS = 2*
Idle Prop Gain ~ 2 0.32 0.32 0.32 0.32 0.32
Rated Prop Gain ^ 2 0.32 0.32 0.32 0.32 0.32
Idle Int Gain = 2 (I s) 0.43 0.35 0.35 0.35 0.35
Rated Int Gain = 2 (i s) 0.43 0.43 0.43 0.43 0.43
Idle SDR = 2 23 23 23 23 23
Rated SDR = 2 23 23 23 23 23
Prv>paain Multiplier
1 \ \ 1 1
•DYNAMICS = 3*
Prop Gain = 3 0.32
Inlcrgal Gain = 3 (1 s) 0.43
'’DR = 3 23
•DYNAMICS = 4*
Prop Gain = 4 0.32
Intcrgal Gain = 4 (1 s) 0.43
SDR =4 23
Propgain Multiplier
•G.MN SLOPED
Load BKPT = I
(%)
Multiplier = I
Load BKPT = 2 ro)
Multiplier = 2
sheet 3
Scnicc Value List
.C-onfigure Prompt Start VaIkk Finai %'alue / Kngine
i*GAIN RATIO*
Error Window 4 I (rpm) ioo
Gain Ratio = !
1
Error Window ~ 2 (rpm) 10
Gain Ratio 42 2
Error Window 4 3 (rpm) 10
Gain Ratio 4 3
2
Error Window 4 4 (rpm) II)
Gain Ratio 4 4
2
*ENGINE SPEED*
Enable LP Kilters TRIE
Low Pass Filler Freq. (Hz) 6
Enable Nofc/i Filter 4 / TRIE
liter 4 I FrequencN' (Hz) 3

ilter 4 \ Q Factor 4
E-mable Notch Filter 4 2 TRIE
Filler ~ 2 Frequency (Hz)
Filter 4 2Q Factor
Sensor Weight
Two Speed Sensor?
Clutch Delas
(s)
Clutch in Speed (rpm)
Clutch in Window (rpm)
Clutch Close Dela\ (s)
*SPEED REFERENCE*
Idle Speed (rpm) 250
Minimum Speed (rpm) 300
Maximum Speed (rpm) 550
’îxed Speed (rpm) 410
ccleraiion Rate (rpm s) 20
Digital Rale = I (rpm s) 10
Digital Rate = 2 (rpm s) 5
.Analogue Rale = 1 (rpm s) 10
.'\jialogue Rate - 2 (rpm s) 5
Fixed Speed Rate (rpm s) 20
DriHip Unload Rate (rpm s)
Idle Rated Switch (rpm) 200
Rem Ref't? 4 mA (rpm) 350
Rem Ref ■<7 20 mA Isoc (rpm) 500
Rem Ref 20 mA Drixip (rpm) 520
Synchrophaser Gain (rpm) I
Ramp to Rated - Digital WAHR
Clutch - IN Offset (rpm) 10
Ref Equal W'îndou (rpni) 15
sheet 4
Senice Value List
.Configure Prompt Start N'alue Final Value I Engine
'*RACK SENSR & LOAD*
Eng 1 Eng 2 Eng 3 Eng 4 Eng 5
6
Rack mA (w Stop Posn (mA) 5
Rack mA - 1 (mA) 7
Load ** o 1 (“o) 0.00
Rack mA » 2 (mA) 9
Lixid ® o ^ 2
(‘’O 25
Rack mA ^ i (mA)
lA>ad% ^3 (%)
Rack mA 4 (mA)
Load 0 4
C’o)
Rack mA 4 5 (niA)
Load“o 5 r^'o)
Rack mA '§) Max Slop (mA)
Lv\ad ® 0 Max Stop
(%) 103
No Load ACT% (ô) 15
0%Load ACT*-o (‘'o) 50
ill Load ACT % C’o) 75
Drixip ("O 4.00
Load Filter (Hz) 1
i*LOAD SHARING*
Load Share Dcla>
(s) 2
Lixid Rate (%s) 15
Unload Rate 30
Unload Trip Level
(%) 10
Load Gain
LON Load Sharing? TRIE
Sei “o Unloading
FALSCH
Unload ®o of ®o Load 40
Enable UTL MW Offset FALSE
*MW DRCX)P*
''IW‘ Droop (%) 4
Filler (Hz) 1
Rated Load (MW)
Enable Drix)p Switch (®o) 0.00
MWLP'^ 4 niA (MW') 0.00
MW' I P '3 20 mA (MW)
sheet 5
Semce Value List
|C'oufigurc Prompt Start Value Final V'atuo !
*ST/\RT MAX LIMITER*
Start Fuel Limit X 1 (rpm)
Start Fuel Limit Y 1 (‘•o)
Start Fuel Limit Y 2
(%)
(%)
Start Fuel Limit X4 (rpm)
Maximum Fuel Limit
Analog Near Fuel Limit
DIGTL Near Fuel Limit
Fuel Limit Shil^
•CI-IARGE AIR LIMIT*

Ihg Air Press 4mA (bar)
hg Air Press 'fl»20mA (bar)
Chg Air Pressure A (bar)
Load ®o A
C*o)
Chg Air Pressure B (bar)
Load%B Cô)
Chg /\ir Pressure C (bar)
Load “o C
(%)
Chg Air Pressure D (bar)
Load ”00
Enable Limiter Dela\
*TORQUE LIMITER*
Engine Speed A (.rpm)
Load ®o A
(°o)
Engine Speed B (rpm)
Load ^ 0 B
''ngine Speed C (rpm)
oad '^0 C (°o)
Engine Speed O (rpm)
Load "0 D
Enable Limiter Dela\
*RUN STOP*
Rundown Time
Pulse Coni .AJam)
Alam^ Pulse Time
•OVERSPKED*
Overspecd Trip
Actuator DEC Pulse
Actuator DEC Level
Ot erspeed Count
Reset OSPD I>clav (mins)
Sen ice Value List
I Configure Prompt ■Start V'aiue Final VaJue / Kngine
j*ANALOG 0:‘P CONFIG*
Eng 1 Eng 2 Eng 3 Eng 4 Eng 5 Eng 6 Eng 7
AO ¥ 1
6
AO #2
6
AO ^3 3
Rack AO 4 mA 4
Rack AO 'a; 20 mA
20
ACT POS AO 'O' 4 mA 0.00
ACTPOSAOa 20 mA
100
niA 'ct Stop POSN 4
mA0“ 0 Load 7
niA ^ 100*’ 0 Load 18
0\ erload Factor ® o
1
Speed 1 AO@ 4 mA 0.00
Speed J AO ® 20 mA 650
Speed 2 AO@ 4 mA. 0.00
'peed 2 AO ® 20 mA 650
peed AO@ 4 mA 0.00
Speed AO 'q 20 mA 650
Limit AO ® 4 mA 0.00
Limit AO 'a 20 mA
110
PID AO 'q- 4 mA 0.00
PID AO '■« 20 mA
no
SPD Ref AO a 4 niA 0.00
SPD Ref .AO 'a 20 mA 650
Limit Dirt*® 4 m.'\
-10
Limit Dirt'® 20 mA
10
Limit O P ACT Load FALSCU
Di/r O P ACT Load FALSCH
Charge /^r AO a 4 mA (bar) 0.00
Charge Air AO o 20 mA (bar) 4
*.n PORT SETUP*

•=Sen Link. 2=HHT 1
*SERVLJNK SETUP*
Baud
l=RS232. 2=RS422
*MODBUS PORT SETUP*

Hardware Conlig
2
Baud Rate 5
Stop Bits
1
Paril>'
1
Timeout
(s)
Enable Modbus AJamis FALSCH
sheet 7
Semce Value List
|C!onfigure Prompt Start Value Final Value / Kneine
•CAL/BRATION* Eng 1 Eng 2 Eng 3 Eng 4 Eng 5 Eng 6 Eng 7
A1 4 1 OlTsel
0.00
AJ 4 I Gain
1
A1 2 Offset
0.00
AI - 2 Gain
1
AI a 3 Offset 0.00
AI ^ 3 Gain
I
Ai 4 4 Offset 0.00
A1 s 4 (}ain
Close LS Relav
FA use U
Manual Load Out?
FALSCH
Load Out Set 1000
LS Lines Offset 0.00
LS I.ines Gain 21845
LS Load Offset 2028
•S Load Gain 8083
NIP ^1 niA Monitor
AN IP d 2 mA .Monitor
AN IP 4 i niA -Monitor
ANJP ^4mA Monitor
AN O P 3 I Offset
0.00
/VNOP=i I Gain
1
AN O.P « 2 (Offset
0.00
AN O P = 2 Gain
1
ANOP:i3 0ftset
0.00
AN O I’ = 3 Gain
1
.AN O P Calibration 4
Actuator O P Offset 0.00
Actuator O P Gain I
•MAINOR ALARM*
AI :: 1 FLT .Monitor
M =2FLT Monitor
1 =3FLT Monitor
AI =4 FLT Monitor
LON =* 1 FLT Monitor
LON = 2 FLT Monitor
Speed Sensor FLT Monitor
SS FLT - TF Enabled Monitor
Modbus Fault Monitor
•MAJOR SD ALARM*
Both SS Failed Monitor
Overspeed Monitor
Mismatch Delected Monitor
sheet 8
•. I
Scn ice Value List

Configure Prompt Start \'alue Final \‘aiue / F.nginc
*F1JEL LIMITING’*
Torque Limilcr Monitor
'7HG /\ir IJmlter Monitor
ax Load Limiter -Mj)nitor
Start Fuel Limiter Monitor
Engine Shutdov.n Monitor
Oterspeed Limiting Monitor
*SPDFI.T OVERRIDE :•
Select 0\crride 2 FAI^CH TRIE TRIE
Firingspeed 40 150 150
Ihsteresis
10
Select Strtlim = 2 ? FALSCH
I COMMENTS:
Work Performed By Final Value List A.Saarl

'Work Date Date 18.02.02
Manual 02845B Contents
Contents
CHAPTER I GENERAL INFORMATION 1
Introduction 1
Application 1
CHAPTER 2 723PLUS DCS 3

723PLUS Digital Control, Declaration of Incorporation 3
723PLUS Digital Speed Control Accessories................ 3
723PLUS Control Specifications................................... 3
CHAPTER 3 ELECTROSTATIC DISCHARGE AWARENESS 7
CHAPTER 4 723PLUS INSTALLATION 9

Scope 9
Unpacking 9
Power Requirements 9
Location Considerations.................. 10
Electrical Connections .................... 10
Shielded Wiring................... 10
Power Supply ....................
Digital Relay Outputs.......... II
Load Sharing Lines Input..... 12
Speed Signal Inputs.............. 12
Analogue Outputs................. 12
Actuator Output................... 13
Discrete Inputs..................... 13
Analogue Inputs................... 13
Serial Communications Ports 13
Termination.............. 13
Grounding & Shielding 15
Local Operator Network........... 16
Internal Jumpers ............. 18
Installation Checkout Procedure 23
CHAPTER 5 SYSTEM DESCRIPTION 25

Engine Speed 25
Speed Sensing ......... 25
Overspeed Protection 26
Speed Filtering......... 26
Speed Control 27
Engine Start ............ 27
Clutch Ready To Close 27
Droop Control ........ 28
Isochronous Load Sharing.... 28
Tandem Isochronous 28
1
Contents Manual 02845B
Droop/Isochronous............ 29
Operating Modes .................. 30
Normal Use for Each Mode 30
Fuel Limiters 31
Start & Maximum Fuel Limiter... 31
Charge Air Pressure Limiter....... 31
Torque Fuel Limiter................... 31
Fuel Limit Indication.................. 31
Fuel Limit Shift 3 2
PID Control & Actuator Output............. 32
Run/Stop & Alarms ........................... 32
Modbus® Communications & Control.... 33
Analogue Outputs .......................... 34
Control Options .......................... 34
Operator Interface .......................... 35
Configure Values List ........................... 38
Service Values List ........................... 39
Configure & Service Descriptions .......... 44
Configure .......................... 44
Service ........................... 49
Modbus® Communications Address List 80
Boolean Writes 80
Boolean Reads ........................... 80
Analogue Reads.......................... 81
Analogue Writes......................... 81
CHAPTER 6 MODBUS® COMMUNICATIONS 83
CliAPTER 7 SETPOINT PROGRAMMING, 89

Introduction 89
Hand Held Programmer and Menus ... 89
Hand Held Programmer Keys 90
Configure Menus................... 90
Service Menus ..................... 92
Adjusting Setpoints 92
PC Interface 93
Interponents Interface............................................. 93
Tuning Parameters..................................... 94
Shutting Down/Re-Staiting/Saving Values 94
Status Bar.................................................. 95
Displaying Parameters............................... 96
Alarm Viewer............................................ 96
Watch Window...................................................... 97
Main Window............................................ 98
ServLink Explorer..................................... 98
ServLink Inspector..................................... 98
u
Manual 02845B Contents
CHAPTER 8 REPAIR & REPLACEMENT 101

Returning Equipment for Repair.......... 101
Identification ........................ 101
Packing a Complete Control.... 101
Replacement Control Information........ 101
Address and Telephone/FAX Numbers 102
Manual Revision History........................... Inside Back Cover

Ordering Manuals ............................. ......... Back Cover
Woodward Governor Company Locations ......... Back Cover
ui
Diagrams. Drawings & Tables Manual 02845B
Diagrams, Drawings & Tables
2-1 723PLUS Digital Speed Control 5

2-2 Hand Held Programmer............ 6
4-1 RS'422 Terminator Locations.................................................................................... 14

4-2 RS-485 Terminator Locations.................................................................................... 14
4-3 723PLUS RS-232 Connection.................................................................................... 15
4-4 723PLUS RS-422 Connection with optional termination at receiver........................ 15
4-5 723PLUS RS-485 Connections with optional termination......................................... 15
4-6 723PLUS RS-422 Connections with optional termination at transmitter.................. 15
4-7 Preferred multipoint wiring using shielded twisted-pair cable with separate signal
ground wire ............................................................................................................ 16
4-8 Alternate multipoint wiring using shielded twisted-pair cable without separate signal
ground wire 16
4-9 Direct Wired Network.................... 17
4-10 Network Wired Via Stubs.............. 17
4-11 723PLUS Control Internal Jumpers 20
4-12 723PLUS Wiring Notes................. 21
4-13 723PLUS Wiring............................. 22
5-1 Operating Modes................................. 30

5-2 Function Block Diagram, Cover Sheet 36
5-3 Function Block Diagram, Overview.... 37
6-1 Modbus® Transmission Modes............... 83

6-2 Modbus® Frame Definition..................... 84
6-3 Modbus® Function Codes....................... 84
6-4 Modbus® Function Codes....................... 85
6-5 Modbus® Slave Exception Error Codes... 85
6-6 Modbus® Master Exception Error Codes 85
6-7 Modbus® Messages................................. 86
6-8 Communication Port Adjustments............ 86
7-1 Hand Held Programmer Functions 91
IV
Manual 02845B General Information
Chapter 1
General Information
Introduction
This manual describes the 723PLUS Droop/Isochronous Control, p/n’s 8280-505 & 8280-
506, for use in single or tandem propulsion systems.
Application
The control is intended for use in propulsion systems, where the engine is directly coupled to
the mechanical drive of the propeller shaft.
The control provides closed loop speed control, with a torsional filter and notch (band-stop)
filters to help to eliminate the problems caused by low frequency oscillations due to engine
inertias and flexible couplings.
Two modes of load control are available:

• Droop control based on a 4-20mA Rack Position Sensor input, or the actuator position.
• Isochronous load sharing with soft loading/unloading. Communications between the two
723PLUS units provides isochronous load sharing at variable speeds, set by a 4-20mA
Analogue Reference, or the Increase/Decrease contacts.
Start and maximum fuel limiters are provided, as well as a charge air pressure limiter based on
the 4-20mA Charge Air Pressure input, and a Torque Limiter.
The control can be adjusted/biased by a 4-20mA input from the Woodward 723
Synchrophaser, which will control the phase of two propeller shafts on a vessel.
The control can be configured for asymmetric load sharing. The load sharing between the two
controls is offset by a certain amount, determined by the 4-20mA input bias.
Both serial ports (J2 & J3) are available for Modbus® communications using RS232, RS422
or RS485. Engine control parameters can be monitored, and certain control ftinctions sent to
the control via the Modbus®.
4-20mA outputs are available for monitoring various control parameters.
1
General Information Manual 02845B
2
Manual 02845B 723PLUS DCS
(
Chapter 2
723PLUS DCS
723PLUS Digital Control

Declaration of Incorporation
In accordance with the EMC directive 89/336/EEC and its amendments, this controlling
device, manufactured by the Woodward Governor Company, is applied solely as a
component to be incorporated into an engine prime mover system. Woodward Governor
declares that this controlling device complies with the requirements of EN50081-2 and
EN50082-2 when put into service per the installation and operating instmctions outlined in
the product manual.
NOTICE; This controlling device is intended to be put into service only upon
incorporation into an engine prime mover system that itself has met the requirements of the
above Directive and bears the CE mark.
723PLUS Digital Speed Control Accessories
Hand Held Programmer (Figure 2-2), part number 9907-205, can be used for adjusting the
723PLUS control setpoints/parameters. It plugs into the J1 serial port of the control.
723PLUS Synchrophaser, part number 8280-504, for phase matching of twin screw
propulsion systems.
723PLUS Control Specifications
Part Numbers:
8280-505 Propulsion Control, J1 Communications defaulted to Hand Held

Programmer.
8280-506 Propulsion Control, J1 Communications defaulted to ServLink.
9907-205 Hand Held Programmer
Note: 8280-505 & 8280-506 are both capable of HHT & ServLink communications via the
J1 port. The part number only reflects the default mode of access to the control.
3
723PLUS DCS Manual 02845B
Power Supply Rating

1340 Vdc (24 or 32 Vdc nominal)
90-150 Vdc (125 Vdc nominal)
Power Consumption
40W nominal
Steady State Speed Band

magnetic pickup: 400 - 15000 Hz
proximity switch: 7.5 - lOOOHz
Digital Inputs (8)

8mA at 24Vdc
Analogue Inputs (4)
4-20 mA or 1-5 Vdc
Analogue Outputs (3)
4-20 mA or 0-1 mA to meter or computer (2)
20-160 mA or 4-20 mA(l)
Actuator Output (1)
20-160 mA or 4-20 mA
Programmer Communication Port (Jl)

RS-422, 9-pin D connector, 1200 to 19200 baud (HHT 1200 only). Hill duplex
Communication Ports (J2 & J3)
RS-232, RS-422, or RS-485, 9-pin D connector, 1200 to 38400 baud, full duplex
Ambient Operating Temperature

-40 to+70 "C (-40 to+158 T)
Storage Temperature
-55 to+105 "C (-67 to +221 T)
Humidity
95% at 38 "C
EMI/RFI Susceptibility
US MIL-STD 461C (Parts 5 & 9)
Humidity
US MIL-STD 810D, Method 507.2, Procedure III
Mechanical Vibration
24-2000 Hz swept sine, 2.5 Gs constant acceleration, resonant dwells - 1 million
cycles, total time 6 hours/axis
Mechanical Shock
US MIL-STD 8IOC, Method 526.2, Procedure I (basic design test). Procedure II
(transit drop test, packaged). Procedure V (bench handling).
Salt Spray
ASTMB 117-73
Approvals
Lloyds, UL, cUL & CSA
4
Manual 02845 B 723PLUS DCS
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Figure 2-1. 723PLUS Digital Speed Control
5
723PLUS DCS Manual 02845B
-109.2- 26.9
(4 300) (1.060)
Woodward
I
◄ ► ♦ A T
1 2 3
162.6
(6.400)
4 5 6
7 8 9
ID }|
+ 0
◄ ► IK
BKSPlpPACq
c
02846-02
Dimensions in millimetres (inches)
Figure 2-2. Hand Held Programmer
6
Manual 02845B I-!lcctrostatic Discharge Awareness
Chapter 3
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 minimise 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, and the work area as much as possible.
7
Electrostatic Discharge Awareness Manual 02845B
8
Manual Q2845B 723PLUS Installation
Chapter 4
723PLUS Installation
Scope
This chapter contains installation instructions for the 723PLUS control. Power requirements,
environmental precautions, and location considerations are included to help you determine the
best location for the control. Additional information includes unpacking instmctions,
electrical connections, and installation checkout procedures.
Unpacking
Before handling the control, read Chapter 3, Electrostatic Discharge Awareness. Be careful
when unpacking the electronic control. Check the control for signs of damage such as bent
panels, scratches, and loose or broken parts. If any damage is found, immediately notify the
shipper.
Power Requirements
The high-voltage version of the 723PLUS Digital Speed Control requires a voltage source of
90 to 150 Vdc. The low-voltage version requires a voltage source of 18 to 40 Vdc.
Maximum power consumption is 40 Watts for both high & low voltage models.
CAUTION
To prevent damage to the control, do not exceed the input voltage range.
NOTE
If a battery is used for operating power, an alternator or other battery-charging device

is necessary to maintain a stable supply voltage.
CAUTION
To prevent damage to the control, make sure that the alternator or other battery
charging device is turned off or disconnected before disconnecting the battery from
the control.
9
723PLUS Installation Manual 02845B
Location Considerations
Consider these requirements when selecting the mounting location:

• adequate ventilation for cooling;
• space for servicing and repair;
• protection from direct exposure to water or to a condensation-prone environment;
• proximity to high-voltage or high-current devices, or devices which produce
electromagnetic interference;
• avoidance of vibration;
• selection of a location that will provide an operating temperature range of ^0 to +70
°C MO to+158 °F).
The control must NOT be mounted on the engine.
Electrical Connections
Shielded Wiring
All shielded cable must be twisted conductor pairs. Do not attempt to tin the braided
shield. All signal lines should be shielded to prevent picking up stray signals from
adjacent equipment. Connect the shields to the nearest chassis ground. Wire exposed
beyond the shield should be as short as possible, not exceeding 50 mm (2 inches). The
other end of the shields must be left open and insulated from any other conductor. DO
NOT run shielded signal wires along with other wires carrying large currents. See
Woodward application note 50532, EMI Control in Electronic Governing Systems for
more information.
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.
2. Using a sharp, pointed tool, carefully spread the strands of the shield.
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.
Installations with severe electromagnetic interference (EMI) may require additional

shielding precautions. Contact Woodward Governor Company for more information.
10
Manual 02845B 723PLUS Installation
Power Supply (Terminals 1/2)
Power supply output must be low impedance (for example, directly from batteries). DO
NOT power the control from high-voltage sources with resistors and zener diodes in
series with the control power input. The 723PLUS control contains a switching power
supply which requires a current surge (around 1 Amp) to start properly.
CAUTION
To prevent damage to the control, do not power a low-voltage control from high-
voltage sources, and do not power any control from high-voltage sources with
resistors and zener diodes in series with the power input.
Run the power leads directly from the power source to the control. DO NOT POWER
OTHER DEVICES WITH LEADS COMMON TO THE CONTROL. Avoid long wire
lengths. Connect the positive (line) to terminal 1 and negative (common) to terminal 2.
A protection device such as a fuse or MCB (rated 4 Amps for the Low-Voltage control
and 2 Amps for the High-Voltage control) should be connected to prevent damage to the
control. If the power source is a battery, be sure the system includes an alternator or
other battery-charging device.
If possible, do NOT turn off control power as part of a normal shutdown procedure.
Leave the control powered except for service of the system and extended periods of
disuse.
CAUTION
Do NOT apply power to the control at this time. Applying power may damage the
control.
CAUTION
To prevent damage to the engine, apply power to the 723PLUS control at least
twenty five (25) seconds prior to starting the engine. The control must have time
to complete its power up diagnostics and become operational. Do not start the
engine unless both the green POWER OK and CPU OK indicators on the 723PLUS
control cover come on, because test failure turns off the output of the control.
Digital Relay Outputs

Major (Shutdown) Alarm (Terminals 3 & 4)
Minor Alarm (Terminals 5 & 6)
Fuel Limit Indication/Ready to Close Clutch (Terminals 7 & 8)
During the set-up of the controls, the user will determine whether the relay outputs are
nonnally open or normally closed contacts.
Contact ratings for minimum 100,000 operations;
resistive - 2.0A at 28Vdc, 0.1A at 115Vac 50 to 400Hz
11
inductive - 0.75A at 28Vdc 0.2 Henry

Load Sharing Lines Input (Terminals 9/10)
Connect the load sharing lines directly to those of another 723PLUS of the same
designation, or to the appropriate terminals of another Woodward unit, for isochronous
load sharing. Use a shielded twisted-pair cable. The shield should be connected
continuously between controls, and grounded at one end only.
Speed Signal Inputs (Terminals 11/12 and 13/14)
Connect a magnetic pickup (MPU) to terminals 11 and 12 (speed sensor #1). If

required, connect a second MPU to terminals 13 and 14 (speed sensor #2). Use shielded
wire for all speed sensor connections. Connect the shield to the chassis. Make sure the
shield has continuity the entire distance to the speed sensor, and make sure the shield is
insulated from all other conducting surfaces.
WARNING
The number of gear teeth is used by the control to convert pulses from the speed
sensing device to engine rpm. To prevent possible serious injury from an
overspeeding engine, make sure the control is properly programmed to convert the
gear-tooth count into engine rpm. Improper conversion could cause engine overspeed.
Analogue Outputs (Terminals 15/16,17/18,19/20)

Rack Position
Actuator Position
Load Level %
Speed #1
Speed #2
Engine Speed
Fuel Limit Level
PID Level
Speed Reference
Use shielded twisted-pair wires to connect to terminals 15(+) & 16(-), 17(+) & 18(-),
and 19(+) & 20(-). For an electrically isolated input device such as a 4 to 20 mA input
analogue meter, the shield should be grounded at the control end of the cable. For input
to other devices, use the recommendation of the device manufacturer.
CAUTION
To prevent possible damage to the control or poor control performance resulting

from ground loop problems, we recommend using current-loop isolators if the
723PLUS control's analogue inputs and outputs are used with non-isolated devices
(common ground system). A number of manufacturers offer 20 mA loop isolators.
12
Consult Woodward Governor Company for further information.
13
Actuator Output (Terminals 21/22)
The actuator wires connect to terminals 21{+) and 22(-). Use shielded wires with the
shield connected to chassis at the control.
Discrete Inputs (Terminals 29 - 36)
Discrete inputs are the switch input commands to the 723PLUS Control. The discrete
inputs may be powered from the 723PLUS Control’s own Discrete Input Power. In this
case, terminals 37 & 38 should be jumpered. This connects the control’s common to the
discrete input common. Terminal 39 then supplies 24Vdc to the discrete inputs. Since
this aux voltage is not isolated from other control circuits, use only isolated contacts (dry
or signal voltage rated) for the discrete circuits. DO NOT POWER ANY OTHER
DEVICES WITH THE DISCRETE INPUT AUX VOLTAGE SOURCE.
If the discrete input voltage (24 Vdc) is supplied from an external source, connect the
voltage source negative (-) to terminal 37. Then run the voltage source positive (+) to
the appropriate switch or relay contact and then to the corresponding discrete input.
Note : There will be no connection to terminal 38 in this case.
Analogue Inputs
Analogue Speed Setting (Terminals 41/42/43)
Rack Position Sensor (Terminals 44/45/46)
Charge Air Pressure (Terminals 47/48/49)
Synchrophaser Bias/Asymmetric Load Share Bias (Terminals 50/51/52)
Use shielded twisted-pair cable to connect to terminals 42(+) & 43(-), 45(+) & 46(-),
48(+) & 49(-) and 51(+) & 52(-). Ensure that a jumper is installed between terminals 50
&51.
CAUTION
To prevent possible damage to the control or poor control performance resulting
from ground loop problems, we recommend using current-loop isolators if the
723PLUS control’s analogue inputs and outputs are used with non-isolated devices
(common ground system). A number of manufacturers offer 20 mA loop isolators.
Consult Woodward Governor Company for further information.
Serial Communications Ports

J1 - Hand Held Programmer/ServLink, RS422 only
J2 & J3 - ServLink/Modbus®, RS232, RS422, RS485
Note: RS485 is not available for ServLink Server communications.
Termination
For RS-422, termination should be located at the receiver when one or more transmitters
are connected to a single receiver. When a single transmitter is connected to one or
more receivers, tennination should be at the receiver farthest from the transmitter.
14
Manual Q2845B 723PLUS Installation
Figure 4-1 is an example.

RS-422
RS-422
II,R-r' JI
u I
[ [
MASTER SLAVE SLAVE
02752-20
ALTERNATE L0CATK)N
FOR MASTER TERMINATION
Figure 4-1. RS-422 Terminator Locations
For RS-485, termination should be at each end of the cable. If termination can’t be
located at the end of a cable, put it as close as possible to the ends. Figure 4-2 is an
example.
RS-485
T T
3 Li ’la
/'
'r I
MASTER SLAVE SLAVE
02752-21
Figure 4-2. RS-485 Terminator Locations
Communicating with a HMI (Human Machine Interface) operator interface is a special

case of Figure 4-1. Because the HMI master cannot put its transmitter into a high-
impedance state, and the bit rate is less than 90k bits/sec, termination is not needed at the
slave. Termination is needed at the HMI receiver, but because there is no way to locate
it there, it has to be put at the alternate location.
If you don't know if a master can put its transmitter into a high-impedance state,
terminate the line as shown in Figure 4-1. It does not hurt to terminate the line even
when it’s not needed as in the case of the FIMI operator interface.
Termination is accomplished using a three-resistor voltage divider between a positive

voltage and ground. The impedance of the resistor network should be equal to the
characteristic impedance of the cable. This is usually about 100 to 120 ohms. The
purpose is to maintain a voltage level between the two differential lines so that the
receiver will be in a stable condition. The differential voltage can range between 0.2 and
15
6 volts; the maximum voltage between the receiver input and circuit ground must be less
than 10 volts. There is one termination resistor network for each J2 and J3 port located
on the 723PLUS. Connection to this resistor network is made through the 9-pin
connectors on pins 6 and 9.
See Figures 4-3 through 4-6 for termination and cable connection examples.
j.
jE. a ■
Ri. 2_
<L
RECX)MMtNt)tD MAX
I SiC GND
£1=. A
CAW.ELEN(Tnt
l5MEm5
<50 FEET)
KETOMMENDEI) MAX
723 OTWER RS232 723 CÂBLELENOni

1200 METRES CTWEB R5422
J2/J3 DEVICE J2/J3 DEVICE
(4000 FEET)
02846-22
Figure 4-3. 723PLUS RS-232 Connection Figure 4-4. 723PLUS RS-422 Connections
with optional termination at receiver
♦ Sv
1' !T
A PI-
*sv.
.aii. i
.SL A
9C CMP StC CHD
A
RECOMMENDED MAX
RECOMMENDED MAX
CABLE LENGTH
CABLE LENGTH
1200 METRES 723
723 1200 METRES OTHER RS4aS
J2/43 DEVICE MASTER (4000 FEET) SLAVE
(4000 FEET)
02846-23
Figure 4-5. 723PLUS RS-485 Connections with Figure 4-6. 723PLUS RS-422 Connections
optional termination with optional termination at
transmitter
Grounding and Shielding
The RS-422 and RS-485 specifications state that a ground wire is needed if there is no
other ground path between units. The preferred method to do this is to include a
separate wire in the cable that connects the circuit grounds together. Connect the shield
to earth ground at one point only. The alternate way is to connect all circuit grounds to
the shield, and then connect the shield to earth ground at one point only. If the latter
method is used, and there are non-isolated nodes on the party line, connect the shield to
ground at a non-isolated node, not an isolated node. Figures 4-7 and 4-8 illustrate these
cabling approaches.
Note: Non-isolated nodes may not have a signal ground available. If signal ground is not
available, use the alternate wiring scheme in Figure 4-8 with the signal ground connection
removed on those nodes only.
16
NODE 1 NODE 2 NODE 3
SQ SG SQ
/ \ / \
T TI T
\
X I
X X I
I
1 1 i 1
\ / /
V \ /
SHIELD TWISTED PAIR WIRING SIGNAL GROUND

02752-24
Figure 4-7. Preferred multipoint wiring using shielded Kvistcd-pair cable

with separate signal ground wire.
NODE 1 NODE 2 NODE 3
SG SG SG
i
/
I
\
i I T
\
/ \
I I \
I
I
X X x: \ I
I
\ / \ /
.r'
TWISTED PAIR WIRING
SHIELD AND SIGNAL GROUND
02752-25
Figure 4-8. Alternate multipoint wiring using shielded twisted-pair cable

without a separate signal ground wire.
Note: The signal ground connection is not required if signal ground is unavailable.
Local Operator Network (LON)

To Other Tandem 723 (Terminals 23/24)
Synchrophaser (Terminals 26/27)
The network may be wired directly from I/O module to I/O module, as shown in Figure 4-9,
or the I/O modules may be connected to the network via stubs as in Figure 4-10. The
network must be terminated at both ends
17
723PLUS Installation Manual Q2845B
723PLUS 725PLUS 723PLUS 723PLUS 723PLUS
O NETWORK CABLE LENGTH

02845-06
Figure 4-9. Direct Wired Network
723PLUS 725PLUS 723PLUS 723PLUS 723PLUS
t
2£*: o
z
O LiJ
5-*
UJ CD
Z =>
l/i
TERMINAL BLOCKS
NETWORK CABLE LENGTH

02845-07
Figure 4-10. Network Wired Via Stubs
The cable used for the network will affect the overall system performance with respect to
distance, stub length, and total number of nodes supported on a single channel. Echelon®
recommends the use of UL Level IV, 0.325 mm^ (22 AWG) twisted pair cable for the
network bus as defined in UL’s LAN Cable Certification Program, UL document number
200-120 20 M/11/91
Proper LonWorks™ network wiring is critical to assure that the network operates correctly.
The following requirements must be met:
l?Use only recommended shielded twisted pair cabling for the LonWorks™ network.
Correct cable is available from Woodward, Belden, or other suppliers providing an
equivalent cable.
Woodward part number 2008-349
Belden
PO Box 1980
Richmond, IN 47375
(1) 317 983 5200
18
Maniuil 02845B 723PLUS Installation
Belden part number
P/N Description
9207 PVC 0.52 mm^ (20 AWG) shielded. NC Type CL2, CSA Cert. PCC FT
1.
89027 Teflon 0.52 mm^(20 AWG) shielded, Plenum version. NEC Type CMP,
CSA Cert. FT 4.
YR28867 PVC 0.325 mm^ (22 AWG) shielded.
YQ28863 Plenum 0.325 mm^ (22 AWG) shielded.
2? MaximiuTi cable length is 150 metres for operating temperatures between -20 and 55
degrees C, and 50 metres for operating temperatures between -40 and 55 degrees C.
3? Stubs, or wiring drops, connecting intermediate devices to the main cable are limited to
300 mm in length.
4? Shields must be carried through all breakout boxes to provide a continuous shield
throughout the network.
5? The network must be properly terminated at each end of the cable. Internal components
are provided in the 723PLUS DCS, which provide proper network termination with the
installation of a jumper on the controls at each end of the cable. Intermediate nodes should
not have the termination Jumper installed.
Internal Jumpers
The 723PLUS control has ten, two-position internal jumpers (JPRl through JPR20)
located on the top of the printed circuit board. If it is necessary to change any jumper to
match the control requirements, and suits the nature of the software, be sure to read
Chapter 3, Electrostatic Discharge Awareness.
Ensure that the power to the control is switched off, before removing the cover. Using a
small pair of tweezers, carefully remove the appropriate jumper and replace it securely
over the proper two connectors (see Figure 4-11).
19
The jumper connections are listed:
JPRIO analogue output #1 0-1 mA

* JPR9 analogue output #1 0-20 mA
JPR12 analogue output #2 0-1 mA

* JPRIl analogue output #2 0-20 mA
JPR13 & JPR2 actuator output #1 0-200 mA, single

* JPR13 & JPRl actuator output #1 0-20 mA, single
JPR14 & JPR2 actuator output #1 0-160mA, tandem
* JPR15 & JPR3 actuator output #2 0-200 mA, single

JPR15 & JPR4 actuator output #2 0-20 mA, single
JPR16& JPR3 actuator output #2 0-160mA, tandem
JPR5& JPR17 speed sensor #1 proximity switch

* JPR6& JPR18 speed sensor #1 magnetic pickup
JPR7 & JPR20 speed sensor #2 proximity switch

* JPR8& JPR19 speed sensor #2 magnetic pickup
*—default jumper settings
20
Manual 02845 B 723PLUS Installation
V
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Figure 4-11. 723PLUS Control Internal Jumpers
21
723PLUS Installation Manual 02S45B
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Figure 4-12. 723PLUS Wiring Notes
22
Q
i O CD <
TBI u> <

CONTROL SUPPLY VOLTAGE
a
1 40 VOC
CM
2 CD
3
MAJOR (SHUTDOWN) ALARM CD
4 No_r
LO UJ
lij
5 MINOR ALARM DISCRETE OUTPUTS I
67 NOj IT)
FUEL LIMIT INDICATION/READY TO CLOSE CLUTCH
NOj
a9 CD
I LOAD SHARING LINES
CD
10
u
N
(7> CD
e
J1 II RS422 COMMUNICATION PORT (HANDHELD TERMINAL/SERVLINK)
T02
^ q: LO
1 DC I— Z)
SPEED SENSOR INPUT
OJ 12 >2 0
13
SPEED SENSOR INPUT <12 RACK POSITION }-00
14 L4 <? QC
IS A ACTUATOR POSITION X
16 LOAD LEVEL % _|0 o

ANALOGUE OUTPUTS SPEED #1 Q_ LO O
17
4-20 mA SPEED #2 _j to
8 SELECTABLE
X. ENGINE SPEED CL CL
19 FUEL LIMIT LEVEL
20 PIO LEVEL <QCo

^
clcl
+ “1 ACTUATOR OUTPUT SPEED REFERENCE CL
21 -JO- 200 mA
O
22 < ^0
^Csl
25 3 LON NETWORK TO OTHER TANDEM 723
24
25
26 Q
LON NETWORK TO SYNCHROPHASER
27
ro 28 (Note 12)
T83
29 A RUN/STOP
B 41-
30 ■I INCREASE SPEED/LOAD
31
C
h DECREASE SPEED/LOAD
ow
ixzuj•
S2. CLUTCH ENGAGED
i. HP h DISCRETE INPUTS
> cc
33 UNLOAD oaxii
F
34 ISOCHRONOUS/OROOP
G FIXED SPEED/FUEL LIMIT SHIFT
35 z
36 a DIGITAL/ANALOGUE SPEED SEHING
0^5
37 -----------(DISCRETE COMMON) S'-
38 + 24V0C DISCRETE INPUT) +5VDC AUXILIARY Q
POWER - 100mA MAX) O
39 DEVICE POWER
(SOmA MAX) O
40 s
41
+_
42 ANALOGUE SPEED SEHING
-*■/-
U COM 4-20mA OR 1-SV (Note 4)
if)
44 hi
45 V- I-
f[ RACK POSITION SENSOR
O
46 COM 4-20mA OR 1-5V (Note 4)
k ANALOGUE INPUTS
47
48
$ V- 1 CHARGE AIR PRESSURE
4-20mA OR 1-5V (Note 4)
q:
49 COM O
50
SYNCHROPHASER BIAS OR
5
6 V- ASSYMETRIC LOAD SHARING BIAS
52 COM 4-12-20mA
I-
UJ
UJ
LOl J2 ooo MODBUS COMMUNICATIONS RS232. RS422 OR RS48S (ASCII/RTU)
I
< V)
z
UJ
MODBUS COMMUNICATIONS RS232, RS422 OR RS485 (ASCII/RTU) d < UJ
•- Z
CL LJ
UJ _f
m
to
UJ <
cc O
Q O
m <
Figure 4-13. 723PLUS Wiring
23
Installation Checkout Procedure
With the installation complete, carry out the following checkout procedure before
beginning set point entry or initial start-up adjustments.
1. Visual inspection
A. Check the linkage between the actuator and fuel metering device for looseness
or binding. Refer to the appropriate actuator manual, and Manual 25070, Electric
Governor Installation Guide for additional information on linkage.
WARNING
To prevent possible serious injury from an overspeeding engine, the actuator

lever or stroke should be near but not at the minimum position when the fuel
valve or fuel rack is at the minimum fuel delivery position.
B. Check for correct wiring in accordance with the plant wiring diagram.
C. Check for broken terminals and loose terminal screws.
D. Check the speed sensor(s) for visible damage. If the sensor is a magnetic
pickup, check the clearance between the gear and the sensor, and adjust if
necessary. Clearance should be between 0.25 and 1.25 mm (0.010 and 0.050 inch)
at the closest point. Make sure the gear runout does not exceed the pickup gap.
Refer to the manual 82510 Magnetic Pickups And Proximity Switches For Electric
Governors, for information.
2. Check for grounds
Check for grounds by measuring the resistance from all control terminals to chassis. All
terminals except terminals 2 and 38 should measure infinite resistance (the resistance of
terminals 2 and 38 depends on whether a floating or grounded power source is used). If
a resistance less than infinite is obtained, remove the connections from each terminal one
at a time until the resistance is infinite. Check the line that was removed last to locate the
fault.
24
Manual 02S45B 723PLUS Installation
25
System Description Manual 02845B
Chapter 5
System Description
Engine Speed
vSpeed Sensing
The control has two speed sensing inputs, and may be configured for torsional filtering, for
smoother operation with soft couplings, or high signal select, giving speed sensing
redundancy should one signal fail. If the torsional filter has been selected, the speed sensors
should be positioned on either side of the coupling; sensor #1 on the engine side, and sensor
#2 on the reduction gear side. If the high signal select is utilised, then both speed sensing
devices should be located on the same speed sensing disc.
Each speed sensor input has a failed speed detection device, with an override function which
is active during engine start-up. The Alarm #1 and Alarm #2 LED’s located on the 723PLUS
control, give indication when either input has failed, (LED #1 - Sensor #1, LED #2 - Sensor
#2). Speed sensor #2 failure detection is overridden until the clutch is closed, and the SSU2
Fault Ovrd Dly period has elapsed.
Whilst the clutch is dis-engaged, speed sensor #2 is ignored, and only speed sensor #1 is
utilised for speed control. Failure of speed sensor #1 whilst the clutch is dis-engaged, will
cause the control to shut the engine down, whereby the control will drive the actuator output
to 0%, and the Major Alarm will be activated (relay output #1).
Once the clutch is engaged, speed sensor #2 is switched in, either for torsional filtering, or for
high signal selection. When the clutch engaged signal input is received, if the torsional filter is
selected, after the Clutch Delay period has expired, the torsional filter will be enabled.
If the torsional filter is enabled, failure of either speed sensor will result in the activation of the
Minor Alarm, and control will continue with one speed signal. The PropGain Multiplier will
be switched in to decrease the Proportional Gain value. If high signal select is chosen, failure
of a speed sensor will also give continued control with one speed signal, and the Minor Alarm
will be activated (relay output #2).
The option is available to disable the Minor Alarm if one speed sensor fails, for situations
where only one speed sensor is utilised. The Alarm LED on the front panel of the 723PLUS
will still illuminate if no speed signal is sensed, but the Minor Alarm will not activate.
Failure of both speed sensors will initiate a shutdown, whereby the control will drive the
actuator output to 0%, and the Major Alarm will be activated.
26
Manual 02S45B System Description
WARNING
If the engine has been shutdown by the 723PLUS control due to both speed sensors
failing, do NOT attempt to start the engine until the faults have been located and
rectified. Failure of the pickups can only be detected w hilst the engine is running, i.e. the
signal must already exist for the failure detection to operate. If the 723PLUS cannot
detect engine speed during start-up, the actuator output will go to maximum, possibly
driving the engine into an overspeed condition. The engine should be equipped with an
additional overspeed shutdowTi device that operates totally independently of this control,
to protect against runaway or damage to the engine, with possible personal injury or loss
of life.
Qvcrspced Protection
The control may be configured to shut the engine down, when an overspeed is detected
{Overspeed Trip level exceeded), or to enable a pulse to decrease the actuator level, in order
to help force the engine below the trip level;
When the engine speed exceeds the Overspeed Trip level, the control will force the actuator
output to a level determined by the Actuator Dec Levels in order to help bring the engine
speed down. The actuator is forced to this level until the engine speed falls below the
Overspeed Trip level, and then for a further period determined by the Actuator Dec Pulse.
Each time an overspeed occurs, it is counted, and once the counter reaches the Overspeed
Count level, the engine will be shutdown. The overspeed counter is reset to zero each time
the engine is stopped, or after the Reset Ospd Delay period has expired, after the first
overspeed is counted, whichever occurs sooner.
Note; If the Overspeed Count parameter is set to ‘T, the engine will be shutdown the first
time an overspeed is detected.
WARNING
The engine should be equipped with an additional overspeed shutdown device, that
operates totally independently of this control, to protect against runaway or damage to
the engine, with possible personal injury or loss of life, should this control fail.
Speed Filtering
If enabled, the torsional filter can be used to help prevent the control from reacting to
torsionals across a flexible coupling. This works by ‘averaging’ out the speed sensing signals
fi’om either side of the coupling, although this can be weighted more heavily to one side than
the other, by adjusting the Sensor Weight.
For systems with low fiequency oscillatoly modes due to engine & system inertias, and
flexible couplings, which can become difficult to control, three Notch/Band-Stop Filters are
provided. These filters can reduce the signal transmission through the control, by reducing the
signal gain at the resonant frequency, and hence preventing the control from reacting to these
unwanted frequencies.
There is one filter on each of the two speed sensor inputs, and then a third on the output from
27
the torsional filter/high signal select bus, before the engine speed signal reaches the PID
controller.
Speed Control
Engine Start
When the Run/Stop contact is selected to run, the speed reference is at Idle Speed. The
reference will then remain at idle, until the engine speed exceeds the Idle/Rated Switch speed,
at which time the speed reference will ramp to a level, depending on the state of the
Digital/Analogue Speed Setting and the Fixed Speed contact inputs:
• If digital mode is selected, the speed reference will ramp to Rated Speed at the
Acceleration Rate, provided that the tuneable parameter Ref To Rated In Dig is set
TRUE. The idle-to-rated ramp may be interrupted by momentarily closing the Decrease
contact input. If the Ref To Rated In Dig parameter is FALSE, the control will remain at
Idle Speed, until an increase/decrease command is given.
Closing the Increase contact will raise the speed reference towards the Maximum Speed at
the Inc/Dec Rate #/, and closing the Decrease contact will lower the speed towards the
Minimum Speed at the Inc/Dec Rate #7.
• If analogue mode is selected, the speed reference will ramp to the speed determined by the
4-20mA Analogue Speed Setting input, at the Acceleration Rate. Further speed
adjustments can then be made by increasing or decreasing the Analogue Speed Setting,
and the reference will alter at the Analogue Rate #7.
• If fixed speed is selected, the speed reference will ramp to the Fixed Speed, at the
Acceleration Rate. Further adjustments can then be made using the Increase/Decrease
contact inputs, as above.
Clutch Ready To Close
Digital Output #3 may be configured to give a clutch ready to close signal. This relay output
may also be configured as normally open, or normally closed.
For a single engine application (i.e. one engine on one shaft), or for the first engine of a
tandem application (i.e. two engines on one shaft) start-up, the clutch ready to close signal is
activated when the engine speed reaches the Clutch In Speed, +/- the Clutch In Window. For
the second engine start-up of a tandem application, the output is activated when the engine
speed reaches the speed of the first engine (transmitted via the LON), +/- the Clutch In
Window.
The output remains activated until the clutch engaged contact input is closed.
28
Maniml 02845B System Description
Droop Control
To operate in Droop mode, the Isochronoiis/Droop contact input must be selected to Droop
mode.
The speed droop value is calculated based on the Droop percentage, and the load on the
engine. The engine load will be derived from the Rack Position Sensor input. Should this
signal fail, the load will be determined based on the position of the actuator output. Failure of
the load signal input will activate the Minor Alarm, which will be reset once the signal is
healthy.
If in digital speed setting mode, closure of the Increase contact will cause the speed reference
to increase at the Inc/Dcc Rate #2, therefore causing the engine to take on load (if available),
when in parallel, or increase speed if running alone.
Closure of the Decrease contact will cause the speed reference to decrease at the Inc/Dec
Rate #2, therefore causing the engine to shed load (if possible), if mnning in parallel, or
decrease speed if running alone.
If in analogue speed setting mode, increasing the 4-20mA Analogue Speed Reference input
will cause the engine to take on load, and decreasing the input will cause the engine to shed
load. The reference will alter at Analogue Rate #2.
Isochronous Load Sharing
Isochronous load sharing is enabled by selecting Isochronous mode with the

Isochronous/Droop, provided that the Clutch Engaged contact is also closed, and there are
no faults detected on the LON.
For a single engine application, the control will keep the engine at the speed reference,
whether set by the 4-20mA Analogue Speed Setting input, or by the digital
Increase/Decrease contact inputs, as the load is increased/decreased.
If the Rack Position Sensor input signal should fail whilst in isochronous load sharing, the
control will continue to share load, with load based on the actuator output. Once the fault is
rectified, and the signal fault reset (either automatically or by using the Modbus® Reset), the
control will switch back to using the load input.
Whilst the control is operating in isochronous load sharing, the droop reference is
continuously tracking, so that if the control is switched into droop mode, the transfer will be
bumpless, if the control is in digital mode. If the control is in analogue mode, there will be
some change in speed/load, the magnitude of which depends on the speed reference, and the
load on the engine.
Note: It is recommended that before switching into droop mode, the control is switched
into digital mode first
Tandem Isochronous
For tandem propulsion systems, the first engine connected in isochronous mode will maintain
29
constant engine speed (unless the speed reference is adjusted), as the load is
#
increased/decreased. When the second engine is connected, the load is increased/decreased at
the Load Rate, until the load sharing between the two engines is equal. Any changes in system
load will then affect both engines equally.
In order to achieve isochronous load sharing, both engines must follow the same speed
reference. Therefore, via the LON, both units communicate their speed reference to each
other. Each unit will then select the higher of the two references, therefore both will be
controlling using the same reference.
For a tandem system to operate in isochronous mode with analogue speed setting, both units
must be selected to analogue speed setting mode. If one is switched into digital mode (or if
the analogue setting input fails), then the other unit will be forced into digital mode. The
Increase/Decrease contact inputs to the unit selected to digital mode, can be used to adjust
the speed reference of both machines, as the machine which is still selected to analogue, will
be following the reference of the other machine only. It’s own speed setting will be ignored,
and it’s Increase/Decrease contact inputs will still be disabled, until it is switched into digital
mode.
If the option for asymmetric load sharing is selected, the 4-20mA bias should be input to one
control of the pair only. When the input bias is set to 12mA, the load sharing between the two
controls will be equal. If adjusted above 12mA, the load on the engine accepting the input is
decreased, wliilst the load on the other engine is increased. Adjustment below 12mA is vice
versa.
For Example, if the bias is inpvit to engine #1, and adjusted to 16mA, and the total system
load is at 50% capacity; the 16mA equates to a difference of 50% load, therefore engine #1
will have 25% load, and engine #2 will have 75% load. If the input was adjusted to 20mA,
engine #2 would have all of the load, whilst engine #1 would have zero load - 20mA equates
to a 100% load difference.
Whilst the load sharing is unbalanced, load changes are reflected equally on both engines,
hence retaining the same load difference between the two engines.
For Example, if engine #1 load = 25%, engine #2 load = 75%, and 20% system load is
removed, engine #1 load = 15%, engine #2 load = 65%, hence retaining the 50% load
difference.
The control provides a function for auto soft unloading of the engine. The Unload contact
should be closed (momentarily) when the control is in isochronous load sharing. The engine
load will then be ramped down at the Unload Rate, until the Unload Trip Level is reached.
Alternatively, the load can be ramped to a level, which is a percentage of the load level at
which the Unload command was issued. This can be achieved by setting the parameter Sel %
Unloading TRUE, and setting Unload % of%Load to the desired level. ®
The unloading ramp may be stopped, if necessary, by momentarily closing the Increase
contact. The control will the automatically ramp back into isochronous load sharing.
Droop/Isochronous
For base loading of one machine against the other, it is possible to switch one machine into
droop mode, whilst the other remains in isochronous mode. Whatever speed setting mode
each unit is selected to, both will be forced into digital mode, with the Increase/Decrease
contact inputs, enabled on both.
30
Maniuil 02845B System Description
If the speed reference is increased/decrease on the isochronous machine, the load will remain
the same proportionally on each machine, but the system speed will increase/decrease.
If the speed reference is increased/decreased on the droop machine, this will cause the droop
machine to take load from the isochronous engine, or shed load onto it.
Should load on the system increase/decrease, this will affect the load on the isochronous
machine, whilst the load on the droop machine remains constant.
Operaring Modes
Following is a table, which shows the mode of operation of each machine, depending on how
each machine is selected to operate.
Note: Those shown in Italics are the modes, which are forced by the control, rather than
selected.
Definitions of terms:
Digital Droop Control operates in droop mode and responds only to digital
Increase/Decrease contact input commands.
Digital Isochronous :- Control operates in isochronous load sharing, with speed reference
adjusted only by digital Increase/Decrease contact input commands.
Analogue Droop :- Control operates in droop mode and responds only to adjustment of the
4-20mA analogue reference input.
Digital Isochronous :- Control operates in isochronous load sharing, with speed reference
adjusted only by the 4-20mA analogue reference input.
Selected Mode Operating Mode

Engine No. 1 Engine No, 2 Engine No.l Engine No.2
#1 Digital Droop Digital Droop Digital Droop Digital Droop

#2 Digital Droop Analogue Droop Digital Droop Digital Droop
#3 Analogue Droop Analogue Droop Analogue Droop Analogue Droop
#4 Digital Isoch Digital Isoch (Digital Isoch_______ Digital Isoch
#5 Digital Isoch Analogue Isoch Digital Isoch (Inc/Dec Isoch (Inc/Dec inputs
inputs enabled) disabled)___________
#6 Analogue Isoch Analogue Isoch Analogue Isoch Analogue Isoch
#7 Digital Droop Digital Isoch Digital Droop Digital Isoch
#8 Analogue Droop Digital Isoch Digital Droop Digital Isoch
#9 Digital Droop Analogue Isoch Digital Droop Digital Isoch
#10 Analogue Droop Analogue Isoch | Digital Droop Digital Isoch
Figure 5-1. Operating Modes
Normal Use for Each Mode
#1 Manual load sharing, using the Increase/Decrease command inputs.

#2 No recognised use for Digital Droop/Analogue Droop, therefore analogue machine
forced into digital, and used as mode #1.
#3 Manual load sharing using the analogue speed setting input (possibly from a
31
potentiometer in the ECR (Engine Control Room)), OR

#4 Automatic load sharing controlled by the CP control system. Synchronising of shaft
alternator may be made through the CP control.
#5 Automatic load sharing by the 723PLUS DCS, with speed setting controlled via the
Increase/Decrease command inputs, either manually, or from the CP control system. The
highest speed reference is followed by both controls, therefore all increase/decrease
commands should be issued to both units. The high signal select frinction is to prevent the
two units attempting to load share with slightly dilTerence speed references, not so that the
commands need only be issued to one control only. Synchronising of the shaft alternator
can be made using the Increase/Decrease command inputs.
#6 No recognised use for Digital Isoch/Analogue Isoch, therefore the speed reference of
the analogue machine directly follows that of the digital machine. Synchronising of the
shaft alternator can be made using the tncrcase/Decrease commands to the digital machine.
#7 Normal propulsion control with 723 controlled automatic load sharing. The speed
reference is altered either manually or from the CP control system. The highest speed
reference is followed by both controls.
#8 - #10 All selected combinations of a Droop/Isochronous pair of engines, will always
result in both units in digital speed setting mode. This mode can be selected when constant
(base) load level is required on one machine. The base load level can be adjusted using the
increase/decrease commands on the droop machine. Adjustment of speed setting on the
isoch machine will increase/decrease the system speed.
Fuel Limiters
Start & Maximum Fuel Limiter
The Start Fuel Limits for limiting overflielling or flooding during engine start-up is active
when the engine is started. This limit is derived from a four point curve, to give flexibility of
the limiting level at different engines speeds, as the engine is started.
When the PID takes control, the Start Fuel Limit is switched out, and the Maximum Fuel
Limit is switched in, until the next time the engine is started.
Charge Air Pressure Fuel Limiter
A four point curve provides fuel limiting based on the 4-20mA Charge Air Pressure input
signal. This limiter is only active once the Clutch Engaged contact is closed, and the Enable
Lim Delay period has expired.
Torque Fuel Limiter
A four point curve provides fuel limiting based on the engine speed signal. This limiter is only
active once the Clutch Engaged contact is closed.
Fuel Limit Indication
A relay output is provided to give an indication when the actuator output is nearing any one
of the fuel limiters, i.e. within the Near Fuel Limit parameter.
Fuel Limit Shift
32
Manual 02845B System Description
Each fuel limiter is fed into a Low Signal Select bus, the output of which serves to limit the
actuator, should the PID output increase to that level.
If configured, when the contact input is closed, the fuel limit level, output from the LSS bus is
increased by a value determined by the Fuel Limit Shift %.
PID Control & Actuator Output
The output has tuneable PID dynamics, a Gain Slope function (which adjusts Proportional
Gain as the engine load changes), a Gain Ratio llinction (which multiplies the Proportional
Gain as a Lmetion of the speed error), and Deri\ati\'e Dynamics (the PID dynamics are
adjusted by a multiplier, as the rate of change of engine speed exceeds a certain level - see
tuneable descriptions for more detail).
Four sets of dynamics (Proportional Gain, Integral Gain & S.D.R) are provided:
• Set #I is active when the Clutch Engaged and Fixed Speed contacts are both open.
• Set #2 is active when the Clutch Engaged contact is closed, and the Fixed Speed
contact is open.
• Set #3 is active when the Clutch Engaged contact is open, and the Fixed Speed contact
is closed.
• Set #4 is active when the Clutch Engaged and Fixed Speed contacts are both closed.
The dynamics can be multiplied individually by a multiplier, which is based on the speed
derivative. As the absolute value of the derivative exceeds a set level (according to a two-
point curve), the P, I & D terms can be increased/decreased, as the derivative value further
increases. This option can be chosen instead of the Gain Ratio function, but may be used in
conjunction with the Gain Slope function.
When the torsional filter is operational, if one of the speed sensors should fail, the
Proportional Gain is multiplied by the PropGain Multiplier, in order to attempt to slow the
control down, and prevent it responding to torsionals, for which the torsional filter to was
enabled to help minimise.
Run/Stop & Alarms
Closure of the Run/Stop contact (or opening if so configured), will release the actuator
output from zero to the Start Fuel Limit level. The ‘Run’ signal will also act as a reset to any
speed sensor faults, and the 723PLUS electronic overspeed trip latch (unless the Modbus®
Reset has been enabled). The reset function provided by the Run/Stop contact will only be
effective, provided that the engine speed has fallen below 350Hz, and the Rundown Time
period has elapsed.
Opening the Run/Stop contact (or closing if so configured), will cause the control to clamp
the actuator output to zero.
Major Alarm:
33
The Major Alarm will be activated when the engine is shutdown by the 723PLUS control:
• if the Ox’erspeed Trip level is exceeded, when immediate shutdown is enabled, OR if the
Overspeed Count level is reached, if this function is enabled instead. (See the Overspeed
Protection section earlier in this chapter)
• if both speed sensor inputs should fail
• if speed sensor #1 should fail whilst the clutch is dis-engaged
The relay contact will be opened continuously, unless the option for Pulse Alarm is selected,
in which case, the contact will be opened for the Pulse Alarm Tune, and will then be re
closed.
Minor Alarm:
The Minor Alarm will be activated:
• if one speed signal fails
• if the Rack Position Sensor input fails - below 1mA, above 22mA
• if the Charge Air Pressure input fails - below 2mA, above 22mA
• if the Analogue Speed Reference input fails - below 2mA, above 22mA
• if the Synchrophaser Bias input fails - below 2mA, above 22mA
• if the Modbus® serial communications have failed
• if there is a fault on the LON
Rectification and reset of the fault, will reset the Minor Alarm.
Modbus® Communications & Control
Instead of the hardwired inputs, the Modbus® communication can receive the following
commands from a higher level system.
• Run Engine
• Stop Engine
• Increase Speed/Load
• Decrease Speed/Load
• Unload
• Droop Mode
• Isochronous Mode
• Reset
• Digital Speed Setting
• Analogue Speed Setting
Each input which will be selected via the Modbus® instead of hardwired, should be
individually chosen in Configure mode.
In addition to the control signals, a number of parameters can also be monitored via the
Modbus®. A full listing including addresses can be found at the end of this chapter.
34
Analogue Outputs
Through the 723PLUS 4-20mA analogue outputs, it is possible to monitor any three of the
following (4mA & 20mA setpoints configurable);
• Rack Position (mA)
• Actuator Position (%)
• Engine Load (% )
• Speed Input #1 (rpm)
• Speed Input #2 (rpm)
• Engine Speed (rpm)
• Fuel Limit Level (%act or %load)
• PID Level {%)
• Speed Reference (rpm)
The analogue outputs are configured under the ÂNALOG O/P CONFIG* menu in Service.
Control Options
The following options are available with the 723PLUS Propulsion Control, all configurable
via the operator interface:
• Digital O/P #3 configurable for Fuel Limit Indication or Clutch Ready to Close.
Digital O/P #3 is also configurable for normally open or nomially closed.
• The Run/Stop contact input may be configured such that the contact is closed to Run.
and opened to Stop, instead of the default, open to Run, close to Stop.
• The Isochronous/Droop contact input may be configured such that the contact is opened
for Isochronous, closed for Droop, instead of the default, open for Droop, close for
Isoch.
• The Analogue/Digital contact input may be configured such that the contact is opened
for Digital, closed for Analogue, instead of the default, close for Digital, open for
Analogue.
• Digital I/P #7 configurable for Constant Speed Selection or Fuel Limit Shift.
• The digital output for the SD Alarm configurable for normally open or normally closed,
for the healthy condition.
• The digital output for the Minor Alarm configurable for normally open or normally
dosed, for the healthy condition.
• The Synchrophaser Bias can be input to the control via the hardwired input, or via the
LON.
• Analogue Input #4 may be configured for the Synchrophaser Bias or Assymetric Load
Share Bias.
• The Overspeed is configurable for immediate shutdown, or to pulse the actuator down, to
keep the engine running.
35
Operator Interface
The parameters within the control may be configured and monitored using either a Hand Held
Programmer, or using the ServLink Server and Graphical User Interface (more details of this
can be found in Chapter 8 - Setpoint Programming).
Each of the two part numbers, 8280-505 & 8280-506 can be switched between the HHT and
Servlink, via a tuneable, either in the operator interface or the HHT. When the switch is made,
there is a delay of 30 seconds before the control actually switches over.
However, whichever is selected by the tuneable, when the power to the control is switched
off, and then back on again, the communications will be re-selected to the Default Mode,
which is HHT for 8280-505, and ServLink for 8280-506, for a period of 30 seconds. After
this period, the control will switch to the mode defined by the tuneable Mode in the
HHT/Servlink menu.
36
Manual 02845 B System Description
Q I U m <
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I Figure 5-2. Function Block Diagram - Cover Sheet
37
System Etescription Manual 02845B
a o 1 1 <
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15
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Figure 5-3. Function Block Diagram - Overview n
38
Configure Values List
Heading Default Range Final

Prompt Value
PASSCODE
ENABLE CONFIGURE 723 0 to 32767
ENABLE SERVICE 723 0 to 32767
ENGINE SPEED
PULSES/REV #1 155 40 to 500
MAXIMUM MZ#1 2519 500 to 10000
PULSES/REV #2 155 40 to 500
MAXIMUM HZ #2 2519 500 to 100(X)
TORSIONAL FILTER? FALSE False to True
RATED SPEED 750.0 0.0 to 2000.0
FINAL DRIVER
ACTUATOR niA @ 0% 10.0 0.0 to 2(X).0
ACTUATOR mA @ 100% 180.0 10.0 to 200.0
REVERSE ACTING? FALSE False to True
MODBUS J2
MODE 2 1 to 2
SLAVE ADDRESS 1 1 to 247
MODBUS .13
MODE 2 1 to 2
SLAVE ADDRESS I 1 to 247
CONFIGURE
ENABLE CALIBRATION FALSE False to True
ENABLE AIR l/P FALSE False to True
ENABLE I/P m FALSE False to True
ENABLE LOAD I/P FALSE False to True
TANDEM NODE # 1 1 to 2
SYSTEM NODE # 1 I to 4
SINGLE PROPULSION? FALSE False to True
CONTROL OPTIONS
DIG 0/P #3 CL CLOSE FALSE False to True
OPEN I/P TO RUN? TRUE False to True
OPEN TO SEL DIGITAL FALSE False to True
OPEN TO SELISOC FALSE False to True
DIG I/P #7 FL SHIFT FALSE False to True
SD ALARM NO? FALSE False to True
MINOR ALARM NO? FALSE False to True
LON SYNCHROPHASER? FALSE False to True
ENABLE LOAD OFFSET? FALSE False to True
OVERSPEED SD? TRUE False to True
I RELAY O/P #3 NO? TRUE False to True
CONF MODBUS I/P'S

DROOP/ISOCHRONOUS FALSE False to True
DIGITAUANALOGUE FALSE False to True
START/STOP FALSE False to True
UNLOAD FALSE False to True
RESET FALSE False to True
INCREASEDECREASE FALSE False to True
39
System Description Manual Q2845B
Service Values List
Flcading Default Range Final

Prompt Value
DISPLAY ANALOGUES
ENGINE SPEED (Monitor)
SPEED REFERENCE (Monitor)
ACTUATOR POSITION (Monitor)
ENGINE LOAD (Monitor)
ANALOGUE REFERENCE (Monitor)
DROOP BIAS (Monitor)
SYNCHROPHASER BIAS (Monitor)
CHARGE AIR PRESSURE (Monitor)
SYSTEM LOAD % (Monitor)
FUEL LIMIT ACT% (Monitor)
FUEL LIMIT LOAD % (Monitor)
CHARGE AIRmA (Monitor)
ANALOGUE REF mA (Monitor)
RACK SENSOR mA (Monitor)
DISPLAY BOOLEANS
LOAD SHARING (Monitor)
ANALOGUE SELECTED (Monitor)
ANALOGUE ACTIVE (Monitor)
DIGITAL SELECTED (Monitor)
DIGITAL ACTIVE (Monitor)
CLUTCH IN (Monitor)
SD ALARM (Monitor)
MINOR ALARM (Monitor)
NEAR FUEL LIMIT (Monitor)
DYNAMICS #1
IDLE PROP GAIN#1 0.25 0.01 to 10.0
RATED PROP GAIN U\ 0.25 0.01 to 10.0
IDLE INT GAIN #1 (1/s) 0.5 0.01 to 10.0
RATED INT GAIN #1 (1/s) 0.5 0.01 to 10.0
IDLE SDR#I 10.0 0.01 to 100.0
RATED SDR#1 10.0 0.01 to 100.0
ENABLE DERIV DYN FALSE False to True
DYNAMICS #2
IDLE PROP GAIN #2 0.35 0.01 to 10.0
RATED PROP GAIN #2 0.35 0.01 to 10.0
IDLE INT GAIN #2 (I/s) 0.63 0.01 to 10.0
RATED INT GAIN #2 (I/s) 0.63 0.01 to 10.0
IDLE SDR #2 14.55 0.01 to 100.0
RATED SDR #2 14.55 0.01 to 100.0
PROPGAIN MULTIPLIER 1.0 0.01 to 1.0
DYNAMICS #3
IDLE INT GAIN #3 (1/s) 0.63 0.01 to 10.0
RATED INT GAIN #3 (1/s) 0.63 O.OI to lO.O
IDLE SDR #3 10.0 0.01 to 100.0
RATED SDR #3 10.0 0.01 to 100.0
40
DYNAMICS #4*'*
IDLE INT GAIN #4 (I/s) 0.63 0.01 to 10.0
RATED INT GAIN #4 (1/s) 0.63 0.01 to 10.0
IDLE SDR #4 14.55 0.01 to 100.0
RATED SDR tf4 14.55 0.01 to 100.0
PROPGAIN MULTIPLIER 1.0 0.01 to 1.0
GAIN SLOPE
LOADBKPT#! (%) 50.0 0.0 to 110.0
MULTIPLIER#! 1.0 0.01 to 10.0
LOAD BKPT #2 (%) 100.0 0.0 to 110.0
MULTIPLIER #2 1.0 0.01 to 10.0
GAIN RATIO
ERROR WINDOW#! (rpm) 100.0 0.0 to 100.0
GAIN RATIO #1 1.0 0.0 to 10.0
ERROR WINDOW #2 (rpm) 10.0 0.0 to 100.0
GAIN RATIO #2 2.0 0.0 to 10.0
GAIN RATIO #3 2.0 0.0 to 10.0
GAIN RATIO #4 2.0 0.0 to 10.0
DERIV DYNAMICS
PDERIVBKPT#! (rpm/s) 500.0 O.OI to 500.0
P MULTIPLIER#! 1.0 O.OI to 10.0
P DERIV BKPT#2 (rpm/s) 500.0 0.01 to 500.0
P MULTIPLIER #2 1.0 0.01 to 10.0
IDERIVBKPT#! (rpm/s) 500.0 0.01 to 500.0
I MULTIPLIER#! 1.0 0.01 to 10.0
I DERIVBK.pt #2 (rpm/s) 500.0 0.01 to 500.0
1 MULTIPLIER #2 1.0 0.01 to 10.0
D DERIV BKPT #1 (rpm/s) 500.0 0.01 to 500.0
D MULTIPLIER #1 1.0 0.01 to 10.0
D DERIV BKPT #2 (rpm/s) 500.0 0.01 to 500.0
D MULTIPLIER #2 1.0 0.01 to 10.0
ENGINE SPEED
FILTER # I FREQUENCY (Hz) 16.0 O.OI to 16.0
FILTER #1 Q FACTOR 0.707 0.707 to 25.0
FILTER #2 FREQUENCY (Hz) 16.0 0.01 to 16.0
FILTER #3 FREQUENCY (Hz) 16.0 0.01 to 16.0
ENABLE FILTER #3 FALSE False to True
SENSOR WEIGHT 0.5 0.0 to 1.0
TWO SPEED SENSORS? TRUE False to True
SS#2 FAULT OVRD DLY (s) 5.0 0.0 to 5.0
CLUTCH DELAY (s) 0.0 0.0 to 30.0
CLUTCH IN SPEED (rpm) 500.0 0.0 to 2000.0
CLUTCH IN WINDOW (rpm) lO.O 0.0 to 100.0
SPEED REFERENCE
IDLE SPEED (rpm) 400.0 0.0 to 2000.0
MINIMUM SPEED (rpm) 450.0 0.0 to 2000.0
MAXIMUM SPEED (rpm) 795.0 0.0 to 2000.0
41
FIXED SPEED (rpm) 750.0 0.0 to 2000.0

ACCELERATION RATE (rpm/s) 15.0 0.0 to 1000.0
DIGITAL RATE #I (rpm/s) 2.0 0.0 to 1000.0
DIGITAL RATE #2 (ipm/s) 2.0 0.0 to 1000.0
ANALOGUE RATE #1 (rpm/s) 2.0 0.0 to 1000.0
ANALOGUE RATE #2 (rpm/s) 2.0 0.0 to 1000.0
FIXED SPEED RATE (rpm/s) 15.0 0.0 to 1000.0
I IDLE/RATED SWITCH (rpm)
REM REF @ 4mA (rpm)
350.0
450.0
0.0 to 2500.0
0.0 to 2000.0
REMREF@20mAISOC (rpm) 795.0 0.0 to 2000.0
REM REF @20mA DROOP (rpm) 780.0 0.0 to 2000.0
SYNCHROPHASER GAIN 1.0 0.01 to 50.0
REF TO RATED IN DIG TRUE False to True
ENGINE LOAD
RACK SENSOR mA#l 7.0 4.0 to 20.0
LOAD%#l 0.0 0.0 to 100.0
RACK SENSOR mA #2 9.0 4.0 to 20.0
LOAD % #2 25.0 0.0 to 100.0
LOAD % #3 50.0 0.0 to 100.0
LOAD % #4 75.0 0.0 to 100.0
LOAD % #5 100.0 0.0 to 100.0
NO LOAD ACT% 15.0 0.0 to 100.0
FULL LOAD ACT% 75.0 0.0 to 100.0
DROOP (%) 4.0 0.0 to 15.0
LOAD FILTER (Hz) 2.0 0.05 to 100.0
LOAD SHARING
LOAD SHARE DELAY (s) 2.0 0.0 to 30.0
LOAD RATE (%/s) 5.0 0.0 to 1000.0
UNLOAD RATE (%/s) 20.0 0.0 to 100.0
UNLOAD TRIP LEVEL (%) 10.0 0.0 to II 0.0
LOAD GAIN 5.0 0.0 to 20.0
LON LOAD SHARING? FALSE False to True
•B
SEL % UNLOADING FALSE False to True
UNLOAD % OF %LOAD 40.0 0.0 to 110.0
START/MAX LIMITER
START FUEL LIMIT XI (rpm) 0.0 0.0 to 2000.0
START FUEL LIMIT Y1 (%) 25.0 0.0 to 100.0
START FUEL LIMIT X2 (rpm) 300.0 0.0 to 2000.0
START FUEL LIMIT X3 (rpm) 400.0 0.0 to 2000.0
START FUEL LIMIT X4 (ipm) 500.0 0.0 to 2000.0
MAXIMUM FUEL LIMIT (%) 100.0 0.0 to 100.0
NEAR FUEL LIMIT % 0.0 0.0 to 100.0
FUEL LIMIT SHIFT % 100.0 -100.0 to 100.0
CHG AIR LIMITER

CHG AIR PRESS @4mA (bar) 0.0 0.0 to 6.0
CHG AIR PRESS @20mA (bar) 6.0 0.0 to 6.0
CHG AIR PRESSURE A (bar) 0.0 0.0 to 6.0
LOAD % A 50.0 0.0 to 150.0
42
Manual 02845R System Description
CHG AIR PRESSURE B (bi\r) LO 0.0 to 6.0

LOAD % B 50.0 0.0 to 150.0
CHG AIR PRESSURE C (bar) 2.0 0.0 to 6.0
LOAD%C 75.0 0.0 to 150.0
CHG AIR PRESSURE D (bar) 3.0 0.0 to 6.0
LOAD % D 100.0 0.0 to 150.0
I ENABLE LIM DELAY (s) *B 0.0 0.0 to 60.0
TORQUE LIMITER
ENGINE SPEED A (rpm) 200.0 0.0 to 2000.0
LOAD % A 20.0 0.0 to 150.0
ENGINE SPEED B (rpm) 350.0 0.0 to 2000.0
LOAD%B 40.0 0.0 to 150.0
ENGINE SPEED C (rpm) 700.0 0.0 to 2000.0
LOAD % C 80.0 0.0 to 150.0
ENGINE SPEED D (rpm) 750.0 0.0 to 2000.0
LOAD%D 100.0 0.0 to 150.0
RUN/STOP
RUNDOWN TIME (s) 2.0 0,0 to 300.0
PULSE/CONT ALARM FALSE False to True
ALARM PULSE TIME (s) 1.0 1.0 to 30.0
OVERSPEED
OVERSPEED TRIP (rpm) 860.0 0.0 to 2000.0
ACTUATOR DEC PULSE (s) 0.2 0.02 to 5.0
ACTUATOR DEC LEVEL (%) 20.0 0.0 to 100.0
OVERSPEED COUNT 100 Oto 100
RESET OSPD DELAY (mins) 0.1 0.0 to 1440.0
ANALOG O/P CONFIG

ANALOGUE OUTPUT #1 1 1 to 10
ANALOGUE OUTPUT #2 6 I to 10
ANALOGUE OUTPUT #3 8 I to 10
RACK O/P @ 4mA 4.0 0.0 to 22.0
RACK O/P @ 20mA 20.0 0.0 to 25.0
ACT POS O/P @ 4mA 0.0 0.0 to 100.0
ACT POS O/P @ 20mA 100.0 0.0 to 100.0
% LOAD O/P @ 4mA 0.0 0.0 to 120.0
% LOAD O/P @ 20mA 100.0 0.0 to 120.0
SPEED I O/P @ 4mA 0.0 0.0 to 2000.0
SPEEDl O/P @ 20mA 1000.0 0.0 to 2000.0
SPEED2 O/P @ 4mA 0.0 0.0 to 2000.0
SPEED2 O/P @ 20mA 1000.0 0.0 to 2000.0
SPEED O/P @ 4mA 0.0 0.0 to 2000.0
SPEED O/P @ 20mA 1000.0 0.0 to 2000.0
LIMIT O/P (g 4mA 0.0 0.0 to 100.0
LIMIT O/P (g 20mA 120.0 0.0 to 130.0
PIDO/P(@4mA 0.0 0.0 to 100.0
PID O/P (g 20mA 100.0 0.0 to 150.0
SPD REF O/P @ 4mA 0.0 0.0 to 2000.0
SPD REF O/P @ 20mA 1000.0 0.0 to 2000.0
LIMIT O/P A(rr/LOAD? FALSE False to Tmc
HHT/SERVLINK
BAUD 9 1 to 10
MODE 2(1) 1 to 2
MODBUS J2
43
HARDWARE CONFIG 2 1 to 3
BAUD RATE 5 1 to 7
STOP BITS ! 1 to 3
PARITY I I to 3
TIMEOUT (s) 5.0 0.0 to 60.0
ENABLE J2 ALARMS FALSE False to True
MODBUS J3
HARDWARE CONFIG 2 I to 3
BAUD RATE 5 I to 7
STOP BITS 1 1 to 3
PARITY I 1 to 3
TIMEOUT (s) 5.0 0.0 to 60.0
ENABLE J3 ALARMS FALSE False to True
CALIBRATION
ANALOGUE I/P OFFSET 0.0 -10.0 to 10.0
ANALOGUE 1/P GAIN 1.0 0.01 to 10.0
AIR I/P OFFSET 0.0 -10.0 to 10.0
AIR I/P GAIN 1.0 0.0 i to 10.0
SYNCH I/P OFFSET 0.0 -10.0 to 10.0
SYNCH I/P GAIN 1.0 0.01 to 10.0
LOAD I/P OFFSET 0.0 -10.0 to 10.0
LOAD I/P GAIN 1.0 0.0 to 10.0
CLOSE LS RELAY FALSE False to True
MANUAL LOAD OUT? FALSE False to True
LOAD OUT SET 1000.0 0.0 to 1000.0
LS LINES OFFSET 0 0 to 32767
LS LINES GAIN 21845 0 to 32767
LS LOAD OFFSET 2028 0 to 32767
LS LOAD GAIN 8083 Oto 32767
ANO/P#l OFFSET 0.0 -1000.0 to 1000.0
AN O/P #1 GAIN 1.0 0.5 to 1.5
AN O/P #2 OFFSET 0.0 -1000.0 to 1000.0
AN O/P #2 GAIN 1.0 0.5 to 1.5
AN O/P #3 OFFSET 0.0 -1000.0 to 1000.0
AN O/P #3 GAIN 1.0 0.5 to 1.5
AN O/P CALIBRATION 4.0 0.0 to 20.0
MINOR ALARM
ANALOG REF I/P FLT (Monitor)
CHG AIR I/P FLT (Monitor)
SYNCH BIAS I/P FLT (Monitor)
RACK SENSOR I/P FLT (Monitor)
LON#I FLT (Monitor)
LON #2 FLT (Monitor)
SPEED SENSOR FLT (Monitor)
SS FLT-TF ENABLED (Monitor)
MODBUS J2 FLT (Monitor)
MODBUS J3 FLT (Monitor)
MAJOR SD ALARM
BOTH SS FAILED (Monitor)
SS FLT-CLUTCH OPEN (Monitor)
OVERSPEED (Monitor)
FUEL LIMITING
TORQUE LIMITER (Monitor)
CHG AIR LIMITER (Monitor)
44
START/MAX LIMITER (Monitor)
45
Configure & Service Descriptions
Configure
PASSCODE
ENABLE CONFIGURE This parameter must be set to the correct passcode value, in order
to enable the Configure menus. If the value is incorrect, then no
configure values are displayed, and therefore cannot be altered.
To obtain the passcode value, please contact Waitsila NSD.
ENABLE SERVICE This parameter must be set to the correct passcode value, in order
to enable the Service menus. If the value is incorrect, then no
service values are displayed, and therefore cannot be altered.
To obtain the passcode value, please contact Waitsila NSD.
ENGINE SPEED
PULSES/REV #1 This is the number of teeth (or holes) on the speed sensing disc,
for the speed sensors connected to the 723. Speed Sensor #1
should be located on the engine side of the coupling.
MAXIMUM HZ#1 This parameter allows tuning of the speed sensing algorithm, to
obtain the optimum resolution for sensing speed. It is important
that the following instructions for tuning these parameters is
adhered to. The Maximum Hz should be calculated based on both
the minimum and maximum controlling speeds:
(Maximum Speed x Pulse/Rev x 1.3)/60 = A
(Minimum Speed x Pulse/Rev x 4)/60 = B
If B > A then use A as the Maximum Hz. If B < A then use B as
the Maximum Hz, provided that B is greater then 1.1 x
Overspeed Trip Frequency. If not, then contact Woodward
Governor for further assistance.
Calculate separately for each speed sensor input, if Pulses/Rev #1
& Pulses/Rev #2 are different.
PULSES/REV #2 This is the number of teeth (or holes) on the speed sensing disc,
for the speed sensors connected to the 723. Speed Sensor #2
should be located on the generator/gearbox side of the coupling,
if the torsional filter is used, otherwise, it should be located on the
same speed sensing disc as sensor #1.
MAXIMUM HZ #2 This parameter allows tuning of the speed sensing algorithm, to

obtain the optimum resolution for sensing speed. It is important
that the following instructions for tuning these parameters is
adhered to. The Maximum Hz should be calculated based on both
the minimum and maximum controlhng speeds:
(Maximum Speed x Pulse/Rev x 1.3)/60 = A
(Minimum Speed x Pulse/Rev x 4)/60 = B
46
Manual Q2845B System Description
If B > A then use A as the Maximum Hz. If B < A then use B as

the Maximum Hz, provided that B is greater then l.I x
Overspeed Trip Frequency. If not, then contact Woodward
Governor for further assistance.
Calculate separately for each speed sensor input, if Pulses/Rev #1
& Pulses/Rev #2 are different.
TORSIONAL FILTER? This will enable the torsional filter if selected true.
RATED SPEED This sets the nominal engine speed, (rpm)
FINAL DRIVER
ACTUATOR mA @ 0% This is the value of the current output to the actuator when the
control calls for 0% fuel (less than minimum stop).
For example: 10mA for direct acting actuator, 180mA for reverse
acting actuator.
ACTUATOR mA @ 100% This is the value of the current output to the actuator when the
control calls for 100% fuel (greater than maximum stop).
For example: 180mA for direct acting actuator, 10mA for reverse
acting actuator.
REVERSE ACTING? If this parameter is selected false (for a direct acting actuator
output), when the control issues a shutdown, the actuator output
will be driven immediately to 0mA (which is normally less than
the 0% fuel position). This worics with the actuator driver, as
additional protection during an engine shutdown.
For a reverse acting actuator output (selected true), this additional
protection is not available, and therefore this action will not occur.
WARNING: If this parameter is selected false, but the
actuator is configured for reverse acting, the actuator output
will be driven to OnuV (max fuel) during an engine shutdown.
Note: To configure the control actuator output for direct or
reverse acting, the Actuator mA @ 0/100% must be correctly set
up, taking into account, the type of actuator supplied (direct or
reverse).
MODBUS J2
MODE This sets the communications protocol of the J2 port. 1=ASCII,

2=RTU.
SLAVE ADDRESS This sets the network address for J2. This will always be set to I
for Point-to-Point communications.
MODBUS J3
47
t
MODE This sets the communications protocol of the J3 port. 1=ASCII,
2=RTU.
SLAVE ADDRESS This sets the network address for J3. This will always be set to 1
for Point-to-Point communications.
CONFIGURE
ENABLE CALIBRATION If selected true, the ^CALIBRATION* menu will be displayed

under Service.
The parameters for calibrating should not normally need tuning,
however, an Offset & Gain term is available for the calibration of
each analogue input or output.
ENABLE AIR I/P If selected false, will override the failed signal detection of the
charge air pressure i/p, and disable the charge air pressure limiter.
ENABLE I/P #4 If set false, then any alarms generated from analogue input #4 will
be overridden. This parameter should be set false if neither the
synchrophaser bias nor the asymmetric load sharing bias is being
utilised.
ENABLE LOAD I/P If selected false, will override the failed signal detection of the
rack position sensor i/p. When the load input is disabled, load is
based on the internally derived position feedback.
TANDEM NODE# This parameter identifies the control address, as it's part in the
tandem pair. Of the tandem pair, one must have address 1, whilst
the other must have address 2. EACH CONTROL MUST
HAVE A UNIQUE ADDRESS. Failure to give each one a
unique address will result in the inability of the two 723's to
communicate over the LON, and therefore successful load sharing
will not be possible.
SYSTEM NODE # This parameter identifies the control address, as it's part in the
synchrophasing network.
For a system with two engines on each shaft, the Port engine
controls should use addresses 1 & 2, whilst the Starboard engine
controls must be addressed 3 & 4 - EACH CONTROL MUST
HAVE A UNIQUE ADDRESS.
For a system with one engine per shaft, the Port engine control
should use address I or 2, whilst the Starboard engine control
must be addressed 3 or 4.
SINGLE PROPULSION? Should be selected true for control of a single engine on a shaft. It
should be selected false for tandem systems, i.e. where two
engines are operating on each shaft.
48
CONTROL OPTIONS
DIG 0/P #3 CL CLOSE If true, digital output #3 will be configured to activate when the
CKitch Ready to Close logic is true. If false, then this output will
activate when the Fuel Limiting logic is true.
OPEN I/P TO RUN? If set true, the Run/Stop input will operate as:
Open to Run, Close to Stop.
If set false, the input will operate:
Close to Run, Open to Stop.
OPEN TO SEL DIGITAL If set true, digital input #8 will be configured open to select digital
speed setting mode, close for analogue. Otherwise, in the default
state (false), the input will be close for digital, open for analogue.
OPEN TO SEL ISOC If set true, digital input #6 will be configured open to select
isochronous mode, close for droop. Otherwise, in the default state
(false), the input will be close for isochronous, open for droop.
DIG I/P #7 FL SHIFT If set true, closure of digital input #7 will shill the fuel limit levels,
by a certain (tuneable) amount.
If set false, closure of digital input #7 wall select the fixed speed
level, (and hence digital speed setting mode).
SD ALARM NO? If set true, the SD Alarm output, (digital output #1) will be de
energised in the healthy state (i.e. contact open).
If set false, when the alarm state is healthy, the output is energised
MINOR ALARM NO? If set true, the Minor Alarm output, (digital output #2) will be de
energised in the healthy state (i.e. contact open).
If set false, when the alarm state is healthy, the output is energised
LON SYNCHROPHASER? This value should be set true, if the synchrophaser bias is to be
sent via the LON, rather than hardwired.
ENABLE LOAD OFFSET? If set tme, analogue input #4 will be configured for the
asymmetric load sharing bias, whereby the load sharing between a
pair of engines is offset by an amount determined by the 4-20mA
input. If set false, the input will be configured for the
synchrophaser bias input.
OVERSPEED SD? If selected true, the control will shut the engine down, as soon as
an overspeed is detected. If selected false, the actuator decrease
pulse logic will be effective instead, when an overspeed is
detected.
RELAY O/P #3 NO? * If set true, digital output #3 will be energised when the Rmetion is
activated, and de-energised when the function is not activated.
49
CONF MODBUS I/PS
DROOP/ISOCHRONOUS If selected true, the control input for droop/isochronous mode

selection is received via the Modbus®. If false, then the input is
hardwired.
DIGITAL/ANALOGUE If selected true, the control input for digital/analogue speed

setting selection is received via the Modbus®. If false, then the
input is hardwired.
START/STOP If selected true, the control input for starting/stopping the engine
is received via the Modbus®. If false, then the input is hardwired.
UNLOAD If selected true, the control input for unloading is received via the
Modbus®. If false, then the input is hardwired.
RESET If selected true, the reset command can be sent via Modbus®. All
faults which are normally self-resetting will instead remain latched
until a reset is received (provided that the fault has been cleared).
If false, then speed sensor faults are reset when the Run/Stop
contact input is closed, and all other faults are self-resetting, i.e.
reset automatically when the fault is cleared.
INCREASEADECREASE If selected true, the control inputs for Increase/Decrease

Speed/Load are received via the Modbus®, If false, then the
inputs are hardwired.
50
Service
DISPLA Y ANALOGUES
ENGINE SPEED This displays the current speed of the engine, (rpm)
SPEED REFERENCE This is the rpm reference, after the droop has been taken into
account, if in droop mode, or taking into account the error bias if
in isochronous mode. This also includes the synchrophaser bias (if
used), (rpm)
ACTUATOR POSITION This is the % actuator output demanded by the control.
ENGINE LOAD This is the % engine load.
ANALOGUE REFERENCE This is the speed reference demanded by the 4-20mA input, (rpm)
i
DROOP BIAS This is the bias on the speed reference, as determined by the
droop calculation, based on droop programmed, engine load and
the speed reference, (rpm)
SYNCHROPHASER BIAS This value is the bias on the speed reference, due to the effect of
the synchrophaser, either by the analogue input, or via the LON.
(rpm)
CHARGE AIR PRESSURE This is the value of the charge air pressure input, (bar)
SYSTEM LOAD % This parameter displays the current system load level, determined
either Irom the analogue load sharing lines, or the LON lines,
depending on which method has been selected for isochronous
load sharing.
FUEL LIMIT ACT % This is the lowest fuel limit level, expressed as % actuator.
FUEL LIMIT LOAD % This is the lowest fuel limit level, expressed as % load.
CHARGE AIR mA This is the value of the charge air pressure input to the control.
(mA)
ANALOGUE REF mA This is the value of the analogue speed reference input to the
control. (mA)
RACK SENSOR mA This is the value of the rack position sensor input to the control.
(mA)
51
DISPLA Y BOOLEANS
LOAD SHARING This value will be TRUE' when the control is in isochronous load
sharing mode.
ANALOGUE SELECTED This value will be TRUE' when the control is selected for
analogue speed setting mode.
ANALOGUE ACTIVE This parameter will display TRUE, if the analogue speed setting is
active.
DIGITAL SELECTED This value will be 'TRUE' when the control is selected for digital
speed setting mode.
DIGITAL ACTIVE This parameter will display TRUE, if the digital speed setting is
active.
CLUTCH IN This value will be 'TRUE' when the clutch engaged contact is
tme, and the 'Clutch Delay' period has expired.
SD ALARM This value will be TRUE’ when the Shutdown Alarm is activated.
MINOR ALARM This value will be TRUE' when the Minor Alarm is activated.
NEAR FUEL LIMIT This value will be 'TRUE when the Fuel Limiting Indication is
activated.
DYNAMICS m
IDLE PROP GAIN #I This parameter sets the Proportional Gain term at Idle Speed,
when the clutch is open, and the Fixed Speed contact input is
open. At speeds between idle & rated, the proportional gain term
is increased/decreased linearly between the two setpoints.
PID proportional gain adjustment for the dynamics gain.
Increasing the P term increases the gain, a value for P that is too
large will cause oscillation, if P is too small the offset from a
transient will be too large. The gain setting varies with the engine
speed;
Note: Below idle speed, the proportional gain will remain at the
Idle Prop Gain level.
RATED PROP GAIN #1 This parameter sets the Proportional Gain term at Rated Speed,
when the clutch is open, and the Fbced Speed contact input is
52
speed:
Note; Above rated speed, the proportional gain will remain at the
Rated Prop Gain level.
IDLE INT GAIN#1 This parameter sets the Integral Gain tenn at Idle Speed, when
the clutch is open, and the Fixed Speed contact input is open. At
speeds between idle & rated, the integral gain tenn is
increased/decreased linearly between the two setpoints.
PID integrator rate adjustment for the dynamics, affects kW
recovery rate aller a transient. A value for the I term that is too
large will change the actuator current slowly and speed will take a
long time to return to set speed after a transient, giving
overdamped response. If the I term is too small the actuator
current will move too fast and speed will overshoot and response
will be underdamped. (1/s)
Note; Below idle speed, the integral gain will remain at the Idle
Int Gain level.
RATED INT GAIN #1 This parameter sets the Integral Gain tenn at Rated Speed, when
the clutch is open, and the Fixed Speed contact input is open. At
PID integrator rate adjustment for the dynamics, alTects kW
recovery rate after a transient. A value for the 1 term that is too
will be imdcrdampcd. (1/s)
Note: Above rated speed, the integral gain will remain at the
Rated Int Gain level.
IDLE SDR#I This parameter sets llie S.D.R. term at Idle Speed, when the
clutch is open, and the Fixed Speed contact input is open. At
speeds between idle & rated, the S.D.R. terni is
PID derivative ratio adjustment for the dynamics. Set the amount
of derivative (or lead) action the control will have. Increasing the
derivative ratio value above 1 will decrease the derivative function
giving the control a PI type action. A value too large will make
the system less responsive. A value too small will make the
system oscillate, and cannot be compensated for with the
proportional gain or the integrator rate.
Note: Below idle speed, the S.D.R. will remain at the Idle S.D.R.
level.
RATED SDR#1 This parameter sets the S.D.R. term at Rated Speed, when the
clutch is open, and the Fixed Speed contact input is open. At
53
speeds between idle & rated, the S.D.R. term is

Note: Above rated speed, the S.D.R. will remain at the Rated
S.D.R. level.
ENABLE DERIV DYN If tme, the Gain Ratio function will be switched out, and the
Derivative Dynamics function will be switched in. Both llinctions
are multiplying, and will work on whichever dynamics is switched
in at the time (#1 or #2). The Gain Ratio multiplies the
Proportional Gain, based on the speed error, whilst the Derivative
Dynamics multiply all three PID terms (individually tuneable),
based on the rate of change of engine speed.
Example:
P Muliiplier U2
Proportional
Gain Multiplier
P Multiplier#!
P Dcriv Bkpl P Deriv Bkpt

#2
Speed Derivative
DYNAMICS U2
IDLE PROP GAIN #2 This parameter sets the Proportional Gain term at Idle Speed,
when the clutch is closed, and the Fixed Speed contact input is
speed:
54
is increased/clecreased linearly between the two setpoints.

Increasing the P term increases the gain, a value for P tliat is too
large will cause oscillation, if P is too small the ofi'set from a
speed:
Note: Above rated speed, the proportional gain will remain at the
IDLE INT GAIN #2 This parameter sets the Integral Gain term at Idle Speed, when
the clutch is closed, and the Fixed Speed contact input is open. At
speeds between idle & rated, the integral gain term is
recovery rate after a transient. A value for the I term that is too
Note: Below idle speed, the integral gain will remain at the Idle
Int Gain level.
RATED INT GAIN #2 This parameter sets the Integral Gain term at Rated Speed, when
the clutch is closed, and the Fixed Speed contact input is open. At
speeds between idle & rated, the integral gain terni is
IDLE SDR #2 This parameter sets the S.D.R. term at Idle Speed, when the
clutch is closed, and the Fixed Speed contact input is open. At
level.
55
RATED SDR #2 This parameter sets the S.D.R. term at Rated Speed, when the
clutch is closed, and the Fixed Speed contact input is open. At
derivative ratio value above 1 will decrease the derivative flmction
S.D.R. level.
PROPGAIN MULTIPLIER The value of this parameter determines the value of proportional
gain in the control, should a speed sensor fail when the torsional
filter is enabled. The purpose of this parameter is to slow the PID
down in the event of the torsional filter being disabled, when a
speed sensor fails.
DYNAMICS
closed. At speeds between idle & rated, the proportional gain
term is increased/decreased linearly between the two setpoints.
speed:
speed:
the clutch is open, and the Fixed Speed contact input is closed. At \v'
56
speeds between idle & rated, the integral gain term is

recovery rate after a transient. A value for the I tenn that is too
will be luiderdampcd. (1/s)
Int Gain level.
the clutch is open, and the Fixed Speed contact input is closed. At
clutch is open, and the Fixed Speed contact input is closed. At
level.
clutch is open, and the Fixed Speed contact input is closed. At
57

S.D.R. level.
DYNAMICS
large will cause oscillation, if P is too small the ofTset from a
speed:
speed:
the clutch is closed, and the Fixed Speed contact input is closed.
At speeds between idle & rated, the integral gain term is
recoveiy rate after a transient. A value for the I term that is too
Int Gain level.
the clutch is closed, and the Fixed Speed contact input is closed.
At speeds between idle & rated, the integral gain term is
PID integrator rate adjustment for tiie dynamics, affects kW
58
clutch is closed, and the Fixed Speed contact input is closed. At
level.
clutch is closed, and the Fixed Speed contact input is closed. At
derivative ratio value above I will decrease the derivative function
S.D.R. level.
PROPGAIN MULTIPLIER The value of this parameter determines the value of proportional
gain in the control, should a speed sensor fail when the torsional
filter is enabled. The purpose of this parameter is to slow the PID
down in the event of the torsional filter being disabled, when a
speed sensor fails.
GAINSLOPE
59
Multiplier #2
Proportional
Gain
Multiplier
Multiplier#]
I
I
I
Load Bkpt #1 Load Bkpt #2
Engine Load
LOAD BKPT#1 This is the load breakpoint associated with 'Multiplier #1', for the
curve set up to calculate a proportional gain multiplier, which is
dependent on the engine load. At loads between points #1 & #2,
the multiplier is increased/decreased linearly between these two
points.
For values of load at, or less than, breakpoint #1, the multiplier
will be 'Multiplier #1'.
MULTIPLIER#! This is the multiplier, associated with 'Load Bkpt #T, for the
calculation of the gain multiplier.
LOAD BKPT #2 This is the load breakpoint associated with 'Multiplier #2', for the
curve set up to calculate a proportional gain multiplier, which is
dependent on the engine load. At loads between points #1 & #2,
the multiplier is increased/decreased linearly between these two
points.
For values of load at, or greater than, breakpoint #2, the
multiplier will be 'Multiplier #2'.
MULTIPLIER #2 This is the multiplier, associated with 'Load Bkpt #2’, for the
calculation of the gain multiplier.
60
CiAINHATIO
Gain lirror
Ratio Window
t
Proportional
Gain
Multiplier
i.o
Speed Error
ERROR WINDOW #1 This value is the magnitude of a speed error at which the control
automatically switches to fast response, whilst the clutch is open,
and the Fixed Speed contact input is open. The control uses the
absolute value of speed error, to make this switch.
GAIN RATIO #1 This sets the ratio of the gain setting at steady state to the gain
setting during transient conditions, whilst the clutch is open and
the Fixed Speed contact is open. The Gain Ratio operates in
conjunction with the Error Window and Proportional Gain
adjustments, by multiplying the Proportional Gain setpoint by the
Gain Ratio when the speed error is greater than the Error
Window. This makes the control dynamics fast enough to
minimise engine speed overshoot on start-up and to reduce the
magnitude of speed error when loads are changing. This allows a
lower gain at steady state for better stability and reduced steady-
state actuator linkage movement.
The Gain Ratio function is disabled, if the Derivative Dynamics
are enabled, and vice versa.
ERROR WINDOW #2 This value is the magnitude of a speed error at which the control
automatically switches to fast response, whilst the clutch is
closed, and the Fixed Speed contact input is open. The control
uses the absolute value of speed error, to make this switch.
setting during transient conditions, whilst the clutch is closed and
the Fixed Speed contact is open. The Gain Ratio operates in
61

ERROR WINDOW #3 This value is the magnitude of a speed error at \vhich the control
automatically switches to fast response, whilst the clutch is open,
and the Fixed Speed contact input is closed. The control uses the
absolute value of speed error, to make this switch.
*B
setting during transient conditions, whilst the clutch is open and
the Fixed Speed contact is closed. The Gain Ratio operates in
The Gain Ratio Rmetion is disabled, if the Derivative Dynamics
ERROR WINDOW #4 * This value is the magnitude of a speed error at which the control
automatically switches to fast response, whilst the clutch is
closed, and the Fixed Speed contact input is closed. The control
uses the absolute value of speed error, to make this switch.
GAIN RATIO #4 *“ This sets the ratio of the gain setting at steady state to the gain
setting during transient conditions, whilst the clutch is closed and
the Fixed Speed contact is closed. The Gain Ratio operates in
DERIV DYNAMICS
P DERIV BKPT#1 This value is breakpoint #1 which relates to 'P Multiplier #1' of
the curve to determine the Proportional Gain multiplier, based on
the engine speed derivative (rate of change of speed), (rpm/s)
P MULTIPLIER#! This value is the multiplier #1 which relates to 'P Deriv Bkpt #1
62
of the curve to determine the Proportional Gain multiplier, based

on the engine speed derivative (rate of change of speed).
P DERIV BKPT #2 This value is the breakpoint #2 which relates to 'P Multiplier #2’
on the engine speed derivative (rate of change of speed), (rpm/s)
P MULTIPLIER #2 This value is tlie multiplier #2 which relates to 'P Deriv Bkpt #2'
on the engine speed derivative (rate of change of speed).
I DERIV BKPT#1 This value is breakpoint #1 which relates to 'I Multiplier #1' of the
curve to determine the Integral Gain multiplier, based on the
engine speed derivative (rate of change of speed), (rpm/s)
I MULTIPLIER#! This value is the multiplier #1 which relates to 'I Dcriv Bkpt #1' of
the curve to determine the Integral Gain multiplier, based on the
engine speed derivative (rate of change of speed).
I DERIV BKPT #2 This value is the breakpoint #2 which relates to 'I Multiplier #2’ of
I MULTIPLIER #2 This value is the multiplier #2 which relates to 'I Deriv Bkpt #2' of
D DERIV BKPT#1 This value is breakpoint #1 which relates to 'D Multiplier #T of

the curve to determine the S.D.R. multiplier, based on the engine
speed derivative (rate of change of speed), (rpm/s)
D MULTIPLIER#! This value is the multiplier #1 which relates to 'D Deriv Bkpt #1'
of the curve to determine the S.D.R. multiplier, based on the
D DERIV BKPT #2 This value is the breakpoint #2 which relates to 'D Multiplier #2'
D MULTIPLIER #2 This value is the multiplier #2 which relates to 'D Deriv Bkpt #2'
ENGINE SPEED
FILTER#! FREQUENCY This is the frequency at which the band-stop (notch) filter will
operate and should be set to the resonant frequency of the speed
signal #1. (Hz)
FILTER#! QFACTOR For speed signal #1, this parameter adjusts the attenuation of the
signal frequency, filtered by the band-stop filter. The minimum
63
value of 0.707 results in zero attenuation, and as the value is

increased, the attenuation is increased, and the range of
frequencies affected broadens.
FILTER #2 FREQUENCY This is the frequency at which the band-stop (notch) filter will
operate and should be set to the resonant frequency of the speed
signal #2. (FIz)
FILTER #2 Q FACTOR For speed signal #2, this parameter adjusts the attenuation of the
signal frequency, filtered by the band-stop filter. The minimum
value of 0.707 results in zero attenuation, and as the value is
increased, the attenuation is increased, and the range of
frequencies affected broadens.
FILTER #3 FREQUENCY This is the frequency at which the band-stop (notch) filter will
operate. Filter #3 is for filtering the final speed signal, i.e. after the
High Signal Select bus or the Torsional Filter. (Hz)
FILTER #3 Q FACTOR For filter #3, this parameter adjusts the attenuation of the signal
frequency, filtered by the band-stop filter. The minimum value of
0.707 results in zero attenuation, and as the value is increased, the
attenuation is increased, and the range of frequencies affected
broadens.
ENABLE FILTER #3 If selected false, band-stop filter #3 will be switched out, and the
engine speed will be fed directly from the High Signal Select bus
or the Torsional Filter (whichever is selected).
SENSOR WEIGHT When using the torsional filter, it is possible to weight one speed
sensor input more heavily than the other. If this value is set
between 0.5 and 1, sensor #1 will be weighted more heavily then
sensor #2. Between 0 and 0.5, sensor #2 will be more heavily
weighted.
TWO SPEED SENSORS? If selected false, the minor alarm relay will not be activated,
should a speed sensor input fail. The Alarm LED on the front of
the 723 however, will still illuminate, as the failure is continuously
detected. The purpose of this parameter, is to prevent the minor
alarm activating, when only one speed pickup is used.
SS#2 FAULT OVRD DLY This parameter sets the time for which failure of the second speed
pickup is overridden if the torsional filter is selected, when the
clutch engaged contact is closed. The timer starts when the
contact closes, (s)
CLUTCH DELAY This value is the delay after which the control receives the clutch
engaged contact input closed, before certain control functions can
operate - this is in place in order to ensure that the clutch is
actually engaged before switching into isochronous mode,
enabling the torsional filter etc. (s)
64
CLUTCH IN SPEED This is the speed (+/- the 'Clutch In Window') at which the Clutch
Ready to Close signal is activated, for a single (or first) engine
start-up. (rpm)
CLUTCH IN WINDOW For a the first (or single) engine start-up, when the engine speed
reaches the Clutch In Speed, within the Clutch In Window, the
Clutch Ready to Close signal is activated.
For a second engine start-up (tandem propulsion system), when
the engine speed reaches that of the first engine, within the Clutch
In Window, the Clutch Ready to Close signal is activated, (rpm)
SPEED REFERENCE
IDLE SPEED This value is provided for engine start-up. It is independent of the
'Minimum Speed' setpoint and may be set to a lower value. Idle
Speed is selected when engine is first started, (rpm)
MINIMUM SPEED This is the lowest rpm value to which the speed reference may be
driven by closing the Decrease Speed/Load contact input, (rpm)
MAXIMUM SPEED This is the highest rpm value to which the speed reference may be
driven by closing the Increase Speed/Load contact input, (rpm)
FIXED SPEED When the Fixed Speed contact input is closed (terminal 35 - if
enabled), this is the level to which the speed reference is ramped.
(rpm)
ACCELERATION RATE This is the rate at which the speed reference ramps from 'Idle
Speed' to 'Rated Speed', if the Digital/Analogue contact is closed,
or from 'Idle Speed' to the analogue reference, if the
Digitai/Analogue contact is open, (rpm/s)
DIGITAL RATE#1 This is the rate at which the speed reference is

increased/decreased using the Increase/Decrease contacts, when
the Clutch Engaged contact is open, (rpm/s)
DIGITAL RATE #2 This is the rate at which the speed reference is

increased/decreased using the Increasc/Decrease contacts, when
the Clutch Engaged contact is closed, (rpm/s)
ANALOGUE RATE #1 This is the rate at which the speed reference is

increased/decreased to follow the analogue reference input, when
the clutch is open. When the engine is first started, the
'Acceleration Rate' is enabled to initially ramp to the analogue
reference, and once the analogue reference level is reached, then
this rate is enabled for any further adjustment of the input, (rpm/s)
ANALOGUE RATE #2 This is the rate at which the speed reference is
65
increased/decreased to follow the analogue reference input, when

the clutch is closed, (rpm/s)
FIXED SPEED RATE This is the rate at which the speed reference is ramped to the
'Fixed Speed’ level, and fixed speed is selected (contact on
terminal 35 closed), (rpm/s)
IDLE/RATED SWITCH The speed reference will start to ramp to the 'Rated Speed' or the
analogue reference, when this switch speed is exceeded. It is
recommended that this parameter is tuned to a value slightly
lower than the 'Idle Speed', (rpm)
REM REF @ 4mA This is the value of the analogue speed reference which will be set
in the control when the input is 4mA. (rpm)
REM REF @20mA ISOC This is the value of the analogue speed reference which will be set
in the control when the input is 20mA and ISOC is selected.
The two 20mA values (ISOC & DROOP) are required to
minimise the change in speed if the running mode is switched
from DROOP to ISOC whilst the Analogue speed reference is in
use. If the droop reference is set higher than the isoc reference
by the number of RPM that the speed is drooped by for a given
load, if the mode is changed at that load, the speed change will be
zero. A speed change will occur if the mode is switched at any
other load.
Hint: To avoid a speed change, switch to DIGITAL control
before changing mode, (rpm)
REM REF @20mA DROOP This is the value of the analogue speed reference in RPM which
will be set in the control when the input is 20mA and DROOP is
selected, (rpm)
SYNCHROPHASER GAIN Adjustment of this value will increase or decrease the effect of the
synchrophaser input bias on the speed reference.
REF TO RATED IN DIG If set TRUE, when the control is in digital mode, when the engine
is started, the speed reference will be ramped to Rated Speed
once the Idle/Rated Switch speed is exceeded. Otherwise, if set
FALSE, the speed reference will remain at Idle Speed.
ENGINE LOAD
RACK SENSOR mA#l For scaling the rack position sensor input, this sets the mA level
corresponding to the percentage load level set by 'Load % #1'.
L0AD%#1 For scaling the rack position sensor input, this sets the % load
level corresponding to the milliamp input set by 'Rack Sensor mA
#r.
66
RACK SENSOR mA #2 For scaling the rack position sensor input, this sets the mA level
LOAD % #2 For scaling tlie rack position sensor input, this sets the % load
#2’.
LOAD % #3 For scaling the rack position sensor input, this sets the % load
#3'.
LOAD % #4 For scaling the rack position sensor input, this sets the % load
#4’.
corresponding to the percentage load level set by 'Load % US'.
LOAD % US For scaling the rack position sensor input, this sets the % load
US'.
NO LOAD ACT % This value is the actuator % output at zero load.
FULL LOAD ACT % This value is the actuator % output at full load.
DROOP This is the % of the current speed reference by which the speed
reference is drooped from zero to full load. (%)
LOAD FILTER This is the filter value. This value should not need to be adjusted,
but can be used to filter any undesirable frequencies picked up by
the rack position sensor. (Hz)
LOAD SHARING
LOAD SHARE DELAY For the first engine on line, this is the time period for which the
control will delay switching into Isochronous Load Sharing, after
the Clutch engaged contact is received. Otherwise, if it is the
second engine on line, the control will be switched into load
sharing, after the 'Clutch Delay' period has expired, (s)
LOAD RATE This is the rale at which the control increases/decreases the load.
67
when soft loading into isochronous load sharing, (%/s)
UNLOAD RATE This is the rate at which the control decreases the load, when
using the auto unload function in isochronous load sharing mode.
(%/s)
UNLOAD TRIP LEVEL This is the load level to which the control will unload the engine,
when the auto unload ftmction is used in isochronous load
sharing. (%)
LOAD GAIN This parameter sets the sensitivity to the load share error.
LON LOAD SHARING? Selecting this value to true will enable load sharing across the
Local Operator Network, instead of the analogue load sharing
lines.
SEL % UNLOADING If set TRUE, when the Unload command is issued (when the
control is isochronous load sharing), the load will be ramped
down to a level, which is a percentage of the original load level.
UNLOAD % OF %LOAD This value, expressed as a percentage of the original load level
(i.e. the load level sampled at the time the Unload command was
issued), is the level to which the load is ramped, when the Unload
command is issued, and the Sel % Unloading parameter is set
TRUE.
68
START/MAX LIMITER
Example:
XI,Y1 X2.Y2
80%
Fuel Limit
Level
X3.Y3 X4.Y4
40%
lOOrpm 250rpm
Engine Speed
Note: X4 must be > X3 which must be > X2 which must be >X1.

START FUEL LIMIT XI For the tour-point start fuel limit curve, this parameter defines the
engine speed level XI, at which the fuel limit is set to a level
determined by Y1. At engine speeds above X1, the tliel limit level
is increased/decreased linearly between Y1 & Y2, and below XI,
the fliel limit curve is extrapolated with respect to the curve
defmed between X1,Y1 and X2,Y2. (rpm)
START FUEL LIMIT Y1 For the four-point start fuel limit curve, tliis parameter defines the
fuel limit level Yl, pertaining to the engine speed XI. (%)
START FUEL LIMIT X2 For the four-point start fuel limit curve, this parameter defines the
engine speed level X2, at which the fuel limit is set to a level
detemiined by Y2. At engine speeds below XI, the fuel limit level
is increased/decreased linearly between Y2 & Yl, and above X2,
the fuel limit level is increased/decreased linearly between Y2 &
Y3. (rpm)
START FUEL LIMIT Y2 For the four-point start fuel limit curve, this parameter defines the
fuel limit level Y2, pertaining to the engine speed X2. (%)
determined by Y3. At engine speeds below X3, the fuel limit level
is increased/decreased linearly between Y3 & Y2, and above X3,
the fuel limit level is increased/decreased linearly between Y3 &
Y4. (rpm)
fuel limit level Y3, pertaining to the engine speed YX. (%)
determined by Y4. At engine speeds below X4, the fuel limit level
69
is increased/decreased linearly between Y4 & Y3, and above X4,

the fuel limit curve is extrapolated with respect to the curve
defined between X3,Y3 and X4,Y4. (rpm)
fuel limit level Y4, pertaining to the engine speed X4. (%)
MAXIMUM FUEL LIMIT This is the maximum % actuator output during normal engine
operation. This limit should normally be set just above the output
at full load. The start fuel limit is switched out, and the maximum
fuel limit is switched in, once the PID controller has taken control
for 3 seconds. (%)
NEAR FUEL LIMIT % This parameter determines the difference between the actuator
output and the nearest fuel limiter (as a % actuator position),
before the fuel limit indication output is activated (if enabled).
FUEL LIMIT SHIFT % This is the amount of bias that will be applied to the fuel limit
levels, if the Fuel Limit Shift contact input is closed (terminal 35 -
if enabled). (%)
CHG AIR LIMITER
Load Limit
Level (%)
Charge Air Pressure (bar)
Note: Chg Air Press D must be > Chg Air Press C which must be
> Chg Air Press B which must be greater than Chg Air Press A.
CHG AIR PRESS @4mA This is the value of the charge air pressure input, at 4mA.(bar)
CHG AIR PRESS @20mA This is the value of the charge air pressure input, at 20mA. (bar)
CHG AIR PRESSURE A This parameter configures the charge air pressure for point A, of
the charge air fuel limiter curve, (bar)
LOAD % A This parameter configures the load % for point A, of the charge
air fuel limiter curve.
70
CHG AIR PRESSURE B This parameter configures the charge air pressure for point B, of
LOAD % B This parameter configures the load % for point B, of the charge
CHG AIR PRESSURE C This parameter configures the charge air pressure for point C, of
LOAD % C This parameter configures the load % for point C, of the charge
CHG AIR PRESSURE D This parameter configures the charge air pressure for point D, of
LOAD % D This parameter configures the load % for point D, of the charge
ENABLE LIM DELAY ‘ This is the period for which enabling the charge air limiter is
delayed, once the clutch is engaged/generator cb aux is closed.
TORQUE LIMITER
Load Limit
Level (%) A
B
Engine Speed (rpm)
Note: Engine Speed D must be > Engine Speed C which must be

> Engine Speed B which must be greater than Engine Speed A.
ENGINE SPEED A This is the engine speed at which the actuator output is limited to
a level equivalent to the load defined by 'Load % A', (rpm)
LOAD % A This is the level to which the load is limited, when the engine
speed is at 'Engine Speed A'.
The load limit level is increased/decreased linearly between points
A & B, and for engine speeds below that defined by point A, the
load limit curve is extrapolated with respect to the curve defined
between A & B. (%)
71
ENGINE SPEED B This is the engine speed at which the actuator output is limited to
a level equivalent to the load defined by 'Load % B'. (rpm)
LOAD % B This is the level to which the load is limited, when the engine
speed is at 'Engine Speed B'.
A & B, and B & C. (%)
ENGINE SPEED C This is the engine speed at which the actuator output is limited to
a level equivalent to the load defined by 'Load % C. (rpm)
LOAD % C This is the level to which the load is limited, when the engine
speed is at 'Engine Speed C.
B & C, and C & D. (%)
ENGINE SPEED D This is the engine speed at which the actuator output is limited to
a level equivalent to the load defined by 'Load % D'. (rpm)
LOAD % D This is the level to which the load is limited, when the engine
speed is at 'Engine Speed D’.
C & D, and for engine speeds above that defined by point D, the
load limit curve is extrapolated with respect to the curve defined
between C & D. (%)
RUN/STOP
RUNDOWN TIME After a shutdown, this is the period for which the engine speed
must be below 350Hz, before the control will recognise the ‘run’
command, (s)
PULSE/CONT ALARM If selected true, the major alarm will be activated for the Alarm
Pulse Time' if a shutdown condition occurs. If false, the alarm
will remain latched, until the next 'mn' command is received.
ALARM PULSE TIME If'Pulse/Cont Alarm’ is selected tme, this is the period for which
the major alarm is activated, (s)
OVERSPEED
OVERSPEED TRIP This value sets the speed at which the engine is considered by the
control, to be overspeeding.
If the 'Overspeed SD?' parameter is set true, the engine will be
shutdown as soon as an overspeed is detected.
Otherwise, each time an overspeed is detected, a counter is
incremented by 1. At that time, a timer is started, and once the
72
■Reset Ospd Delay' period has expired, the counter will be reset.
The counter is also reset each time the engine is stopped.
When an overspeed is detected, if the total niunber of overspeeds
counted is less than the 'Overspeed Count' level, the engine will
force the actuator output down to the 'Actuator Dec Level', for a
period detennined by the 'Actuator Dec Pulse'. The 'Actuator Dec
Pulse' timer does not start until the engine speed has fallen below
the 'Overspeed Trip' level. If the number of overspeeds counted
reaches the 'Overspeed Count' level, the engine will be shutdown.
Please see Engine Manufacturer’s recommendation for the value
of this parameter.(rpm)
ACTUATOR DEC PULSE The actuator is forced to a lower level if an overspeed is detected,
until the engine speed falls below the 'Overspeed Trip' and then
for a further period of time determined by this parameter, (s)
See the description for 'Overspeed Trip'.
ACTUATOR DEC LEVEL This is the level to which the actuator is forced if an overspeed is
detected. (%)
See the description for ’Overspeed Trip'.
OVERSPEED COUNT This is the number of overspeeds which may occur before the
engine is shutdown. For a value of 1, the engine will be shutdown
each time an overspeed is detected.
See the description for ’Overspeed Trip'.
RESET OSPD DELAY When an overspeed first occurs, a timer is started. Once this timer
reaches the 'Reset Ospd Delay' time, the overspeed counter is
reset to zero, (mins)
See description for 'Overspeed Trip'.
ANALOG 0/P CONFIG
ANALOGUE OUTPUT #1 This selects the analogue value required through output #1,
terminals 15 & 16.
Output scanned/updated every 20ms.
1= Rack Position (4-20 input)
2=Actuator Position (%)
3=Percentage Load (%)
4=Unfiltered Speed #1 (rpm)
5=Unfiltered Speed #2 (rpm)
6=Engine Speed (Filtered) (rpm)
7=Fuel Limit (%)
8=PID Level (%)
9=Speed Reference (rpm)
10=Calibration Output
terminals 17 & 18.
73
See above for selection numbers.

terminals 19 & 20.
See above for selection numbers.
RACK 0/P@4mA This sets the analogue output level at 4mA representing the Rack
Sensor input.
This value is scanned/updated every 40ms.
RACK O/P @ 20mA This sets the analogue output level at 20mA representing the
Rack Sensor input.
This value is scanned/updated every 40ms
ACT POSO/P@4mA This sets the analogue output level at 4mA representing actuator
position.
ACT POS O/P @ 20mA This sets the analogue output level at 20mA representing actuator
position.
%LOAD O/P @ 4mA This sets the analogue output level at 4mA representing
percentage load.
% LOAD O/P @ 20mA This sets the analogue output level at 20mA representing
percentage load.
SPEEDl O/P @ 4mA This sets the analogue output level at 4mA representing unfiltered
speed through input # 1.
SPEEDl O/P @ 20mA This sets the analogue output level at 20mA representing
unfiltered speed through input #1.
SPEED2 0/P@4mA This sets the analogue output level at 4mA representing unfiltered
speed through input #2.
SPEED2 O/P @ 20mA This sets the analogue output level at 20mA representing
unfiltered speed through input #2.
SPEED O/P @ 4mA This sets the analogue output level at 4mA representing engine
speed (filtered).
74
SPEED 0/P @ 20mA This sets the analogue output level at 20mA representing engine
speed (filtered).
LIMIT 0/P (g 4mA This sets the analogue output level at 4mA representing the fuel
limit level, which can be represented as an actuator output, or
load level.
LIMIT O/P(g20mA This sets the analogue output level at 20mA representing the fuel
limit level, which can be represented as an actuator output, or
load level.
PID 0/P @ 4mA This sets the analogue output level at 4mA representing the PID
level.
PID 0/P @ 20mA This sets the analogue output level at 20mA representing the PID
level.
SPD REF 0/P @ 4mA This sets the analogue output level at 4mA representing the speed
reference.
SPD REF 0/P @ 20mA This sets the analogue output level at 20mA representing the
speed reference.
LIMIT 0/P ACT/LOAD? The analogue output representing fuel limit level, can be
expressed as a % load, or % actuator level. If this parameter is
false, the output will be in terms of load, otherwise if true, then
will be represented as an actuator %.
HHT/SERVLINK
BAUD For ServLink communications via the J1 port, this sets the desired
baud rate. An integer number in the range 1 to 10 is to be used
representing: 1-110, 2=300, 3=600, 4=1200, 5=1800, 6=2400,
7=4800, 8=9600, 9=19200, 10=38400. The preferred baud rates
are 9600 and 19200.
MODE This parameter allows switching between tlie Handheld Terminal
and ServLink Server for communications via the J1 port. A value
of 1 will select ServLink, and a value of 2 will select the HHT.
Note: If the power to the control is switched off and then on,
communications via the JI port will be set to the 'Default Mode'
75
of the control, which is HHT for p/n 8280-505, and ServLink for
p/n 8280-506, for 30 seconds, after which time it will switch to
the selected mode, if different.
MODBUS J2
flARDWARE CONFIG This value sets the communications hardware configuration for
the J2 port; 1=RS232, 2=RS422, 3=RS485
BAUD RATE This value sets the desired baud rate for the J2 port; an integer
number in the range 1 to 7 is to be used representing: 1=1200,
2=1800, 3=2400, 4=4800, 5=9600, 6=19200, 7=38400. The
preferred baud rates are 9600 & 19200. If the chosen baud rate is
38400, then both J2 and J3 must be set identical.
STOP BITS This value sets the desired number of stop bits for the J2 port; an
integer number in the range 1 to 3 is to be used representing: 1=1,
2=1.5, 3=2.
PARITY This value sets the desired parity for the J2 port; an integer
number in the range 1 to 3 is to be used representing: l=OFF,
2=ODD, 3=EVEN.
TIMEOUT If no communication is received within the timeout period, a

communications error will occur, (s)
ENABLE J2 ALARMS If set false, communications errors from the J2 port are ignored
by the control, otherwise if set true, a communications error will
activate the minor alann.
MODBUS J3
HARDWARE CONHG This value sets the communications hardware configuration for
the J3 port; 1=RS232, 2=RS422, 3=RS485
BAUD RATE This value sets the desired baud rate for the J3 port; an integer
number in the range 1 to 7 is to be used representing: 1=1200,
2=1800, 3=2400, 4=4800, 5=9600, 6=19200, 7=38400. The
preferred baud rates are 9600 & 19200. If the chosen baud rate is
38400, then both J2 and J3 must be set identical.
STOP BITS This value sets the desired number of stop bits for the J3 port; an
integer number in the range 1 to 3 is to be used representing: 1=1,
2=1.5, 3=2.
PARITY This value sets the desired parity for the J3 port; an integer
number in the range 1 to 3 is to be used representing: l=OFF,
2=ODD, 3=EVEN.
76
TIMEOUT If no communication is received within the timeout period, a

communications error will occur, (s)
ENABLE J3 ALARMS If set false, communications errors from the J3 port are ignored
by the control, otherwise if set true, a communications error will
activate the minor alarm.
CALIBH4TION
ANALOGUE I/P OFFSET If it is necessary to calibrate the Analogue Speed Reference input,
adjustment of this parameter will alter the offset.
To calibrate the input, set the mA to zero, and ensure that the
control is measuring zero. If not, adjust the offset until it does.
Then set the niA input to 20mA. Ensure that the control is
measuring 20. If not, adjust the gain until it does. Return the mA
input to zero, and check that the control is still measuring zero. If
not, repeat the calibration process.
ANALOGUE I/P GAIN If it is necessary to calibrate the Analogue Speed Reference input,
adjustment of this parameter will alter the gain.
AIR I/P OFFSET If it is necessary to calibrate the Charge Air Pressure input,
control is measuring zero. If not. adjust the offset until it does.
Then set the mA input to 20mA. Ensure that the control is
AIR I/P GAIN If it is necessary to calibrate the Charge Air Pressure input,
SYNCH I/P OFFSET If it is necessary to calibrate the Synchrophaser input, adjustment

of this parameter will alter the offset.
To calibrate the input, simulate the clutch closed, (i.e. close input
to terminal 32) set the mA to 4mA, and ensure that the
synchrophaser bias reads -10 (for Synchrophaser Gain set to 1). If
not, adjust the offset until it does. Then set the mA input to
20mA. Ensure that the synchrophaser bias reads 10. If not, adjust
the gain until it does. Return the mA input to 4mA, and check
that the synchrophaser bias still reads -10. If not, repeat the
calibration process.
SYNCH I/P GAIN If it is necessary to calibrate the Synchrophascr input, adjustment

of this parameter will alter the gain.
LOAD I/P OFFSET If it is necessary to calibrate the Rack Position Sensor input.
77

control is measuring zero. If not, adjust the offset until it does.
Then set the mA input to 20mA. Ensure that the control is
LOAD I/P GAIN If it is necessary to calibrate the Rack Position Sensor input,
CLOSE LS RELAY Whilst calibrating the load out to the load sharing lines, this
parameter should be set true in order to manually close the load
sharing relay.
MANUAL LOAD OUT? For calibrating the load output to the load sharing lines, if this is
set true, adjustment of the 'Load Out Set' parameter is allowed.
LOAD OUT SET If the 'Manual Load Out' is set due, this parameter will adjust the
value output to the load sharing lines, for the purpose of
calibration. The 'Close LS Relay’ parameter should also be set
true, in order to close the load sharing relay, and allow the output
signal onto the load sharing lines.
WARNING: For the purpose of calibration of the load sharing
lines I/O, the load sharing connections to any other units should
be disconnected, and this should be carried out with the engine
stopped. Forcing a voltage onto the load sharing lines, whilst still
connected to other load sharing units, will have a detrimental
effect to the load sharing and frequency of the system.
LS LINES OFFSET This is the offset parameter for calibration of the load sharing lines
input to the control.
To calibrate the load sharing lines, remove the connections to
terminals 9 & 10, check that the load share lines read 0%. If not,
adjust the offset. Then, inject 3V onto terminals 9 & 10, and
check that the load share lines are reading 100%. If not, adjust the
gain. Disconnect the voltage source, check that the load share
lines read 0%, if not, repeat the calibration process.
The offset and gain terms are the number of bits representing the
voltage on the load share lines, for scaling the output of the
analogue/digital converter.
LS LINES GAIN This is the gain parameter for calibration of the load sharing lines
input to the control.
LS LOAD OFFSET This is the offset parameter for calibration of the load level output
to the load sharing lines.
To calibrate this output, set to true, the parameters 'Close LS
Relay' (to manually close the load share relay) and 'Manual Load
Out?' (to allow the load level out to the load sharing lines to be
78
manually set), and ensure that there are no connections to

terminals 9 & 10.
Adjust the 'Load Out Set' to zero, and using a calibrated
voltmeter, check that the voltage measured across terminals 9 &
10 is zero. If it is not. adjust the offset tenn. Then adjust the 'Load
Out Set' to 1000, check the voltage across terminals 9 & 10,
which should measure 3V. If it does not, then adjust the gain.
Take the 'Load Out Set’ back to zero and measure the voltage, if
it does not read zero, repeat the calibration process.
The offset and gain terms are the number of bits representing the
load out to the load share lines, for scaling the output of the
digital/analogue converter.
LS LOAD GAIN This is the gain parameter for calibration of the load level output
to the load sharing lines.
AN O/P #1 OFFSET This parameter is the offset term, for calibration of analogue
output #1 (terminals 15 & 16).
If it is necessary to calibrate the output, set the parameter
'Analogue Output #1' (in menu *ANALOG O/P CONFIG*) to
10. Then adjust the 'An O/P Calibration' term to zero, and
measure the current from output #1. If it is not zero, then adjust
the offset term. Then adjust the 'An O/P Calibration' term to 20,
and check the current again. If it does not read 20, then adjust the
gain term. Return to zero, and check again, and work through the
calibration process again if necessary.
AN O/P #1 GAIN This parameter is the gain term, for calibration of analogue output
#1 (terminals 15 & 16).
AN O/P #2 OFFSET This parameter is the offset terni, for calibration of analogue
If it is necessary to calibrate the output, set the parameter
the offset term. Then adjust the 'An O/P Calibration’ term to 20,
#2 (terminals 17 & 18).
AN O/P #3 OFFSET This parameter is the offset term, for calibration of analogue
If it is necessaiy to calibrate the output, set the parameter
79
the offset term. Then adjust the 'An O/P Calibration' term to 20,
#3 (terminals 19 & 20).
AN O/P CALIBRATION For any analogue output selected to Option 9 (calibration),

adjustment of this value between 0 & 20 will allow checking and
adjustment of the calibration of the output/metering device,
between 0 and 20 mA.
MINOR ALARM
ANALOG REF I/P FLT If TRUE is displayed, a fault exists with the analogue speed
setting input, i.e. less than 2mA, greater than 22mA.
CHG AIR I/P FLT If TRUE is displayed, a fault exists with the charge air pressure
input, i.e. less than 2mA, greater than 22mA.
SYNCH BIAS I/P FLT If TRUE is displayed, a fault exists with the synchrophaser bias
input, or the asymmetric load sharing bias input (whichever is
configured for use), i.e. less than 2mA, greater than 22mA.
RACK SENSOR I/P FLT If TRUE is displayed, a fault exists with the rack position sensor
input, i.e. less than 1mA, greater than 22mA.
LON#l FLT If TRUE is displayed, a fault exists with LON #1.
LON #2 FLT If TRUE is displayed, a fault exists with LON #2.
SPEED SENSOR FLT If TRUE is displayed, a speed sensor fault exists.
SS FLT-TF ENABLED If TRUE, a speed sensor failure has occurred, when the clutch is
closed, and the torsional filter is enabled.
MODBUS J2 FLT If TRUE is displayed, a fault has been detected on the J2 serial
communications port (MODBUS).
MODBUS J3 FLT If TRUE is displayed, a fault has been detected on the J3 serial
communications port (MODBUS).
MAJOR SD ALARM
BOTH SS FAILED If TRUE is displayed, both speed sensors have failed, causing the
engine to be shutdown.
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Manual 02845 B System Description
SS FLT-CLUTCH OPEN If TRUE is displayed, a fault has occurred in speed sensor #1,
whilst the clutch is open, therefore causing the engine to be
shutdown. Whilst the clutch is open, the control only considers
speed sensor #1 for the speed control loop (as speed sensor #2
MAY be located on the other side of the clutch), therefore, if it
should fail, the engine must be shutdown.
OVERSPEED If TRUE is displayed, an overspeed has occurred, causing the

engine to be shutdown.
FUEL LIMITING
TORQUE LIMITER If TRUE, the torque limiter is within the 'Near Fuel Limit' value of
the actuator output.
CHG AIR LIMITER If TRUE, the charge air pressure limiter is within the 'Near Fuel
Limit' value of the actuator output.
START/MAX LIMITER If TRUE, the start or maximum fuel limiter is within the 'Near
Fuel Limit' value of the actuator output.
81
Modbus® Communications Address List
Boolean Writes
Addr Description
0:0001 Run/Start Engine
0:0002 Stop Engine
0:0003 Increase Speed/Load
0:0004 Decrease Speed/Load
0:0005
0:0006 Unload
0:0007 Droop
0:0008 Isochronous
0:0009
0:0010 Reset
0:0011 Digital Speed Setting
0:0012 Analogue Speed Setting
Boolean Reads
Addr Description
1:0001 *MAJOR/SHUTDOWN ALARM*
1:0002 ♦MINOR ALARM*
1:0003
1:0004
1:0005
1:0006 OVERSPEED - SD
1:0007 BOTH SPEED SENSORS FAILED - SD
1:0008 SPEED SENSOR FAIL, CLUTCH OPEN - SD
1:0009 ANALOGUE REF I/P FAILURE - MINOR
1:0010 CHARGE AIR PRESSURE SENSOR - MINOR
1:0011 SYNCHROPHASER I/P - MINOR
1:0012 SPEED SENSOR FAILURE - MINOR
1:0013 RACK POSITION SENSOR FAILURE - MINOR
1:0014 LON #1 FAULT - MINOR
1:0015 LON #2 FAULT - MINOR
1:0016 COMMS J2 FAULT - MINOR
1:0017 COMMS J3 FAULT - MINOR
1:0018 SPEED SENSOR FLT, TF ENABLED - MINOR
1:0019 LOAD SHARING
1:0020 ANALOGUE SELECTED
1:0021 ANALOGUE ACTIVE
1:0022 DIGITAL SELECTED
1:0023 DIGITAL ACTIVE
1:0024 CLUTCH ENGAGED
1:0025 NEAR FUEL LIMIT
1:0026 READY TO CLOSE CLUTCH
82
Analogue Reads
Addr Description
3:0001 ENGINE SPEED (rpm)
3:0002 ENGINE SPEED #1 (rpm)
3:0003 ENGINE SPEED #2 (rpm)
3:0004 SPEED REFERENCE (rpm)
3:0005 % LOAD
3:0006 ACTUATOR POSITION (%)
3:0007 FUEL LIMIT (ACTUATOR %)
3:0008 FUEL LIMIT (LOAD %)
3:0009 PI D OUTPUT (%)
3:0010 SYSTEM LOAD %
3:0011 LOAD SHARE ERROR
3:0012 SYNCHROPHASER BIAS (rpm)
3:0013 DROOP BIAS (rpm)
3:0014 SPEED REFERENCE BEFORE BIASES
3:0015 CHARGE AIR PRESSURE (bar)
Analogue Writes
Addr Description
4:0001
83
84
Manual 02845B MODIBUS h) Communications
Chapter 6
MODBUS® Communications
The 723PLUS Digital Control utilises AP^G-Modicon Inc’s MODBUS® protocol. The
Modbus® protocol detemiines how the master and slaves establish and break off contact,
how the sender and receiver are identified, how messages are exchanged in an orderly
manner, and how errors are detected. The protocol also controls the query and response
cycle which takes place between the master and slave devices.
The protocol provides for one master and up to 247 slaves on a common line. Each slave is
assigned a fixed unique device address in the range of 1 to 247. Only the master can initiate a
transaction. A transaction consists of a message from the master to one of the slaves and a
response from that slave to the master.
The control supports two modes of transmission for Modbus®. The mode defines the
individual units of information within a message, and the numbering system used to transmit
the data. Only one mode of transmission may be used per Modbus® system; mixing of
modes is not possible. The two transmission modes are ASCII (American Standard Code for
Information Interchange) and RTU (Remote Tenninal Unit). The modes are defined in the
table below (Table 7.1). The 723PLUS DCS uses either the ASCII or the RTU transmission
mode.
ASCII RTU
CODING SYSTEM HEXADECIMAL 8 BIT BINARY
BITS PER CHARACTER 7 8
PARITY EVEN, ODD, NONE EVEN, ODD, NONE
STOP BITS 1 OR 2 1 OR 2
DATA TRANSMITTED 4 BITS 8 BITS
PER CHARACTER
ERROR CHECICING LRC CRC
(LONGITUDINAL (CYCLICAL
REDUNDANCY CHECK) REDUNDANCY CHECK)
Figure 6.1 Modbus® Transmission Modes
In RTU mode, the data is sent in 8-bit binary characters. In ASCII mode, each RTU
character is first divided into two 4-bit parts (high order and low order) and then represented
by their hexadecimal equivalent. The ASCII characters representing the hexadecimal
characters are used to construct the message. ASCII mode uses twice as many characters as
RTU mode. Additionally, in RTU mode, message characters must be transmitted in a
continuous stream. In ASCII mode, breaks of up to 1 second can occur between characters.
There are two communication ports available in the 723PLUS. Both ports may be configured
for RS-232, RS-422 or RS-485 communications. If the communication utilises an RS-232
link, the distance between devices is limited to a maximum distance of 15 metres (50 feet).
The 723PLUS can be programmed as either a master or slave unit. When programmed as a
slave unit, it responds only after being asked for a set of parameters. Typically the 723PLUS
85
MODBUS^^ Communications Manual 02845B
will communicate as a slave with a Modbus® Master device utilising a separate link to each
device. However, if multidropping is used, one or two 723PLUS’s can be connected to one
Master device on a single link.
The data is passed between the Master and the 723PLUS in the form of message frames (see
Table 7.2). On any single multidrop link, each slave address must be unique.
ASCII RTU
CODING SYSTEM HEXADECIMAL 8 BIT BINARY
BITS PER CHARACTER 7 8
PARITY EVEN, ODD, NONE EVEN, ODD, NONE
STOP BITS 1 OR 2 1 OR 2
DATA TRANSMITTED 4 BITS 8 BITS
PER CHARACTER
ERROR CHECKING LRC CRC
(LONGITUDINAL (CYCLICAL
REDUNDANCY CHECK) REDUNDANCY CHECK)
Figure 6.2 Modbus® Frame Definition
The frinction code portion of the message frame tells the addressed slave what function to
perform. Table 6.3 and Figure 6.1 define and list the function codes supported by the
723PLUS.
BEGINNING SLAVE FUNCTION DATA ERROR END OF

OF FRAME ADDRESS CODE CHECK FRAME
CODE
2 CHARS 2 CHARS 4 BITS 2 CHAR CR LF

8 BITS 8 BITS DATA 8 BITS
PER CHAR
3-CHAR 1 CHAR 1 CHAR 8 BITS 2 CHAR 3 CHAR

DEAD TIME 8 BITS 8 BITS DATA 16 BITS DEAD
PER CHAR TIME
Figure 6.3 Modbus® Function Codes
86
Maniml 02845B MODBUS® Communications
MODBUS®
ADDRESS OXXXX IXXXX 3XXXX 4XXXX
0000
DIGITAL DIGITAL ANALOGUE ANALCX3UE

OUTPUTS INPUTS INPUTS OUTPUTS
FFFF
FUNCTION 1,5 & 15 2 4 3.6& 16
CODES
Figure 6.4 Modbus® Function Codes
Figure 6.7 shows typical Modbus® frames for the various function codes. If a slave detects
an error in a message, it will not act on or respond to that message. For any requested data
that is undefined, the slave will respond with a value of zero. The slave will respond with an
exception response if it detects illegal data in a message. The following tables (Figure 6.5 &
6.6) lists the exception errors displayed by the 723PLUS control.
Code Name Meaning

Illegal Function The message function is not an allowable action
2 Illegal Data Address The message start address is not allowable address
9 Checksum Error The received message had an incorrect error check
code
10 Garbled Message The received message could not be decoded
Figure 6.5 Modbus® Slave Exception Error Codes
Code Name Meaning

Illegal Function This exception response received from a slave
2 Illegal Data Address This exception response received from a slave
9 Checksum Error The received message had an incorrect error check
code
10 Garbled Message The received message could not be decoded
20 Unsolicited Message A message was received without being requested
21 Function Mismatch Received message had a function code different from
the command
22 Slave Address Mismatch Received message had an address different from the
command
23 No Response The slave did not respond within 1.5 seconds
Figure 6.6 Modbus® Master Exception Error Codes
87
MODBUS® Communications Manual 02845B
Function Message
Code Type
1,2,3,4 SLAVE FUNCTION START NUMBER ERROR

Query ADDRESS CODE ADDRESS OF POINTS CHECK
SLAVE BYTE
FUNCTION ANALOGUE OR DIGITAL ERROR
1,2,3,4 Response ADDRESS
CODE COUNT DATA CHECK
Query
SLAVE FUNCTION DATA ANALOGUE OR DIGITAL ERROR
5,6 or ADDRESS CODE ADDRESS VALUE CHECK
Response
SLAVE FUNCTION START NUMBER ANALOGUE OR DIGITAL ERROR

15,16 Query ADDRESS CODE ADDRESS OF POINTS DATA CHECK
SLAVE FUNCTION START ERROR

NUMBER
15,16 Response ADDRESS CODE ADDRESS OF POINTS accK
SLAVE FUNCnON ERROR ERROR

ALL Response ADDRESS CODE CODE aiECK
Figure 6.7 Modbus® Messages
The pertinent serialport communications parameters are adjustable. The following table
defines these parameters, and their ranges.
Parameter Typical Value Adjustment Range

Baud Rate 9600 1200 to 38400
Parity None None, Odd, Even
Stop Bits 1 1, 1, 1.5
Figure 6.8 Communication Port Adjustments
The Modbus® communication ports in the 723PLUS are custom programmed for each
application, and have unique Modbus® addresses. The Modbus® address listing consists of
Boolean Writes, Boolean Reads, Analogue Reads, and Analogue Writes. The Boolean reads
and writes are also referred to as input and holding coils. The analogue reads and writes are
also referred to as input registers and holding registers.
All values that can be addressed by Modbus® are considered to be discrete and numeric. The
discretes are a 1 bit binary, on or off value and the numerics are 16 bit values. Registers are
interpreted by the 723PLUS as signed 16 bit integers. The maximum number of analogues in
a single message is 59 for ASCII mode and 118 for RTU mode. The maximum number of
digitals in a single message is 944 for ASCII mode and 1888 for RTU mode.
Boolean Writes (Holding Coils)
88
Maniml 02845B MODBUS® Commimications
Holding coils are logical signals that are both readable from and writable to the 723PLUS.
An example of a Boolean write value would be ‘raise’ or ‘lower’ commands. A logical tme
denoted by the value 1 will cause the command listed in the description to be executed. The
723PLUS control supports function codes 1, 5 and 15. These correspond to reading selected
holding coils, writing to a single holding coil, and writing to a multiple holding coils,
respectively.
Boolean Reads (Input Coils)

Input Coils are logical signals that arc readable from, but not writable to, the 723PLUS. An
example of a Boolean read value would be an alarm indication. The M;’ term in the address
identifies an input coil. The 723PLUS supports Modbus® function code 2, which involves
reading selected input coils.
Analogue Reads (Input Registers)

Input registers are analogue values that are readable from, but not writable to, the 723PLUS.
An example of an analogue read value would be engine speed. The value of the input
registers are stored internal to tlie control as floating point niunbcrs representing engineering
units (i.e. rpm or Hz). The values that are transmitted are integer values ranging from -32767
to +32767. Since Modbus® can only handle integers, values that have a decimal point should
be multiplied by a constant before being sent by Modbus®. The 723PLUS supports
Modbus® function code 4, which involves reading selected input registers.
Analogue Writes (Holding Registers)

Holding registers are analogue values that are writable to, but not readable from, the
723PLUS. An example of an analogue write value would be a kW load reference. The value
of the holding registers are also stored in the control as numbers representing engineering
units. The 723PLUS supports Modbus® flinction codes 3, 6 and 16. These correspond to
reading selected holding registers, writing to a single holding register, and writing to multiple
holding registers, respectively.
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MODBUS® Communications Manual Q2845B
90
Maniml 02845B Setpoint Protrramming
Chapter 7
Setpoint Programming
Introduction
Due to the differences between installations, plus system and component tolerances, the
723PLUS control must be tuned to each system for optimum performance.
This chapter contains information on how to enter control setpoints, using either a Hand Held
Programmer or a PC Interface, (whichever is provided for the application).
WARNING
An improperly calibrated control could cause an engine overspeed or other damage to

the engine. To prevent possible serious injur>’ from an overspeeding engine, read this
entire procedure before starting the engine.
The 723PLUS has two types of tuneable; the Service tuneable and the Configure tuneable.
The Service tuneables allow tuning while the engine is running. The Configure tuneables may
only be adjusted if the control (and hence the I/O) is shutdown, and therefore, the engine
stopped.
The System Description for each type of 723PLUS control will contain a list of each tuneable
parameter, with it’s default value and range of adjustment. A second list will provide an
individual description of each tuneable.
Hand Held Programmer and Menus
The Hand Held Programmer is a hand-held computer terminal that gets its power from the
723PLUS control. The terminal connects to the RS^22 communication serial port on the
control (terminal Jl). To connect the terminal, slightly loosen the right-hand screw in the
cover over Jl and rotate the cover clockwise to expose the 9-pin connector. Then firmly seat
the connector on the terminal into Jl.
The programmer does a power-up self-test whenever it is plugged into the control. When the
self-test is complete, the screen will display two lines of information. This is information
relating to the application. Pressing the 'ID' key will change the display to show the part
number of the control.
The programmer screen is a four-line, backlighted LCD display. The display permits you to
look at two separate functions or menu items at the same time. Use the 0 “Up/Down Arrow”
key to toggle between the two displayed items. The BKSP and SPACE keys will scroll
through the display to show the remainder of a prompt if it is longer than the display screen's
19 characters.
91
Setpoint Programming Manual 02845B
The 723 PLUS has two sets of menus; the Service menus and the Configure menus. The
Service menus allow easy access and tuning while the engine is running. The Configure
menus may only be entered if the I/O is shutdown, and hence the engine stopped.
Hand Held Programmer Keys
The programmer keys do the following functions (see Figure 7-1):

^ (left arrow) Moves backward through Configure or Service, one menu at a time.
► (right arrow) Advances through Configure or Service, one menu at a time.
(up/down arrow) Toggles between the two displayed items.
(up arrow) Moves backward through each menu, one step at a time.
(down arrow) Advances through each menu, one step at a time. Selects Service
from Main Screen.
(turtle up) Increases the displayed set point value slowly.
(turtle down) Decreases the displayed set point value slowly.
(rabbit up) Increases the displayed set point value quickly (about 10 times faster
than the turtle keys).
(rabbit down) Decreases the displayed set point value quickly (about 10 times
faster than the turtle keys).
— (minus) Decreases setpoint values by one step at a time.
+ (plus) Increases setpoint values by one step at a time.
(solid square) Not used.
ID Displays the 723PLUS control part number and software revision
level.
ESC To return to menu header or to main screen.
SAVE Saves entered values (set points).
^BKSP Scrolls left through line of display.
^ SPACE Scrolls right through line of display.
ENTER Used when entering exact values and accessing Configure.
= (equals) For entering exact values (within 10%).
. (decimal) To select Configure.
Configure Menus
To access the Configure menus, the engine must be shutdown. Press the . key. The display
will show, To select configure, press entef. Press the ENTER key and the display will show,
To shutdown I/O, press entef. Press the ENTER key and this will allow you into the
Configure menus. Note: If the engine is running during this process, it will be shutdown due
to shutting dowu the I/O of the control. To move between the menus use the and ► keys.
To move through the setpoints within a menu, use the and keys. Once within a menu.
to return to the menu header, press the ESC key.
To exit the Configure menus press the ESC key. The setpoints will be automatically saved
when leaving Configure.
92
Manual Q2845B Setpoint Programming
VWoODWARn
TOGGLES BETWEEN UPPER

AND LOWER DISPLAYS MOVES BACKWARD
THROUGH EACH MENU.
ADVANCES THROUGH ONE STEP AT A TIME
CONEIGURE OR SERVICE
ADVANCES THROUGH
EACH MENU. ONE
MOVES BACKWARD THROUGH STEP AT A TIME.
CONFIGURE OR SERVICE ALSO SELECTS SERVICE MODE
"TURTLE" (SLOW) KEYS

INCREASE OR DECREASE
DISPLAYED SET POINT V/
SLOWLY.
"RABBIT" (FAST) KEYS - NUMBER KEYS FOR

INCREASE OR DECREASE ÊNTERING EXACT
DISPLAYED SET POINT 01 SETPOINT VALUES
INCREASES OR DE
SETPOINT BY ONE
STEP AT A TIME
SELECTS CONFIGURE MODE

DISPLAYS PART
NUMBER AND SOFTWARE
REVISION LEVEL FOR ENTERING EXACT
VALUES (WITHIN 105?)
RETURNS TO MENU HEADER

FOR ACCESSING CONFIGURE
OR MAIN SCREEN
AND ENTERING SETPOINT VALUES
SAVES ENTERED VALUES

(SET POINTS) 02752-19 FOR SCROLLING LEFT AND RIGHT
THROUGH SCREEN DISPLAY
Figure 7-1. Hand Held Programmer Functions
93
Setpoint Proeramminu Manual 02845B
Service Menus
To access the Service menus press the key. To move between menus, and to move
through setpoints within menus follow the instructions as for the Configure menus. Also to
return to the menu header, or to leave Service, follow the Configure instructions.
Adjusting Setpoints
To adjust a set point, use the ‘Turtle Up” or the “Rabbit Up” keys to increase the value, and
the “Turtle Down” or “Rabbit Down” keys to decrease the value. The “Rabbit Up” and
“Rabbit Down” keys will make the rate of change faster than the “Turtle Up” and “Turtle
Down” keys. This is useful during initial set-up where a value may need to be changed
significantly. Where necessary, to select TRUE, use either the “Turtle Up” or the “Rabbit
Up” keys, and to select FALSE, use the “Turtle Down” or “Rabbit Down” keys.
To obtain an exact value, press the = key. Key in the required figure and press ENTER.
Note: This may only be done if the figure is within 10% of the existing value, or for any
adjustments made in Configure.
To save setpoints at any time, use the SAVE key. This will transfer all new set point values
into the EEPROM memory. The EEPROM retains all set points when power is removed
from the control.
CAUTION
To prevent possible damage to the engine resulting from improper control settings,
make sure you save the set points before removing power from the control. Failure
to save the set points before removing power from the control causes them to revert
to the previously saved settings.
94
Manual 02845B Setpoint Protzramming
PC Interface
A PC Interface may be provided for tuning parameters, instead of the Hand Held
Programmer. This will consist of the ServLink Server, which acts as the interface between the
PC and the 723PLUS. The hardware communication link is configureable for RS232 or
RS422 (RS422 only if using the 723PLUS J1 port), and the communications protocol is the
Woodward developed ServLink. A control specific application for tuning the parameters may
have been developed using the Interponent Library. The Interponent Library is a assortment
of Borland Delphi based components developed by Woodward, including Angular & Bar
Gauges, ‘LED’s’, Status Text & an Alarm Viewer for displaying information, Edit Boxes for
turring analogue parameters, and Check Boxes for tuning Boolean parameters.
Alternatively, the Woodward Watch Window can be used to interface with the ServLink
Server, as a means for displaying the Service & Configure tuneables/monitors, with the ability
for tuning the parameters. Watch Window also offers the ability to upload the tuneable
parameters from the control, into a file, and also to download the parameters stored in the file,
into a control (of the same type/application).
With each application manual, a list of each of the tuneable parameters will be provided along
with a description of each. Also, a listing of each of the tuneables with the default values and
the range of adjustment will be included.
The PC Interface should be installed on a PC running a Windows 32 operating system (e.g.

Windows 95 or NT).
Interponents Interface
To open the tuning application, run the ‘.exe’ installed.
The example below shows a typical page of tuneables:
SCAUNG] CAUBRATiON) relay test mode ENGINE CONTROL | _______________________
ED REF I SYNCH | LOADING | FUEL UNIT 1 DYNAMICS f START|

to save
Tabs for
changing Sav9vju5-<-| values in
the control
between
categories Shutdown ^
to
shutdown
Reset
the control
Angular
gauge for
to re-boot
displaying
Ftteimg | Speed Synches | Speed Sensor* | the control
analogue
values
Tofsionai RHer Notch Frilef
Check Box
for ENABLE TORSIONAL RLTER
RLTER FREQUENCE'
changing
boolean
SENSOR WEIGHT
.gjl JL
1 Edit Box for
tuneables RLTER Q FACTOR .
•^1 W changing
analogue
Status Bar Speed Filter tuneables
displaying
E SPEED FILTER
status of
control
£
Not Active.
95
Setpoint Progmmmin^ Manual 02845B
Tuning Parameters
For tuning boolean parameters, a Check Box is used.
To select the item ‘False’ the box should be unchecked, e.g.

n "e'nable torsional filter
To select the item ‘True’ the box should be checked, e.g.

^ ENABLE TORSIONAL FILTER
For tuning analogue parameters, an Edit Box is used, e.g.

A
^1 y FILTER FREQUENCY
The arrows are used for adjusting the value of the parameter. The outlined arrows are for
adjusting the value slowly, and the filled arrows will adjust the value more quickly. An exact
value may be entered by double-clicking the cursor over the value, and typing the value in
using a keyboard. Then press <Enter> or the ‘=‘ button (which has replaced the up/down
arrows) to send the value to the control, e.g.
0.5| SENSOR WEIGHT
To enter an exact value in Service mode, the new value must be within 10% of the old value.
Any value may be entered in Configure Mode (control shutdown), provided it is within the
limits set in the control.
Shutting Do»^l/R(^-Starting/Saving Values
If an attempt is made to adjust a Configure tuneable, an error dialogue will appear to state
that the value may only be changed when the control is shutdown, e.g.
Eifor TRANSI SV.N^(82dO-^$]
Value can only be changed when the control is shutdown.
OK Help
To shutdown the control, the engine must first be stopped. Shutting down the control will
cause an I/O lock-out. If the engine has not already been stopped, shutting down the
control will either stop the engine, or result in an overspeed. Press the “Shutdown
button.
j’- Shutdown
96
Manual 02845B Setpoint Proeiamming
The following dialogue will then appear:

Confiim
\E\
CONTROL WILL BE SHUTDOWN! Conlinue?
Yes No
Pressing “Yes” will shutdown the control.
To re-start the control, press the “Reset” button

Reset
The control will then re-start, taking about 30 seconds to do so.
To save the setpoints, press the “Save Values” button

Save Values
This will transfer all new setpoint values into the EEPROM memory. The EEPROM retains
all setpoints when power is removed from the control.
CAUTION
To prevent possible damage to the engine resulting from improper control settings,
make sure you save the set points before removing power from the control. Failure
to save the set points before removing power from the control causes them to revert
to the previously saved settings.
Status Bar
The status bar at the bottom of the interface screen, shows the status of the control at any
time. Below shows the status text which you may see.
T. T
T
Active is the normal healthy operation of the control & interface.
jNi^'Aciive: ‘ ■n'TVTTTsar?
Not Active will mean that the interface is not connected to a control.
« . ..V.-
ts-
Saving Values in Control will appear when the Save Values button has been pressed.
[SfiUHjngdb^ control. —TTCT

i
Shutting Down Control will appear when the Shutdown action has been confirmed.
] Control is shutdown.
K
97
Control is Shutdown will appear when the control has been shutdown using the Shutdown
button.
[ReseUirg corôl...
Resetting Control will appear when the Reset button has been pressed following a shutdown.
This text will remain until the control is Active.
Displaying Parameters
For displaying analogue parameters, an angular gauge, a bar gauge or a simple text line is
used. e.g.
54 56 58 60 62 64 66
BUS Hz
1-H-i TI T
1 I I I I I
GEN. Hz H
I • j » I I I
CHS 3.41237
For displaying boolean parameters, an ‘LED’ or a status text box is used. e.g.
'(g) READY TO START
The LED will change colour dependent on whether the value is true or false.
BLACKOUT START LUEMUal

ENGINE LUBE PRESS. IFfig 1
The status text box can change colour and/or change text (decided at time of application
programming) dependent on whether the value is true or false.
Alarm Viewer
The alarm viewer will display the alarms which occur, detected by the control. The alarm
viewer will retain up to 100 alarms at a time. The alarms appear in order of occurrence, the
latest being at the top. The PC will time stamp each alarm as it is received, although if several
alarms are received at once, they will appear in the order in which they occured within the
control, however they will be stamped with the same time.
98
Manual 02845B Setpoint Pro^raniminiz
CLEAR SELECTED CLEAR ALL ACK. SELECTED ACK. ALL
TimeStamp Description jAckTimeStamp (

ALT- LUBErPMl
The appearance of the alarms is decided during the design period of the interface application,
however t>TDically, as an alarm appears it will display in Red. Once the alarm has been
acknowledged, it will turn Yellow. - Consult the relevant section in the application manual for
specific detail on how your alarm viewer has been configured.
To acknowledge an alarm, select the items you wish to acknowledge and press the “Ack.
Selected” button on the alarm viewer. To acknowledge all unacknowledged alarms and press
the “Ack. All” button, or use the acknowledge all command through the control (if available).
To clear an alarm from the alarm viewer (only possible if the alami is inactive), select the
items that you wish to clear and press the “Clear Selected” button on the alarm viewer. To
clear all inactive alarms press the “Clear All” button, or use the clear all command through the
control (if available).
Watch Window
The Watch Window is a tool for viewing and adjusting the parameters of the 723PLUS
Control. An application can be quickly and easily developed by the user, by assembling a
number of tabbed sheets, onto which are ‘dropped’, the parameters that are required for
monitoring/adjusting. The Watch Window is made up of three types of window; Main
Window, ServLink Explorer and ServLink Inspector.
Following is an example of the Watch Window:
HIsIB
Eie Edk Options Wndow ti«hspeci«1 . .
Net7(<undent^d>) | : Sheeil Sh^.aL
I
Si JACKET WATER PUMP
$ LUB OIL PUMP
Field t*
X’J r Value [■ . Description
Tiue
E START ENGINE r/.'/
S <<Configu*e» I $V^L0A0 45.29
T *4-20mA CaBxation*
^ RATED SPEED (RPM) 500.00
S -COMMISSION ALARMS-
^ -CONnGURE SYSTEM-
SI -CONTROL OPTIONS-
i -engine load-
£ E30S3^2333i
E -RNAL DRIVER-
I E-MODBUS PORT SETUP-
S -PASSWORD -TUNING APPt
E -RELAY TEST MODE*
E -SPEED SENSORS-
E- <<nocategofy»
$ .MASTER
X ALARMS
E ALTiCB
il:
iMin-0;Max-1
A.
99
Main Window
Watch Window
■'i.W-
mi
File Ed^ Sl^ OpHons Window Help .t r.
ttr
y II ^ m • i.
The Main Window is the application controlling window, and provides the standard menus
for opening/closing/saving files, Cut/Copy/Paste of parameters, and also for
adding/removing/renaming tabbed sheets to the application.
ServLink Explorer
Explorer The Explorer is used to browse the set of variables

' Net7(<unidentified>) available through the Servlink Server.
Tf The Explorer is composed a set of tabbed sheets.
I e JACKET WATER PUMP
I E LUB OIL PUMP
Each sheet is associated with a single control from a
; E START ENGINE Servlink network. The sheet’s tab is labelled with the
B- <<Configure>> associated control’s identifier.
i E ’'4-20mA Calibration"
E "COMMISSION AU\RMS" Each sheet contains a tree view, The tree view
: E "CONFIGURESYSTEM" displays the names of the categories and blocks in a
; E "CONTROL OPTIONS-
control’s application program in a hierarchical
i E "ENGINE LOAD"
ESEBBiSS structure. The names at each level in the tree are listed
; E "FINAL DRIVER" in alphabetical order. The Watch Window which is
^ E "MODBUS PORT SETUP" normally supplied will display the Configure and
: E "PASSWORD - TUNING APP Service menu’s only.
: E "RELAY TEST MODE" v>:.
; S "SPEED SENSORS"
Selected variables can be used in Copy & Paste or
E <<no category>>
Drag & Drop operations in order to add a variable to
E .MASTER
(+].. alarms an Inspector. Variables can be selected using the
B' ALT&CB mouse (left click) or keyboard (arrow keys). Selecting
li 1± categories or blocks selects all of the fields underneath
them.
ServLink Inspector
The Inspector is used to monitor and edit variables available through the Servlink Server.
The Inspector is composed of a set of tabbed sheets. Each sheet contains a grid (the grid
shown in the following example is reduced - other fields headers are available to defme which
control a variable relates to, and if relevant, which category and blockname. Each sheet’s tab
is labelled with a user-definable name. The user has the ability to add and remove sheets using
menu items and/or tool bar buttons in the Main Window.
100
Manual 02845B Setpoint Programming
E Inspeclorl Hî
■ Sheell Sheet2 Sheets)
Reid Value Description
/ TWO SPEED SENSORS? True
' ^LOAD 45.28

^ RATED SPEED (RPM} 500.00
I
I
lMin = 0 : Max = l* •
An icon to the left of the variable defines whether it is a monitor value, configure tuneable or
service tuneable (or debug tuneable if relevant)
^ : Service Tuneable
; Monitor Value
; Configure Tuneable
One or more variables can be selected using the mouse (left click) or keyboard (arrow keys).
If the user wishes to select multiple variables, they can do so by performing one of these
sequences:
• Select a variable, hold down the shift key, and arrow up or down until all of the variables
are selected.
• Click on a variable, hold down the shift key, and click on the last variable in the series that
the user wishes to select.
Selected variables can be used in Cut, Copy & Paste or Drag & Drop operations in order to
add a variable to an Inspector. If the selected variable is tuneable or configurable the status
bar will display the minimum and maximum value for that variable. If multiple variables are
selected, the minimum and maximum will not be displayed for any of the selected variables.
The Inspector can have its configuration saved and restored. The Inspector can be closed by
using the Main Window or by clicking the standard windows close button.
101
102
Manual 02845B Repair & Replacement
Chapter 8
Repair & Replacement
Identification
If any part of the electronic control is to be returned to Woodward Governor Company for
repair, attach a tag to the part with the following infonnation:
name and location where the control is installed;

complete Woodward Governor Company part numbeifs) and serial numbeifs);
description of the problem;
V# instructions describing the desired type of repair.
CAUTION
To prevent damage to electronic components caused by improper handling,

read and observe the precautions in Woodward Governor Company Manual 82715,
Guide for Handling and Protection of Electronic Controls, Printed Circuit Boards,
and Modules.
Packing a Complete Control
Use the following materials when returning a complete control;
packing materials that will not damage the surface of the unit;
at least 100 mm (4 inches) of tightly packed, industry-approved packing material;
a packing carton with double walls;
a strong tape around the outside of the carton for increased strength.
Replacement Control Information
When ordering a replacement (or spare) electronic control, include the following information:
the part numberfs) that is on the enclosure nameplate, plus any prefixes or suffixes;
the unit serial number, which is also on the nameplate.
103
Repair & Replacement Manual 02845B
Address and Telephone/FAX Numbers
Use the following addresses when shipping or corresponding:
Woodward Governor (U.K.) Ltd.

Engine Controls
350 Basingstoke Road
Reading
Berkshire
RG2 ONY
England
TELEPHONE: 44 (0) 118 9752727 (24 hours a day)

FAX: 44(0)118 9751599
Woodward Governor Nederland B.V. }

Hoofdweg 601
PO Box 34
2130 AA
Hoofddorp
The Netherlands
TELEPHONE: 31 (0)23 5661111

FAX: 31 (0)23 5636529

1000 East Drake Road
PO Box 1519
Fort Collins, CO 80522-1519
USA
TELEPHONE: 1 970 4825811

FAX; 1 970 4983047
104
Manual Revision History
All modifications made to this manual, since the last revision of the manual are marked to the
left hand side by a thick black line.
1. This manual (revision A) has been revised to incorporate changes made to the GAP
software from rev NEW to rev A. (15th September 1998)
2. This manual (revision B) has been revised to incorporate changes made to the GAP
software from rev A to rev B. All items which are relevant only to rev B software, not to
any previous versions, are marked (24th November 1998)
Ordering Manuals
Order manuals from your nearest Woodward Governor Company location.

Please include the following information:
• Your name
• The name and address of your company (write on letterhead or include business card if
available)
• The address where you want the manuals sent (if different from above)
• The quantity wanted of each manual
• The manual number for each manual you are ordering OR the part number and serial number
from the name plate on your Woodward Equipment.
VVe appreciate your comments about the content of our publications.

Woodward Governor (UK) Ltd.
350 Basingstoke Road
Reading
Berkshire
RG2 ONY
England
WOODWARD
Engine, Turbomachiner>', and Hydraulic Turbine Controls

PO Box 3800 (3800 North Wilson Ave), Loveland CO 80539-3800. USA • Phone (970) 663-3900 • Fax (970) %2-7050
E-mail and World Wide Web Home Page—http://w»'w.woodward.com
Registered Firm
IS0900l:1994/Q9001-1994
Certificate QSR-36
DUTCH COUNCIL
FOR CERTIFICATION
23 PLANTS 15 REGIONAL SALES OFHCES 18 DISTRIBUTORSmEPS.

IN 10 COUNTRIES— IN 10 COlWTRIES—__________ IN 7 COUNTRIES—
Australia (New South Wales) Canada (Quebec) Canada (Alberta & Ontario)
Brazil (Campinas) China (Beijing) Mexico (Mexico City)
China (Tianjin) Czech Republic (Plzen) Netherlands Antilles (Curacao)
Germany (AkeivElbe & Kcibra) Germany (Tettnang) Spain (Cadiz)
India (Haryaita) Korea (Pusan) United Kingdom (Dyce, Scotland)
Japan (Tomisato & Kobe) Mexico (Mexico City) Unted States ((3alif<xnia[2], [>elawaie, Indiana,
Netherlands (Hoofddorp & Rotterdam) New Zealand (Giristchurch) Louisiana, Minrresota, Nwth (Carolina, Puerto
Singapore Poland (Warsaw)
Rko, Texas[2], Washington)
United Kingdom (Reading, England, & United Arab Emirates (Abu Dhabi)
Venezuela (Caracas)
Prestwick, Scotland) United States (Alabama, California, Illinois,
United States (Colorado[2], Illinois[3], Pennsylvania, Texas, Washingtcxi)
Michigan(2], New York, South Carolina,
Tennessee)
plus Authorized Independent Service Facilities in 35 countries throughout the world
Complete addres.Vphone/fax/e-mail information for all locations is available on the Internet at:
8
36684L
Woodward
Booster
Servomotor
Single-Cylinder (8901-037, -043, -051)

Tandem (8901-065, -067)
Two-Stage (8901-091, -103)
Installation and Operation Manual
WOODWARD GOVERNOR COMPANY
Manual 36684L
WARNING
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.
The engine, turbine, or other type of prime mover should be

equipped with an overspeed (overtemperature, or overpressure,
where applicable) shutdown device(s), that operates totally
independently of the prime mover control device(s) to protect against
runaway or damage to the engine, turbine, or other type of prime
mover with possible personal injury or loss of life should the
mechanical-hydraulic governor(s) or electric control(s), the
actuator(s), fuel control(s), the driving mechanism(s), the linkage(s),
or the controlled device(s) fail.
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.
© 1974,1998 by Woodward Governor Company
All Rights Reserved
Manual 36684 Booster Servomotor
TABLE OF CONTENTS
Chapter 1. GENERAL INFORMATION 1

INTRODUCTION..................................... 1
DESCRIPTION........................................ 1
TYPES OF BOOSTERS........................ 1
Single-Cylinder Booster................... 2
Tandem Booster.............................. 2
Two-Stage Booster.......................... 2
Chapter 2. INSTALLING AND ADJUSTING A BOOSTER SERVOMOTOR 7

GENERAL RULES.............................................................................................. 7
Location......................................................................................................... 7
Oil Lines......................................................................................................... 7
Oil Leakage.................................................................................................. 7
Starling-Air Valve.......................................................................................... 7
INSTALLING AND ADJUSTING A SINGLE CYLINDER BOOSTER............... 7
INSTALLING AND ADJUSTING A TANDEM BOOSTER................................ 8
INSTALLING AND ADJUSTING A TWO-STAGE BOOSTER......................... 10
Chapters. PRINCIPLES OF OPERATION...................................... 17

HOW SINGLE-CYLINDER AND TANDEM BOOSTERS OPERATE 17
First Phase of Operation............................................................... 17
Second Phase of Operation........................................................ 17
HOW A TWO-STAGE BOOSTER OPERATES................................ 18
First Phase of Operation............................................................... 18
Second Phase of Operation........................................................ 18
Third Phase of Operation............................................................ 18
Chapter 4. REPLACEMENT PARTS 19

ORDERING REPLACEMENT PARTS 19
PARTS LIST FOR FIGURE 4-1......... 19
Chapters. SERVICE OPTIONS....................................................... 25

PRODUCT SERVICE OPTIONS....................................................... 25
Replacement/Exchange.............................................................. 25
Flat Rate Repair........................................................................... 26
Flat Rate Remanufacture............................................................ 26
RETURNING EQUIPMENT FOR REPAIR....................................... 26
Packing a Control......................................................................... 26
Additional Instructions.................................................................. 27
REPLACEMENT PARTS INFORMATION......................................... 27
HOW TO CONTACT WOODWARD.................................................. 27
OTHER SERVICE FACILITIES.......................................................... 27
ADDITIONAL AFTERMARKET PRODUCT SUPPORT SERVICES 28
Woodward Governor Company i

Booster Servomotor Manual 36684
SYSTEM TROUBLE-SHOOTING GUIDE.......................... 29

Actuators........................................................................ 29
Linkage........................................................................... 29
Valves............................................................................. 29
Oil/Hydraulic System..................................................... 30
Fuel Injection Pumps..................................................... 30
Fuel/Steam Conditions.................................................. 30
Control, Alarm, And Fault Indications.......................... 30
Input Signals.................................................................. 30
Output Signals............................................................... 31
Transducers.................................................................... 31
Magnetic Pickups And Other Speed Sensing Devices 31
Input Voltage/Power Supplies...................................... 31
Electrical Connections................................................... 32
Voltage Regulator.......................................................... 32
External Devices............................................................ 32
TECHNICAL ASSISTANCE................................................ 33
General........................................................................... 33
Prime Mover Information.............................................. 33
Governor Information..................................................... 33
LIST OF FIGURES
1-1. Schematic of Single Booster Connections to PG-Type of Governor.... 3

1-2. Schematic of Tandem Booster Connections to PG-Type of Governor 3
1-3. Outline Drawing of Single Booster......................................................... 4
1-4. Outline Drawing of Tandem Booster...................................................... 5
1-5. Outline Drawing of Two-Stage Booster.................................................. 6
2-1. Governors Used with Single-Cylinder Boosters.................................... 12
2-2. Governors Used with Single-Cylinder Boosters.................................... 13
2-3. Governors Used with Tandem Boosters................................................ 14
2-4. Governors Used with Two-Stage Boosters........................................... 15
3-1. Single Booster, Phase 1.......................................................................... 17
3-2. Single Booster. Phase 2.......................................................................... 17
3-3. Two-Stage Booster, Phase 1.................................................................. 18
4-1. Exploded View of Single Boosters......................................................... 20
4-2. Exploded View of Tandem Boosters...................................................... 22
4-3. Exploded View of Two-Stage Boosters.................................................. 24
M Woodward Governor Company

CHAPTER 1
GENERAL INFORMATION
INTRODUCTION This manual covers the three types of Woodward booster servomotor;
• Low-volume, single-cylinder booster
• Medium-volume, double-cylinder (tandem) booster
• High-volume, two-stage booster
DESCRIPTION A booster servomotor supplies pressurized oil to mechanical-hydraulic governors

and electro-hydraulic actuators at the instant starting air reaches the engine. This
instant oil pressure eliminates the time required for the rotary gear pump in the
governor to build up enough oil pressure to move the linkage. This produces a
faster start, which conserves starting air, and in vessels with direct reversible
engines, improves maneuverability.
When the booster is inactive, a piston is held at one end of a cylinder by a spring.
The cylinder is full of oil supplied from a line from the governor's sump.
Compressed air applied to the side of the piston opposite this oil forces the piston
against the oil, which flows through ports at the other end of the cylinder to the
governor.
When air is removed from the piston, the spring returns the piston to its rest
position. Reduced pressure in the cylinder causes oil to flow into it from the sump.
Check valves at all oil ports allow oil to flow in only one direction. This prevents
oil in the booster from flowing back to the governor's sump when the booster
operates, and prevents oil in the booster outlet lines from flowing back into the
booster when it is inactive.
TYPES OF Boosters are available with different air-to-oil pressure ratios, making them
BOOSTERS suitable for both high and low air pressure applications:
Model Type Pressure Ratio
(Oil Out to Air In)
8901-037,-043 single-cylinder 1:1
8901-051 single-cylinder 2:1
8901-065 tandem 1:1
8901-067 tandem 2:1
8901-091 two-stage 2:1
8901-103 two-stage 3:1
Single-cylinder boosters supply enough oil for governors with small and medium
work outputs, such as UG-8/-40, EGB-I0/-13, 3161, and PG governors with
outputs of 16 and 23 J (12 and 17 fl-lbs).
Woodward Governor Company 1

Booster Servomotor Manual 36684 #
Tandem boosters, with larger volumes of oil and three oil outlets, are appropriate
for PG-29/-58, EG-29/-58, and PG-TM 58 governors (39/79 J; 29/58 fl-lb).
Two-stage, high-volume boosters meet the boost oil requirements for PG, EGB,
and PG-TM governors with 271,407. and 678 J (200, 300, and 500 ft-lb) power
cases.
Single-Cylinder (Figures 1-1 and 1-3)

Booster
Single-cylinder boosters have two oil outlets: one is unrestricted, and one has a
built-in orifice-type restriction. Outlet #1 (unrestricted) is connected directly to
the governor's oil pressure system. Outlet #2 (restricted) can be used to pressurize
the speed setting servo, which compresses the speeder spring of PGA, PGPL. and
PGG governors equipped with any shutdown feature.
A single-cylinder booster has two air inlets, one restricted and one unrestricted.
Using the restricted air inlet results in slower movement of the fuel rack.
Tandem Booster (Figures 1-2 and 1-4)
Tandem boosters have two cylinders and three oil outlets. Outlet # I is
unrestricted. The other two outlets arc restricted by an adjustable needle valve.
Oil outlet #1 is connected to the governor’s accumulator. Outlet #2 is connected to

the speed setting servo (of PGA, PGPL, and PGG governors equipped with any
shutdown feature). Outlet #3 is connected to a point directly under the power
piston.
If outlet #2 is used, its needle valve determines the rate at which the speeder
spring is compressed. The needle valve in outlet #3 controls the rate at which the
power piston moves.
Two-Stage (Figures 1-5, 2-4, and 3-3)

Booster
Two-stage boosters have three oil outlets, but a two-stage feature allows oil to
flow through outlet #2 before it flows through the other two outlets.
In most applications, outlet #1 supplies oil to the power piston in the governor.
Outlet #2 supplies oil to the speed setting servo (of PGA, PGPL, and PGG
governors equipped with any shutdown feature). Outlet #3 supplies oil to the relay
piston.
2 Woodward Governor Company

\ BOOSTER OUTLET TUBINO TO

SPEED SETTING St RVO
SPEE0SETT1NG SERVO
AIR PRESSURE
SPRING LOADED INCREASE
PUMP OIL PRESSURE
ACCUMULATOR
SPEEDER SPRING.
1^ j SUMP OIL PRESSURE
INTERMEDIATE OIL PRfiSSU
□ TRAPPED OIL AND POWER

CYLINDER OIL PRESSURE
OUTLET NO.I
OUTLET N0.2
PILOT
WITH ORIFICE
VALVE
PLUNGER.
BOOSTER
^ \ SERVOMOTOR
GEAR PUMP
AIR SUPPLY UP
TO 500 PSy-
DRIVE SHAFT CREASE

FUEL
AIR EXHAUST
STARTING Al R VALVE
ADJUSTING SCREW TO LIMIT

AMOUNT FUEL PUMPS ARE
OPENED WHEN STARTING
Figure 1-1. Schematic of Single Booster Connections to PG-Typc of Governor
y.V.’v .ss-vw outlet
Tandem
7?’//.////> .t 7 OUTLETS? BOOSTER
V-.'s'. CONNECTIONS
OUTLET « 3
SPEEDER SPRING
mu iNTi"Me>oTi oii»«tjjuoi
Vi
V POWER
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m MIV'O'I. ’"(SSvnl Vi m
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m SKioecmwoit pncLSvMe o M TO
OIL ACCUMULATOR fez VI ZZ2^ SUMP
^ NEEDLE
a PILOT
^ VALVE "
PLUNGER CONTROL a VALVE
LAND
PUMP
PILOT VALVE
BUSHING I
increase!
SUMP
TO
SUMP
f
BUFFER ROTARY
PISTON OUTPUT
SHAFT ^
SUMP
OR fW
SUPPLY 306-S3I
fie4i.o»<fcw
Figure 1-2. Schematic of Tandem Booster Connections to PG-Type of Governor

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Figure 1-5. Outline Drawing of Two-Slage Booster

CHAPTER 2
INSTALLING AND ADJUSTING A BOOSTER SERVOMOTOR
GENERAL Observe the following rules when you install a Woodward booster servomotor.
RULES
Location Install the booster servomotor at a lower level than the governor to prevent air
from being trapped in the booster and oil lines.
Oil Lines Oil lines must slope up from the booster to the governor with a minimum of loops
and bends.
Oil Leakage It is not unusual for small oil particles (from assembly oil) to come out of the vent
hole at initial use of the booster and after several starts in a row. due to oil
particles in the bleed air.
Starting-Air Valve A starting-air valve (supplied by the customer) must be installed in the air line to
the booster. This valve must admit compressed air to the booster at the same time
that starting air is supplied to the engine, and it must vent the air cylinder of the
booster to atmosphere when stiu-ting air is removed from the engine. Air pressure
at the booster air inlet must not exceed 3500 kPa (500 psi).
CAUTION
Purge air from the booster's oil chamber, the tubing, and the
governor before starting the engine, by cycling the booster piston
with start-air or air from a separate source. Failure to purge air
completely may result in sluggish governor response.
INSTALLING AND Models 8901-037, -043, and -051 (Figures 1-3, 2-1, and 2-2)
ADJUSTING A
SINGLE Refer to the general rules at the beginning of this section.
CYLINDER
BOOSTER Figures 2-1 and 2-2 show locations of inlet and outlet ports on Woodward
governors with which a single-cylinder booster can be used. Figure 1-3 shows
locations of ports and the stroke limit screw on a single-cylinder booster.
Install 10 mm (3/8 inch) steel tubing from the sump of the governor to the oil inlet
on the booster.
Install 6 mm (1/4 inch) steel tubing from oil outlet #I on the booster to the power
piston (the inlet marked "OIL FROM BOOSTER OUTLET-1") of the governor.

If the governor is a PGA, PGPL, or PGG equipped with any shutdown feature,
install 6 mm (1/4 inch) steel tubing from oil outlet #2 on the booster to the speed
setting servo (the inlet marked "OIL FROM BOOSTER OUTLET-2”) of the
governor. Otherwise, plug outlet #2 (this plus is delivered with the booster).
Connect a line containing an air-starting valve from the starting-air supply to the
appropriate air inlet on the booster. Use the inlet with the built-in orifice if you
want to move the fuel racks at a slower rate. The other air inlet needs to be
plugged.
Fill the governor with oil to the proper level (refer to the installation manual for
the governor).
When all air and oil connections are secure, purge air from the booster and oil
lines by cycling air to the booster from a remote source without cranking the
engine. Add oil to the governor as needed.
When there is no more air in the booster and oil lines, set the initial opening of the
fuel racks by adjusting the stroke of the booster piston. Turn the stroke limit screw
counterclockwise to increase starting fuel, and clockwise to decrease it. This
screw limits the intake stroke of the booster and the volume of oil supplied to the
governor in one stroke of the booster servomotor.
INSTALLING AND Models 8901-065 and 8901-067 (Figures 1-4 and 2-3)
ADJUSTING A
TANDEM
BOOSTER
NOTE
On PGA governors, decals Indicating where to connect lines from the
booster do NOT apply to tandem boosters. Refer to Figure 2-3 when
connecting a tandem booster to a PGA governor.
Refer to the general rules at the beginning of this section.
Figure 2-3 shows locations of outlet and inlet ports on governors with which a
tandem booster can be used. Figure 1-4 shows locations of stroke limit screws and
ports on a tandem booster.
Connect 10 mm (3/8 inch) steel tubing from the sump of the governor to the oil
inlet on the booster; and from oil outlet #1 of the booster to the accumulator of the
governor.
On PGA, PGPL, and PGG governors equipped with any shutdown feature,
connect 6 mm (1/4 inch) steel tubing from oil outlet #2 on the booster to the speed
setting servo of the governor.

On PGA, PGPL, and PGG governors, connect 6 mm (1/4 inch) steel tubing from
oil outlet #3 on the booster to the power piston of the governor.
Connect a line with an air-starting valve from the starting-air supply to the air inlet
on the booster.
Plug the unused oil outlet and air inlet (these plugs are delivered with the booster).
Fill the governor with oil to the correct level (refer to the installation manual for
the governor).
When all oil and air connections arc secure, purge air from the booster and oil
lines by cycling air to the booster from a remote source without cranking the
engine. Add more oil to the governor as needed.
When there is no more air in the booster and oil lines, limit the volume of oil
going to the governor by adjusting the two stroke limit screws. The positions of
these screws detenninc the maximum volume of oil supplied by the booster. This,
in turn, determines the maximum travel of the fuel racks. Turn the screws
clockwise to reduce the travel of the racks, and counterclockwise to increase the
travel.
Adjust the needle valves in oil outlets #2 and #3. If outlet #2 is used, its needle
valve controls the rate of oil flow to the speeder spring servo, which detennines
how fast the speeder spring servo moves. The needle valve in outlet #3 controls
the rate at which the power piston moves. Turn the needle valve clockwise to
restrict oil flow, and counterclockwise to increase flow.
NOTE
Outlets #2 and #3 are connected to separate cylinders. Outlet #1 is
connected to both cylinders, with check valves preventing flow
between the cylinders. Unequal amounts of oil will flow through the
two outlets if the stroke limit screws are adjusted unequally. It is
usually best to adjust both of these screws the same distance, and
regulate the rate of oil flow through outlets #2 and #3 with their
respective needle valves.

INSTALLING AND Models 8901-091 and 890I-I03 (Figures 1-5 and 2-4)
ADJUSTING A
TWO-STAGE
BOOSTER
NOTE
On PGA, PGPL, and PGG governors, decals indicating where to
connect lines from the booster do NOT apply to two-stage boosters.
Refer to Figure 2-4 when connecting a two-stage booster to a PGA,
PGPL, or PGG governor.
Refer to the general rules at the beginning of this section.
Connect 12 mm (1/2 inch) steel tubing from the sump of the governor to the oil
inlet port on the booster, and from oil outlet #1 on the booster to the power piston
of the governor.
On PGA, PGPL, and PGG governors equipped with any shutdown feature,
connect 8 mm (5/16 inch) steel tubing from oil outlet #2 on the booster to the
speed setting servo of the governor.
Connect 8 mm (5/16 inch) steel tubing from oil outlet #3 on the booster to the
relay piston of the governor.
NOTE
If you have an EGB-200, -300, or -500 actuator, leave oil outlet #3 of
the booster plugged and loosen the plug in outlet #2. Turn the shuttle
piston adjusting screw fully clockwise, thereby opening up the
passage to outlet #1 (otherwise, the booster servomotor remains
inactive). Tighten the plug in outlet #2.
Connect a line with an air-starting valve from the starting-air supply to the air inlet
on the booster.
Fill the governor with oil to the correct level (refer to the installation manual of
the governor).
When all air and oil connections are secure, purge air from the booster and oil
lines by cycling air from a remote source to the booster without cranking the
engine. Add oil to the governor as needed.
When there is no more air in the booster and oil lines, regulate the volume of oil
going to the governor by adjusting the stroke limit screw. If you are not using an
EGB-200, -300, or -500 actuator, adjust the shuttle piston adjusting screw and the
needle valve in oil outlet #3.

Remember that:
• The stroke limit screw limits the volume of oil going to the governor
through oil outlets #1 and #3. This controls the maximum amount of fuel
output during a booster-assisted start.
• If you use outlet #2. the shuttle piston adjusting screw limits the volume
of oil going to the speed setting servo through oil outlet #2.
• The needle valve limits the rale of How of oil through oil outlet #3; this
controls the rale at which the output shaft of the governor moves. The
needle valve setting also limits the stroke of the power piston in the
governor.
Turn the stroke limit screw clockwise to reduce the volume of oil to the governor
and fuel to the engine, and counterclockwise to increase volume.
Turn the needle valve clockwise to reduce the rate and volume of oil How, and
counterclockwise to increase the rate and volume.

I
rt
■j
CONNECT TO I
BOOSTER
INLET
(ALTERNATE) CONNECT TO
CONNECT TO
BOOSTER BOOSTER
OUTLET OUTLET
ALTERNATE-^
BOOSTER OUTLET
CONNECTION
i
I
CONNECT TO
— BOOSTER
CONNECT TO CONNECT TO
INLET BOOSTER BOOSTER
INLET INLET
I (ALTERNATE)
UG 8 U6 40
CONNECT TO
BOOSTER
OUTLET NO. 2
•» CONNECT TO
CONNECT TO BOOSTER
BOOSTER OUTLET NO. 1
OUTLET
(ALTERNATE) Ft
I
•Q- CONNECT TO
CONNECT TO BOOSTER
BOOSTER INLET
INLET I I
(ALTERNATE) 1
¥
I
CONNECT TO
BOOSTER
CONNECT TO
OUTLET BOOSTER
CONNECT TO OUTLET NO. 1
BOOSTER (ALTERNATE)
INLET I CONNECT TO
I BOOSTER
INLET
(ALTERNATE)
CONNECTIONS ARE IDENTICAL ON DIAL S LEVER OOVERNORS
PG
PGA
(Except 29. 58, 200, 300 and 500)
366-535
96-01-13 skw
Figure 2-1. Governors Used with Single-Cylinder Boosters

ALTERNATE CONNECT
TO BOO$Tin OUTLET NO. 2
WHEN RIGHT HAND
OIL GAUGE IS USED
CONNECT TO
BOOSTER OUTLET NO. 2
U8E1/I- TO 1/tS"NPTF
ADAPTER
CONNECT TO
BOOSTER
OUTLET
I
CONNECT TO I
BOOSTER
OUTLET NO. 1
CONNECT TO
BOOSTER
INLET
NOTES:
1. ALL CONNECTIONS ARE 1/1“ NPTF
UNLESS OTHERWISE SPECIFIED. f
2. CONNECTION TO BOOSTER OUTLET CONNECT TO
NO. 1 AND TO BOOSTER INLET MAY BOOSTER
BE MADE AT EITHER LOCATION INLET
SHOWN.
PG-PL EGB 10 a 13
CONNECT BOOSTER
OUTLET IN TOP
OF COOLER
i
NOTE:
FOR REMOTE COOLER CONNECT TO
BOOSTER OUTLET
MAYBE CONNECTED I I BOOSTER
OUTLET NO. 2
INTO COOLER AS
DESCRIBED OR INTO
A TEE FITTINO
AT GOVERNOR OIL
OUTLET TO COOLER.
I CONNECT TO
I* BOOSTER
OUTLET MO. 1
II
._M
I
CONNECT TO
BOOSTER
INLET
CONNECT TO
BOOSTER
INLET EGB 10 solenoid speedsetting
366-536
96-01-13 skw
Figure 2-2. Governors Used with Single-Cylinder Boosters

■~T V
CONNECT TO COP4NECT TO
BOOSTER BOOflTCn
OUIXETNO.S OUTLET NO. 2
(ALTERNATE)
if, ♦
J CONNECT TO
CONNECT TO
BOOBTIA
I
BOOSTER OUTLET HO. 3 «
OUTLET NO. 1
(ALTERNATE)
1
CONNECT TO
f7 BOOSTER
J a
OUTLET NO. 1
Q;
CONNECT TO
BOOSTER 4
INLET
1
PGA 29 & 58
<?•
CONNECT TO
I0
BOOSTER
OUTLET NO. 1
CONNECT TO
BOOSTER
CONNECT
1 TO BOOSTER mLCT
(ALTERNATE)
O
INLET 1
5
T
EGB 29 & 58
CONNECT TO
BOOBTER CONNECT TO
INLET BOOSTER
(ALTERNATE) OUTLETNO. 1
CONmCTTO
BOOSTER J*
INLET
PG-TM 58
366-537
Figure 2-3. Governors Used with Tandem Boosters

Figure 2-4. Governors Used with Two-Stage Boosters


CHAPTER 3
PRINCIPLES OF OPERATION
HOW SINGLE-CYLINDER AND TANDEM BOOSTERS OPERATE
First Phase of Operation
PRESSURE OIL
TOCOVERMOR Refer lo Figure 3-1 (Figure 3-1 represents a single-
(I 0R2 0UTLEIS
AS REH MO 91
cylinder booster; a tandem booster has two pistons and
^-----INLET CHECK VALVE
<1 CLOSED three oil outlets, but its principle of operation is the
OUTLET -T“-
OUTLET-r
CMECK VALVE
OREN
CHECK VALVE OREN same).
When compressed air enters the booster, the piston(s)

moves up, forcing oil through the outlets to the
VENT----- [ governor's pressurized oil system. The governor's
4 power piston moves to increase fuel.
EZ3 SUMR OIL
it'
RRESSUHEOIL
v; A check valve in the oil inlet prevents oil from flowing

AIA PntSASRl from the booster back to the sump in the governor.
ORTlONAL POSITION- Ain SUPPLY PROM
TOR AIR SUPPLV STARTIMC VALVE
A O
-- STIÊ
CIMT SCHEW
Figure 3-1. Single Booster. Phase 1
Second Phase of Operation

----------------SUMTOIL FROM
GOVERNOR
Refer to Figure 3-2 (Figure 3-2 represents a single
OOTLfT-1" GOVERNOR OIL
PRESSURE
cylinder booster; a tandem booster has two pistons and
CHECK VALVE -
CLOSED INLETCHECK VALVE
OPEN
three oil outlets, but its principle of operation is the
GOVERNOR OIL*
PRESSURE
OUTIET -y
CHECK VALVE CLOSED
same).
When starting air is removed, the booster is vented to

atmosphere through the starting-air valve (customer
supplied) in the booster's air line. Spring force returns
the booster’s pislon(s) to the original position. Oil slops
□ SUMPOIl flowing out of the booster. Reduced pressure in the
•M PRESSURE OIL
booster causes sump oil to flow back into the booster.
AIR PRESSURE
The booster is ready lo start again.
Check valves in the oil outlets prevent oil from flowing

back through the oil outlets into the booster.
AIR PRCSSURC
ntlLASkO
MMC
Figure 3-2. Single Booster, Phase 2

HOW A TWO-STAGE BOOSTER OPERATES
First Phase of Operation
When compressed air enters the booster, the main

piston moves to the right, forcing oil to the shuttle
a piston cavity and moving the shuttle piston up. The
iruod
— »wt shuttle piston forces oil through oil outlet #2 and blocks
I
ItMTat — . - loot' Sunil r I
oil outlets #1 and #3.
— BOOST OUTLET »3
(SMALL P0WE:»A*ST0N1
»f^T The shuttle piston adjusting screw limits the stroke of

the shuttle piston, which limits the amount of oil
supplied through oil outlet #2.
Figure 3-3. Two-Stage Booster, Phase 1
Second Phase of Operation
When the shuttle piston reaches the end of its stroke, it uncovers the passages to
outlets #1 and #3, and oil flow through outlet #2 ceases. Oil remaining in the
booster flows through outlets #1 and #3 to the relay and power pistons in the
governor, moving them to increase fuel.
The needle valve in outlet #3 limits the amount of oil

that goes through this outlet and its rate of flow. This, in
turn, limits the stroke of the power piston in the
governor and the rate at which fuel is supplied to the
engine.
incmiVMt-
•OW OVTLtT • }
|TUI1I»6 -
--
-- — #QO»r # I The stroke limit screw limits the stroke of the main
BOOST OUTLBT t3 booster piston, which limits the total amount of oil
ISMAUL POWER PiSTQN^
supplied to the governor by the booster.
kCIOlt VALVf
A0A4ricvr
Check valves prevent oil from flowing from the booster

into the governor's sump.
Third Phase of Operation
The air side of the main piston is vented to atmosphere

through the starting-air valve. Spring forces return the
main booster piston and shuttle piston to their original
OtMOil
positions. Reduced pressure in the booster causes sump
— OuMt # I oil to flow back into the booster.
BOOST OUTLrr €3
iSMAU POWER PISTON)
Check valves prevent oil from flowing into the booster

at from the oil outlet lines.

CHAPTER 4
REPLACEMENT PARTS
ORDERING When ordering replaccmenl parts, include the following information:

REPLACEMENT
1. The booster servomotor part number shown on the nameplate.
PARTS
2. The manual number printed on the cover of the manual (this is Manual
36684).
3. The part reference number in the parts list, and the description of the part or
part name.
Figures 4-1,4-2, and 4-3 and their associated parts lists illustrate and name all (he
replaceable parts of the various booster servomotors. The numbers assigned are
used as reference numbers and are not specific Woodward part numbers.
Woodward will determine the exact part number for your particular booster.
PARTS LIST FOR Part No. Name No. Req'd

FIGURE 4-1 36684-6 0-ring 1
36684-7 Glide Ring 1
36684-15 5/16"-24 Nut 4
36684-16 0-ring 1 or2
36684-23 Glide Ring 1 or 2
36684-24 0-ring 1 or 2
36684-25 Check Valve Assembly 3
36684-31 Cylinder Head 1
36684-32 Booster Spring 1
36684-33 Accumulator Cylinder 1
36684-34 Piston 1
36684-35 End Cap 1
36684-36 5/16"-24 Screw 4
36684-37 Flat Washer 8
36684-38 5/16“ Shakeproof Washer 4
36684-39 1/4" Thread Seal 1
36684-41 1/4“-28 Nut 1
36684-42 1/4"-28 Stroke Limit Screw 1
36684-44 Cylinder Head 1
36684-45 0-ring 1
36684-46 Reducing Bushing 1
36684-49 Piston 1

P/N 8901-051 (2:1 RATIO)
P/N 8901-037, -043 (1:1 RATIO)
366-544
98-01-13 skw
Figure 4-1. Exploded View of Single Boosters


FIGURE 4-2 36684- 6 0-ring 2
36684- 7 Glide Ring 2
36684-15 5/16”-24 Nut 6
36684-18 1/8"-27 Steel Plug 4
36684-23 Glide Ring 2 or 4
36684-24 0-ring 2 or 4
36684-25 Check Valve Assembly 6
36684-34 Piston 2
36684-36 5/16"-24 Screw 6
36684-38 5/16" Shakeproof Washer 6
36684-39 1 /4" Threadseal 2
36684-41 1/4"-28 Nut 2
36684-49 Piston 2
36684-52 Needle Valve 2
36684-53 0-ring 2
36684-55 1 /4"-28 Stroke Limit Screw 2
36684-56 End Cap 1
36684-58 Gasket 4
36684-59 Servo Head 1

P/N 8901-065
(1:1 RATIO)
P/N 8901-067
(2:1 RATIO)
98-01-14 skw
Figure 4-2. Exploded View of Tandem Boosters


FIGURE 4-3 36684-25 Check Valve Assembly 4
36684-63 Booster Servo Piston 1
36684-64 Seal 1
36684-65 Block Vee Seal 2
36684-66 Backup Ring 1
36684-67 Seal Retainer 1
36684-68 .500 Springlock Washer 9
36684-69 .500-13 Cap Screw 1
36684-70 2:1 Ratio Spring 1
36684-72 Booster Servo Sleeve 1
36684-73 Booster Servo End Cap 1
36684-74 4.234 ID O-ring 1
36684-75 .500 Thread Seal 1
36684-76 .500 Flat Washer 1
36684-77 .500-13 Hex Nut 1
36684-78 .500-13 Stroke Limit Screw 1
36684-79 3.484 ID O-ring 1
36684-80 Servo Head Assembly 1
36684-81 Steel Ball 1
36684-82 Ball Check Spring 1
36684-83 Int. Retaining Ring 1
36684-84 Oil Failure Piston 1
36684-85 Spring 1
36684-86 .864 ID O-ring 1
36684-87 Booster Servo Plug 1
36684-88 Int. Retaining Ring 1
26684-89 Needle Valve 1
36684-90 .301 IDO-ring 1
36684-91 Stop Screw 1
36684-92 .312 UNF Steel Plug 1
36684-93 .562 UNF Steel Plug 1
36684-94 .486 IDO-ring 3
36684-95 Breather Filter Cap 1
36684-96 .239 ID O-ring 2
36684-97 Threaded Rod 4
36684-98 .500-20 Hex Nut 8
36684-101 7/16 UNF Plastic Plug 1
36684-104 .351 ID O-ring 1
36684-105 .438 UNF Steel Plug 1

o o
F H
I
iO Ifl
M r>
TJ
1- C fO
o> le o n 9
o
o>
Figure 4-3. Exploded View of Two-Stage Boosters

CHAPTER 5
SERVICE OPTIONS
PRODUCT The following arc the factory options available for the service of Woodward
SERVICE equipment:
OPTIONS
• Replaccmcnt/Exchangc (3-year warranty) (24-hour service)
• Flat Rale Repair (6-month warranty)
• Flat Rate Remanufacture (3-year warranty)
If you are experiencing problems with installation or unsatisfactory perfonnance

• Consult the system troubleshooting guide in this section.
• Contact Woodward technical assistance (sec HOW TO CONTACT

WOODWARD later in this chapter) and discuss your problem. In most
cases, your problem can be resolved over the phone. If not, you can select
which course of action you wish to pursue based on the available services
listed in this section.
Replacement/ Replacement/Exchange is a premium program designed for the user who is in

Exchange need of immediate service. It allows the user to request and receive a like-new
replacement unit in minimum time (usually within 24 hours of the request),
providing a suitable unit is available at the time of the request, thereby minimizing
costly downtime. This is also a Flat Rate structured program and includes the full
3-year warranty.
This option allows customers to call in advance of a scheduled outage or an

unexpected outage and request a replacement control unit. If the unit is available
at the time of the call, it can usually be shipped out within 24 hours. The customer
replaces his field control unit with the like-new replacement and returns the field
unit to the Woodward facility as explained later in this chapter.
Charges for the Replacement/Exchange service are based on a flat rate plus
shipping expenses. The customer is invoiced the Hat rate charge at the time the
replacement unit is shipped and must return the field unit to Woodward within 30
days. If the unit is not received within that time frame, the customer is invoiced
the difference between the flat rate replaccmenl/exchange charge and the current
list price of a new unit.

authorization label is included with every Replacement/Exchange unit that leaves
Woodward. The core should be repackaged and the return authorization label
affixed to the outside of the package. Without the authorization label, receipt of
the returned core could be delayed and cause additional charges to be applied.

Flat Rate Repair Flat Rate Repair is available for the majority of standard products in the field.
This program offers the user repair service for their products with the advantage
of knowing in advance what the cost will be. All repair work carries a 180-day
warranty on replaced parts and labor.
Flat Rate Flat Rale Remanufaclure is very similar to the Flat Rate Repair option with the
Remanufacture exception that the unit will be returned to the user in “like new” condition and
carry with it a full 3-year warranty. This option is applicable to mechanical
products only.
RETURNING If any part of the electronic control is to be returned to Woodward Governor

EQUIPMENT FOR Company for repair, attach a tag to the part with the following information:
REPAIR
• name and location where the control is installed;
• name and phone number of contact person;
• complete Woodward Governor Company part number(s) and serial

number(s);
• description of the problem;
• instructions describing the desired type of repair.
WARNING
Explosion Hazard—Do not connect or disconnect while circuit is live,
unless area is known to be non-hazardous.
Explosion Hazard—Substitution of components may impair

suitability for Class I, Division 2.
CAUTION
To prevent damage to electronic components caused by improper
handling, read and observe the precautions in Woodward Governor
Company Manual 82715, Guide for Handling and Protection of
Electronic Controls, Printed Circuit Boards, and Modules.
Packing a Control Use the following materials when returning a complete control:
• protective caps on all connectors;
• antistatic protective bags on all electronic modules;
• packing materials that will not damage the surface of the unit;
• at least 100 mm (4 inches) of tightly packed, industry-approved packing

material;
• a packing carton with double walls;
• a strong tape around the outside of the carton for increased strength.

Additional When returning equipment to Woodward, please telephone and ask for the
Instructions Customer Service Department [(800) 835-5182 or (970) 663-3900], They will
help expedite the processing of your order through our distributors or local service
facility. Factory repairs will be greatly expedited if a purchase order has been
issued for the item(s) to be repaired. Make arrangements in advance if possible.
REPLACEMENT When ordering replacement parts for electronic controls, include the following
PARTS information:
INFORMATION
HOW TO In North America use the following address when shipping or corresponding:
CONTACT Woodward Governor Company
WOODWARD Industrial Controls Group
PO Box 3800
38a) North Wilson Ave
Loveland CO 80539-3800 USA
TELEPHONE: (970) 663-3900 (24 hours a day)

TOLL-FREE PHONE (in North America); (800) 835-5182
FAX: (970) 962-7050
Woodward Governor Company facilities to obtain the address and phone number
of the facility nearest your location where you will be able to receive information
and service.

Australia 61 2 9758 2322
Brazil 55 19 242 4788
England 44 118 9752727
India 0091 129 232840/41
Japan 81 476 93 4661
The Netherlands 31 235661111
Singapore 65 270 0081
There is also information and e-mail addresses on Woodward’s Internet (World

Wide Web) home page;
http://www.woodward.com
OTHER SERVICE Contact Woodward Governor Company, Customer Service Department, for the
FACILITIES name of your nearest Woodward distributor or service facility.

ADDITIONAL Woodward Aftermarket Services offers the following after-sale support for all
AFTERMARKET Woodward products:
PRODUCT
SUPPORT
SERVICES • Technical Assistance
• Field Service
• Specialized Services
Customer Training is offered either at our facilities in Loveland and Fort Collins,
Colorado, or at the customer’s site. This training, conducted by experienced
trainers, will assure that customer personnel will be able to maintain system
reliability and availability. For information concerning training available, call the
number above and ask for customer training.
Technical As.sistance is available using the Woodward toll-free number. The

technical questions or problem solving during nonnal business hours or as
support for changes or enhancements after the commissioning of your system. For
technical engineering assistance, call the number above and ask for technical
assistance.
Field Service engineers are dispatched from the Woodward facility in Colorado,
provide prompt response. Woodward field engineers arc experienced and are
documentation is updated, and all field engineers are well informed as to new
problems which might arise. Woodward field service engineers are on-call 24
hours a day. Call the number above and ask for field service.
Specialized Services can be tailored to the specific needs of the customer. These
services can be based on a particular aspect of a single service or a combination of
services and are covered under one low-cost service contract. A contract may be
for regularly scheduled training courses or possibly to have a field engineer visit
the customer site at pre-determined intervals to provide a system analysis, verify
proper operation, and make recommendations for maintenance improvements,
enhancements, or other needs. These contracts are usually custom-designed and
structured to allow ultimate flexibility, thereby allowing the customer to plan and
budget more accurately. For more details, contact the Woodward sales
representative, or call the number above and ask for sales support to discuss
specific needs.
For more information on Woodward aftermarket services, access

http://www.woodward.com on the Internet.

SYSTEM The following is a general troubleshooting guide for areas to check which may
TROUBLE present potential difficulties. By making these checks appropriate to your engine/
SHOOTING turbine before contacting Woodward for technical assistance, your system
GUIDE problems can be more quickly and accurately assessed.
Actuators Is the oil clean?
Is the oil level normal?
Does the actuator have the correct hydraulic pressure (if required)?
Does the actuator have the correct pneumatic pressure (if required)?
Does the driveshafl rotate (if required), and in the correct direction?
Is the actuator wiring correct?
Is the direction of the stroke correct?
Has the compensation (if so equipped) been adjusted correctly?
If there is a mechanical governor, are the speed, droop, and load limit
adjusted correctly?
Is the hydraulic return line free and not clogged?
Is there back pressure on the hydraulic return line?
Is the feedback (if any) adjusted correctly and sending the correct signal?
Linkage Is there slop or lost motion?
Is there misalignment, binding, or side loading?
Is there visible wear or scarring?
Does the linkage move smoothly?
Valves Does the valve move through it’s proper stroke smoothly?
Does the valve travel it’s full stroke?
Can mid-stroke be obtained and held?
Does the valve fully seat (close) before the governor reaches full
minimum stroke?
Does the valve fully open before the governor reaches maximum stroke?
Is the bypass valve(s) (if any) in the proper position?
If a steam turbine, are there nicks or contamination which allow steam to

pass when the valve is closed?

Oil/Hydraulic Is the oil at the proper operating pressure?

System
Is the oil temperature too high for the type of oil being used?
Is the oil contaminated?
Does the actuator have sufficient flow of oil?
Are the accumulators (if any) charged to the correct pressure?
Are the filters plugged?
Is the oil pump operating properly?
Fuel Injection Are any rack shafts stuck?

Pumps
Do all rack shafts move through their full stroke smoothly?
Are all rack shaft settings equal, cylinder to cylinder, as the governor
output shaft is rotated from min to max fuel?
Are any drain lines clogged?
Are all injection lines in good condition and free of leaks?
Fuel/Steam Is the engine/turbine inlet pressure at design specification?

Conditions
Is the fuel/sleam pressure in the proper operating range?
Are pressure transducers (if any) located close to the engine/turbine?
Are there any pressure regulating devices or valves which may interfere
with governor operation or proper fuel/sleam flow?
Control, Alarm, Does the governor indicate it is in the correct control mode?
And Fault
Is the governor issuing any alarms?
Indications
Are any of the components of the governor indicating hardware faults?
Docs the actuator demand agree with the actual valve position?
Are any shutdown conditions present?
Have the control dynamics been tuned to match the system response?
Input Signals • Are all input signals properly scaled?
• Are the inputs free of electrical noise and properly shielded?
• Is the wiring correct?
• Have all field input signals to the control been verified?
• Is the polarity of the signals correct?

Output Signals Are ihc outputs calibrated?
Have the actuator drivers been calibrated to the stroke of the fuel injection
pump, fuel valves, or turbine valves?
Are the output signals free of noise and properly shielded?
Is the wiring correct?
Transducers Is the transducer calibrated for the proper range?
Has it been tested by simulating it’s input and measuring it’s output
signal?
Docs the transducer have power?
Are the sensing lines feeding the transducer clear of obstructions?
Are all block, bleed, and bypass valves positioned properly?
Magnetic Pickups Is the wiring between the speed sensing pickup and the control correct?
And Other Speed
Arc there any grounding problems or worn shields?
Sensing Devices
Is the signal sufficient (at least 1.5 Vims)?
Is the signal a clean sine wave or square wave with no spikes or

distortions?
Is the MPU head clean and free of oil or metallic particles?
Is the MPU head free of any nicks or chips?
Is the MPU or proximity probe correctly aligned with the gear?
Is the speed sensing probe adjusted to the correct gap?
Is the speed sensing probe head the correct size for the t(x>thed wheel it is
being used with?
Input Voltage/ Is the input power within the range of the control’s power supply input?
Power Supplies
Is the input power free of switching noise or transient spikes?
Is the power circuit dedicated to the governor only?
Are the control’s supplies indicating that they are OK?
Are the control’s supplies outputting the correct voltage?

Electrical Arc all electrical connections tight and clean?

Connections
Are all signal wires shielded?
Are shields continuous from the device to the control?
Are the shields terminated according to Woodward specifications?
Are there low voltage signal wires running in the same wiring trays as
high voltage wiring?
Are the governor’s signal common or grounds not lied to any other
devices?
Have the signals been checked for electrical noise?
Voltage Regulator Is the voltage regulator working properly?
External Devices Are there external devices the control is dependent on for input signals?
Are these devices providing the correct signal to the control?
Is the external device configured or programmed to be compatible with

the control?

TECHNICAL If you need to telephone for technical assistance, you will need to provide the
ASSISTANCE following information. Please write it down here before phoning:
General Your Name__

Site Location_
Phone Number
Fax Number
Prime Mover EngineATurbine Model Number_____

Information Manufacturer_____________________
Rating___________________________
Application______________________
Governor Please list all Woodward governors, actuators, and electronic controls in your
Information system:
Woodward Governor Part Number and Revision Letter
Serial Number
Serial Number
Serial Number
If you have an electronic or programmable control, please have the adjustment

setting positions or the menu settings written down and with you when you phone.

Woodward Governor Company/Industrial Controls Group
Attention: Marketing Communications
PO Box 3800
Loveland CO 80539-3800 USA
Woodward
WOODWARD GOVERNOR COMPANY / INDUSTRIAL CONTROLS GROUP
Engine, 'nirbomachincry. and Hydraulic Turbine Controls
3800 North Wilson Ave, PO Box 3800. Loveland CO 80539-3800 USA • Phone (970) 663-3900 • Fax (970) 962-7050
E-mail and World Wide W'eb Home Page—http://www.woodward.com
Registered Firm
ISO 9001:1994/Q900 M994
Certificate QSR-36
DUTCH COUNCIL
FOR CERTIFICATION
US FACILITIES
Industrial Controls Group, Fort Collins and Loveland. Colorado
Corporate Headquarters/Aircraft Controls Group. Rockford and Rockton. Illinois
HSC Controls Inc. Buffalo. New York
Additional offices in Birmingham, Alabama; Walnut Creek, California; Olympia Fields. Illinois;
Norristown, Pennsylvania; Houston. Texas; Bellevue. Washington
DISTRIBUTORS
Canada (Edmonton, Alberta; Concord. Ontario). Caribbean (Curasao. Netherlands Antilles)
Mexico (Mexico DF). Scotland (Aberdeen). Spain (Cadiz), Venezuela (Caracas).
I'nited States (Ventura. California; American Canyon. California; Wilmington, Delaware; New Orleans. Louisiana;
Rocky Mount. North Carolina; Houston. Texas; Seattle. Washington)
INTERNATIONAL LOCATIONS
Australia (Kingsgrove). Brazil (Campinas). China (Beijing. Tianjin), Czech Republic (Plzen). England (Reading).
Germany (Aken. Kelbra. Teitnang). India (Ballabgarh). Japan (Kobe, Tomisato). Korea (Pusan). Mexico (Mexico DF).
The Netherlands (Hoofddorp), New Zeala>'d (Christchurch). Poland (Warsaw), Singapore. United Arab Emirates (Abu Dhabi)
plus Authorized Dealers and Authorized Independent Ser> ice Facilities throughout the world
98/5/L

(1-2) Main Engine (Wartsila)

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WARTSILA 46

DELIVERY DOCUMENTS FOR

Vorbemerkungen Preliminary remarks 0

Sicherheits- und Gefahren- Instructions on safety and 1

Inbetriebnehmen Putting into operation 2

Betrieb und Unterhalt Operation and maintenance 3

Beheben von Storungen Troubleshooting 4

Demontage und Montage Disassembly and assembly 5

Ausserbetriebnehmen Taking out of operation 6

Service - Stellen Verzeichnis Guide to service stations 8

Betriebshandbuch Kurzfassung Operation manual abridged 9

ABB Turbo Systems Ltd ZTL 2460-CH A nil

Vorbemerkungen Preliminary remarks

Inhalt Seite Contents Page

HZTL 10409 A »ll

Funktionsbeschreibung Mode of operation

Vorbemerkungen Kap. I Chap. 0 Prelininary remarks

ABB Turbo Systems Ltd 10409 Al IM»

Vorbemerkungen Kap. / Chap. 0 Prelintnary remarks

Befahigung des Personals Qualification of personnel

Ausfuhrungsvarianten Various models

Abschn. Abschnitt CE Compressor end

Nr. Nummer sec. Section

s. siehe Temp. Temperature

u.d.M. uber dem Meer - J- Notes for assembling

- J- Hinweise ftir den Zusammenbau

ABB Turbo Systems Ltd 10409 Jk III!

ABB Turbo Systems Ltd -

Einsatzgrenzen: Application limits:

n Mmax’ t Mmax' Turbolader - Einsatzgrenzen n Mmax’ t Mmax' Turbocharger - application

Kontrollintervalle und Wechsel- Inspection and replacement inter­

Weitere Angaben: Further descriptions:

Kap./Chap. 0 Preliminary remarks

The conditions agreed with the engine

Angaben auf dem Leistungsschild Rating plate information

Wechselzeit des Verdichters

Wechselzeit der Turbine 50

standbetrieb zulassig. only.

The checking intervals and replacement

Vorbemerkungen Kap. / Chap. 0 Preliminary remarks

Angaben auf dem Leistungsschild Rating plate information

Angaben in 1000 h 342

Wechselzeit des Verdichters

Wechselzeit der Turbine

Die Kontroilintervalle und Wechselzeiten The checking intervals and replacement

ABB Turbo Systems Ltd A IIII

Kap. / Chap. 0 Preliminary remarks

The conditions agreed with the engine

Angaben auf dem Leistungsschild Rating plate information

Typ n 360 [^]

Wechselzeit des Verdichters 50

Wechselzeit der Turbine 50

Caution ! The turbocharger is to be used only up

standbetrieb zuiassig. only.

The checking intervals and replacement

Kap. / Chap. 0 Preliminary remarks

The conditions agreed with the engine

Angaben auf dem Leistungsschild Rating plate information

Typ n Mmax 360 [1]

Wechselzeit des Verdichters 50

Wechselzeit der Turbine 50

standbetrieb zuiassig. only.

The checking intervals and replacement

Kap./Chap. 0 Preliminary remarks

Kontrollintervalle und Wechsel- Inspection and replacement inter

Warnung ! Allergien, Hautschaden, Bewusstlosig- Warning ! Allergies, skin disease, unconscious

Note The engine manaufacturer's recommen