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USER MANUAL
Thanks for purchasing products of Wuxi Turbo Auto Power Co., Ltd.
CAUTION:
Company Address:
Wuxi Turbo Auto Power Co., Ltd
No. 203-1, Chengnan Road, New District, Wuxi City, Jiangsu Province, China
Tel: +86-510-85360328 (Tel Exchange to all departments)
Fax: +86-510-85368586
Postal Code: 214028
CONTENTS
1. NOTICE .......................................................................................................2
2. SAFETY INSTRUCTIONS ...........................................................................2
3. INTRODUCTION .........................................................................................5
3.1 FUNCTION AND FEATURES .........................................................................5
3.2 OPERATION CONDITION ............................................................................. 6
4. SYSTEM STRUCTURE ...............................................................................7
4.1 SUMMARIZE ..............................................................................................7
4.2 MACHINE BODY ........................................................................................ 7
4.3 ELECTRICAL TESTING SYSTEM ...................................................................7
4.4 MECHANICAL VIBRATION MEASUREMENT SYSTEM .......................................7
4.5 MAGNETIZING ROTATION SPEED MEASUREMENT SYSTEM ............................7
4.6 COMPRESSED AIR DRIVING SYSTEM ...........................................................8
4.7 LUBRICATION OIL SUPPLY SYSTEM .............................................................8
4.8 AIR-TURBINE-DRIVEN CUTTING DEVICE ......................................................8
4.9 EXHAUST SILENCER SYSTEM .....................................................................8
5. MACHINE FOUNDATION AND INSTALLATION .......................................9
5.1 THE INSTALLATION PLACE ..........................................................................9
5.2 REQUIREMENT OF GROUND BASE...............................................................9
5.3 GAS SOURCE ...........................................................................................9
5.4 POWER .................................................................................................. 10
5.5 PLACEMENT............................................................................................11
6. LUBRICATION OIL ................................................................................... 14
7. PANEL DESCRIPTION ............................................................................. 15
7.1 PANEL OF CORE BALANCING MACHINE ..................................................... 15
7.2 COMPUTER SCREEN DISPLAY .................................................................. 15
8. OPERATION.............................................................................................. 16
8.1 POWER ON AND OFF ...............................................................................16
8.2 TURBOCHARGER INSTALLATION ................................................................ 18
8.3 TESTING ................................................................................................. 21
8.4 SAVE TESTING DATA ................................................................................24
8.5 COMPLETION ..........................................................................................24
8.6 ADJUSTMENT OF ELIGIBLE RANGE ............................................................. 25
9. OLD VERSION CORE BALACNING MACHINE....................................... 26
10. MAINTENANCE ...................................................................................... 28
11. SPECIFICATIONS................................................................................... 29
12. PACKING LIST........................................................................................ 30
1
1. NOTICE
- When unpacking, please check whether the product and the accessories are
all included according to the packing list. If there are any differences, please
contact us in paper.
- If there is any problems with our product quality under normal transportation,
installation, operation and maintenance condition, please contact us in paper
within allotted time.
- If the actual machine has any contradictions with user manual, please
operating subject to the actual machine.
- This manual is for MHB-12 CORE BALANCING MACHINE, and also can be
reference for all the other models or customized core balancing machine.
2. SAFETY INSTRUCTIONS
IMPORTANT!!!
- Please MAKE SURE that the gas valve is closed before operation, (N.B. by
rotating in clockwise by 90 degrees.), because the gas valve will be
completely open when first time use for the convenience of transportation.
- Please make sure that the machine power and computer power are
connected and plugged correctly according to the circuit diagram in the user
manual.
- Please make sure that the safe door is closed all the time during the
operation of machine. Opening of safe door will cause emergency stop.
- Do not open the gas valve without wearing the ear cover.
- Please do not open the gas valve without opening the lubrication oil supply,
in order to avoid the damage of turbocharger.
2
- Handling the machine as shown in Fig 2.1
Fig 2.1
Fig 2.2
3
- IMPORTANT: Safety and warning symbols in the user manual in Fig 2.3
Fig 2.3
4
3. INTRODUCTION
The dynamic balancing of rotation components will directly affect the reliability
of turbocharger, as the rotation speed of turbocharger is from 20,000 rpm up
to about 200,000 rpm.
3.1.2 Features
- The original turbine housings are used as driving parts. The driving force
exerted on the turbine is exactly the same as the real working condition, thus
the measurement of vibration is more precise.
- Short testing time. It only takes five seconds to finish the whole-speed
balancing test.
5
- Easy to operate, and scientific to judge eligibility. Imbalance quantity can be
removed conveniently. Easy installation. Learn to operate within half an hour.
- Oil leaking check. The lubrication oil pressure should be the same as the oil
pressure of the real-working-condition turbocharger. The pressure of
lubrication oil can be adjusted.
- The fluctuating quantity of electrical source voltage should not be over 10%
of nominal value.
6
4. SYSTEM STRUCTURE
4.1 Summarize
The shaft end nut is magnetized by high-performance magnets, and mark the
original point. During measurement, when the shroud of the compressor
wheel is closed, the speed-testing sensor will transform the magnet flux
formed by the magnetized shaft end nut to electrical signals. Therefore the
rotation speed of turbocharger is obtained. The measurement is rapid and
accurate.
7
4.6 Compressed Air Driving System
Compressed air driving system is consists of the compressed air source and
original turbine housing. The turbine is installed on the suspension platform of
the mechanical vibration system. The air-inlet at the lower end of turbine
housing is connected with the compressed air. High-pressure air gets into the
turbine housing, which blows the rotor to rotate in high speed. It only takes
about 2-4 seconds to makes rotor reach the highest working rotation speed.
Lubrication oil supply system is consists of 30-litre oil tank, 3.6L/min pumping
station, automatically heating, cooling, oil control, filtration and oil lacking
alarm system. The two-stage automatically heating and cooling system
controls the oil temperature within 35±2°C precisely and rapidly, in order to
ensure the accuracy and repeatability of measurement parameters.
The oil pressure control system can automatically control the oil pressure
within 2-6kg/cm2. In addition, the oil pressure also can be adjusted by two-
stage micro-manual control.
The oil-lacking alarm will alarm automatically when the oil level is below the
set point.
High performance milling cutter is equipped at the front end of the air-turbine-
driven cutting device to remove imbalance quantity of shaft end nut precisely,
and lead to good balance of turbocharger rotor.
8
5. MACHINE FOUNDATION AND INSTALLATION
The core balancing machine must be placed at solid and level-off ground to
reduce the influence on precision by ground.
Enough space should be left around core balancing machine, for convenience
of installation and daily operation, maintenance and repair.
Core balancing machine should be installed on the ground base, which is built
by reinforced concrete. The strength of the ground base should not be lower
than 16MPa.
Note: The length of the air connection pipe (N.B. between the gas source and
the machine) should be less than 5 meters, and the inner diameter ≥ 40mm.
(See Fig 5.1)
9
Fig 5.1
5.4 Power
Power supply of the machine (N.B. air compressor is not included) requires
380V 3-phases 50Hz 2kW or 220V single-phase 50Hz, and it must be
grounded properly. (See Fig 5.2)
10
Fig 5.2
5.5 Placement
- Silencer is built in the machine. During normal operation, the air must be
exhausted to outdoor properly according to the national standard and rules.
The machine is equipped with interface for installation of exhaust flange.(See
Fig 5.3)
Fig 5.3
- Requirements of the minimum distances from the wall for installation of the
machine are shown in Fig 5.4
11
Fig 5.4
- The ground base must be solid and level off. The horizontal level of
turbocharger installation platform has to be 0.2mm/m. Please use the
gradienter to adjust the turbocharger installation platform. (See Fig 5.5)
Fig 5.5
12
Fig 5.6
Fig 5.7
- To obtain the comfortable operation height, wooden board can be put in front
of the machine for operators.
13
6. LUBRICATION OIL
- The lubrication oil of this machine is the turbocharger engine oil, mainly for
the lubrication of turbocharger. The trademark of the lubrication oil is
10W/CD40. The capacity of oil tank is 30L. Working temperature at 35±2°C.
Working pressure at 2-6bar.
- Add lubrication oil to the oil tank and observe the hydraulic level scale to
ensure that the hydraulic level is between the upper and lower limit. (See Fig
6.1)
Fig 6.1
- The hydraulic system has built-in oil temperature control system which
consists of heater, cooler and temperature sensor, in order to control the oil
temperature within 35±2°C rapidly and precisely. In addition, the hydraulic
system has oil-lacking alarm.
14
7. PANEL DESCRIPTION
15
Display
8. OPERATION
8.1.1 Power On
- Turn on the POWER shown in Fig 8.1, the power indicator lights.
- Turn on the PC POWER, enters “Windows XP”. Double click the “shortcut to
fsb”at the desktop (See Fig 8.2) to enter the program. (See Fig 8.3)
16
Fig 8.1
Fig 8.2
17
Fig 8.3
- If it is the first time to turn on the power and the ambient temperature is very
low, the lubrication oil needs time to warm-up. After several minutes, the oil
temperature will stay within 35±2°C. (N.B. Warm-up time varies with ambient
temperature.)
- The process of power off is just the contrary to power on. Firstly shut down
the computer and then turn off the OIL POWER. After the computer is shut
down, turn off the POWER.
18
8.2.1 Turbine housing installation
- Find or modify the proper connection board for turbine housing. Open the
cabinet gate, and fix the connection board on the turbocharger installation
platform according to the air inlet. (See Fig 8.4) And screw the air inlet of
turbine housing on the connection board. (See Fig 8.5)
Fig 8.4
19
Fig 8.5
- Adjust the position of the air outlet pipe (See Fig 8.6), so that there is no big
gap between the air outlet of turbine housing.(See Fig 8.5)
20
Fig 8.6
8.2.2 CHRA Installation
- Fix the CHRA on the turbine housing. And connect the oil inlet pipe to the oil
inlet on the cartridge by quick coupler.
- The opening and closing of shroud is controlled by clicking the icon on the
computer screen. (See Fig 8.3 Air Cover) Remove the shroud, which covers
the speed-measuring sensor. Adjust the position of the sensor to where 2-
3mm from the shaft end nut and its circle centre points to the nut.
Subsequently, place the suitable size shroud back. And make sure that the
shroud is 2-3mm from the compressor end plate. (See Fig 8.7)
Fig 8.7
- Press the Oil Supply button, and rotate the compressor wheel by hand to
check that all parts are correctly installed and no parts will be crashed at high
rotation speed.
21
8.3 Testing
- Choose the accord turbocharger model and eligible range. If the present
eligible range curve (green) does not fit the current rotor, you can click the
SETUP button. (See Fig 8.8)
Fig 8.8
- If there is new model of turbocharger that eligible range is not existed or the
eligible range needs to be rectified, please be handled professional technical
personnel.
- Mark any one of the impellers of the compressor wheel (N.B. by a marking
pen), and rotate this impeller to the upright top position. (See Fig 8.9)
- Make sure that the marked impeller is upwards, and magnetized the shaft
end nut downwards several times.
22
Marking
Point
Fig 8.9
- Open the air inlet valve slowly and steadily. When the highest rotation speed
is achieved, close the air-inlet valve in anti-clockwise as fast as possible.
- After every testing, the yellow cursor will automatically indicate the position
of the maximum amplitude.
Fig 8.10
23
8.3.4 Remove Imbalance Quantity
- If the tested curve (white) is above the eligible line (green) (See Fig 8.10), it
means the imbalance vibration of CHRA goes beyond the requirement of
eligible line.
- When the tested value is above the eligible value, turbocharger can be
adjusted in two ways.
⑴ Remove the imbalance quantity
- Move the yellow cursor on the curve with mouse, and read the vibration
and angle value at the maximum amplitude.
- Find the angle relative to the marking point on the shaft end nut. (See Fig
8.11) Use air-turbine-driven cutting device to remove the imbalance quantity.
(N.B. If the maximum vibration amplitude is the resonance point, then remove
imbalance according to the second largest point.)
Marking 0°
Point
90° 270°
180°
Fig8.11
- Then retest and if necessary further grinded are made until satisfy balance is
achieved. (See Fig 8.12)
Fig 8.12
24
⑵ Rotate the impeller or replace shaft end nut
- Take off the CHRA, and loosen the shaft end nut. Rotate the impeller
clockwise or anticlockwise by 90 degrees. Or replace the compressor impeller
or shaft end nut, and then tighten the nut. Retest (N.B. The shaft end nut
needs to be magnetized again. One nut can only be magnetized once. The
time taken for one magnetization is 2-3 seconds) until satisfy balance is
achieved.
- The tested curve can be saved in computer in two ways, quick storage and
document storage. Quick storage saves the curve in the computer EMS
memory, it can be quickly referred through selection menu, but it will lose
when the computer is turned off. Quick storage is operated by the buttons
“CURVE”, “QUICK SAVE”and “QUCIK CLEAR”on the screen. Document
storage saves the curve in the hard disk, it will not lose when the computer is
off, but it is not as convenient as quick storage. Document storage is operated
by the “SAVE CURVE”and “LOAD CURVE”.
8.5 Completion
CAUTION: When opening the air cover, the air cover must not be beyond the
red line, to avoid crash with the body of core balancing machine. (See Fig
8.13)
Fig 8.13
25
8.6 Adjustment of eligible range
- To refer previously saved curve, first type in the route and file name (suffix is
per) at the route input, press the “move out”button to put the eligible curve
into EMS memory and to become the current value. E.g. want to move out …
- To test new model, find out whether there are the same curve in the
existed eligible curve; if there is no same eligible curve, or need to re-
generates a new “eligible curve”, then according to the following method:
press the “eligible range”button at the top of screen (password is needed to
ensure the safety of eligible data). Edit program in the eligible range (see Fig
8.14).
First input the model of balancing rotor at the top of the window, then input
maximum eligible vibration values at different rotational speed in array editing
frame below the window, the computer will create green eligible line
automatically after inputs.
- If the current eligible curve needs to be saved, firstly input route and file
name (suffix is per), which you want to save at the route, input entrance,
press “save”button to save the current eligible range in this file name.
Fig 8.14
26
9. OLD VERSION CORE BALANCING MACHINE
Already not applied on our products, For Information Only
Fig 9.1
Fig 9.2
27
- There’ s a 1.5mm high lug boss at the air inlet on the turbine housing
installing platform. A corresponding notch should be made in the relevant
place of the adjusting padding block in order to make sure air inlet of the
compressed air aligns to the air inlet of the turbine housing. If the centre
height of turbine housing is the same as the height of exhaust port of the
balancing machine, under the turbine housing, a notch also should be made
to link the air inlet on the platform (Fig 9.3).
Fig 9.3
- The dimension of the air inlet flange of this machine as following (Fig 9.4):
Fig 9.4
28
10. MAINTENANCE
- The machine should keep clean, metal scraps and other impurities should
be removed after material removing. Impurities around the vibration
measurement parts will affect the precision of the machine.
- The milling cutter of the air-turbine-driven cutting device are easy damaged
parts, it must be replaced immediately when frayed. And please follow the
normal safety precautions when in use.
- Avoid strong vibration and humidity of electric circuit and testing system. And
no lubrication oil gets into.
- Every time after operation, please turn off the oil supply first, and then oil
power. Shut down the computer. At last, turn off the power.
- During long time not using the core balancing machine, please plugged the
machine several hours at intervals.
- Core balancing machine should be operated and maintained by authorized
people.
29
11. SPECIFICATIONS
11.1 Size
- Viscosity: 10W/CD40
30
- Vibration Value: 0.1-20g (1g = 9.8 m/s2)
Accessorize
1 for
3 Magnet (big and small for each)
each
1 for
4 Aluminum wind cover 4 kinds Φ65/Φ76/Φ86/Φ110
each
Padding iron of turbine intake
5 6
flange
Allen screw of adjusted padding M10*23 (length of screw
6 6
iron thread)
31
0.6
16 Trachea φ8
meter
29 Wireless mouse 1
30 Mouse mat 1
31 Keyboard cover 1
Instruction Book of MHB-12
32 Turbocharger VSR Core CD 1
Balancing Machine
32
12.2 Packing List of MHB-15
N Quanti
Title Specification
o. ty
Accessorize
1 for
2 Magnet (big and small for each)
each
φ65/φ86/φ95/ 1 for
3 Aluminum wind cover 4 kinds
φ110 each
1.5 inch
8 High pressure transitional hose 1
L=350mm
33
17 Joint of intake oil nozzle of bearing housing M10×1.5 1
25 Wireless mouse 1
26 Mouse mat 1
27 Keyboard cover 1
34