TDI TURBOTWIN T100-MS User manual

AN08-481 From Tech Development
6800 Poe Ave. •Dayton OH 45414
Tel: [phone] •Fax: [phone]
Website: www.tdi-turbotwin.com
Publication: T1-795
Issued: August 1, 2008
INSTALLATION AND OPERATING
MANUAL
MODEL: T100-MS
TURBOTWIN Gas Turbine Engine
Air Starter

TDI TURBOTWIN™
FROM TECH DEVELOPMENT
Publication: T1-795
Issued: August 1, 2008 Page 1
TABLE OFCONTENTS
SECTION SUBJECT PAGE
1.0 GENERAL INFORMATION ……………………….2
1.1 DESCRIPTION & NEW FEATURES……………..2
1.2 BASIC OPERATION………………………………..2
1.3 PRODUCT IDENTIFICATION……………………. 3
1.4 MOTOR PERFORMANCE & OUTPUT…………..3
2.0 INSTALLING THE MOTOR……………………….4
2.1 ORIENTATION & LUBRICATION…………………5
2.2 SUPPLY & EXHAUST LINE INSTALLATION……6
2.3 MOTOR CONTROLS………………………………7
2.4 INLET PRESSURE CHECK PORT……………….7
2.5 MATCHING MOTOR OUTPUT TO LOAD……….7
3.0 MOTOR OPERATION…………………………….. 7
4.0 PREVENTIVE MAINTENANCE………………….. 8
5.0 TROUBLE SHOOTING GUIDE…………………...9
6.0 TURBOTWIN WARRANTY....................................10

TDI TURBOTWIN™
FROM TECH DEVELOPMENT
Publication: T1-795
Issued: August 1, 2008
Page 2
1.0 GENERAL INFORMATION
Instructionsfor installation, operationandmaintenance
of TDI TURBOTWIN™Model T100-MS Air Starter.
Theseare suitableforuse on a varietyofSolarTurbine
Engine applications including the Centaur & Taurus.
T100-MS starter motor assemblies are used only in
single starter applications.
Review this manual before installing or operating
T100MS Model Air Starters. Questions? Contact
your Authorized TDI Distributor, OEM or TDI directly.
WARNINGS, CAUTIONS AND NOTES
Certain types of information are highlighted in this
manual for your attention:
WARNINGS: - used where NON-
COMPLIANCE will likely result in injury to
personnel or damage to the equipment.
CAUTIONS: - used where there is possibility
of damage to the equipment.
NOTES/IMPORTANT: - used to point out
special interest information or “optimum” use
scenarios.
1.1 DESCRIPTION & NEW FEATURES
T100-MS air starters are extensively upgraded
versions of previous T100Mmodel. The “S” character
(within in the new model nomenclature) designates the
incorporation of many modifications and new product
features including:
oWet-sump (Splash) Oil Lubrication of
planetary gear set & drive end bearings.
oSealed (Vent-less) Gearbox w/Sight Glass
for easy oil level maintenance.
oHigher (ABEC) Spec Turbine Bearings.
oHigher Spec Double-lip Shaft Seals.
oNitride Treated planetary ring gear.
oHigher precision Dynamically Balanced
Rotors.
oNew Labyrinth-Type Primary Seal.
oProprietary Gearbox Venting System
oBalanced Pressure Venting of aft
seal/bearing
NOTE
THISSTARTER ISTOBE SERVICEDONLY BY AUTHORIZEDTDI
TURBOTWIN™ DISTRIBUTORS, DEALERS, AND REPAIR
STATIONS. DO NOT OPERATE THIS STARTER UNLESS IT IS
PROPERLY ATTACHED TO AN ENGINE.
NOTE
External dimensions of new T100-MS starter motors
are near identical to previous T100-M starter.
However, previous TDI starter models cannot be
economically upgraded to incorporate the many
additional features found in the newer models
oTURBOTWIN Upgrades can be easily installed,
generally without inlet/exhaustpiping changes.
oAll TURBOTWIN motors are designed for
operation on either compressed air or on
natural
oTURBOTWIN materials are compatible with
“sour” natural gas and marine environments.
oTURBOTWIN T100MS starters are ATEX
certified.
oAs with all TURBOTWIN turbine motors, mist or
injection type lubrication of the air/gas supply is
NOT required. (remove external lubricators).
NOTE
Throughout this manual, the term “air” is used to
designate the motor drive medium. Unless other wise
stated, "air" means either compressed air or natural
gas.
1.2 BASIC OPERATION
TURBOTWIN T100-MS air starters is a simple turbine
driven, gear reduced air motors, with the following key
differencesvs. other typesofmotorscommonlyusedin
related applications:
Unlike electric motors, power output and
operating speeds correspond (and vary
widely) depending on the dynamic operating
pressures supplied to the motor inlet and the
load imposed. (see performance data).
Unlikevane-type or rotaryscrew-type (positive
displacement)motors, turbine type air motors,
if unloaded/under loaded will operate at much
higher free-speeds.
Turbinetype motors mustbe properly selected
and regulated to operate efficiently, at a
required loaded speed, rather than over a
wide range of inlet supply pressures.

TDI TURBOTWIN™
FROM TECH DEVELOPMENT
Publication: T1-795
Issued: August 1, 2008 Page 3
The basic operation of the motor is as follows:
Pressurized air or natural gas is admitted to the motor
via the inlet port. The air expands through the two-
stage turbine, which produces shaftrotation and motor
output.
Upon a successful engine start (or cycle), turn the air
off to the motor immediately. Minimizing the time the
motor is operating, especially unloaded, will maximize
motor life
IMPORTANT
To attain maximum product life, it is important to
properly match the motor inlet supply pressure,
output and motor speed to required load.
Attain (regulate) starter to the lowest possible
supply pressure required to start the engine.
Minimizing starter back pressure will extend
the life of air motor. Back pressure should not
exceed 15 psig.
1.3PRODUCT IDENTIFICATION
The identification nameplate(s) attached to motor
housing should indicate the following information:
Model designation
P/Ns(OEM &/or aftermarket p/ns may be
present)
Serial Number (date of manufacture)
Maximum Operating (Inlet) Supply Pressure
Direction of Rotation
PART NUMBER IDENTIFICATION TABLE
TDI Part Number Solar Part Number
T115-60034-MSL-1-90 1078362-100
T115-60G34-MSL-1-90 1078362-200
NOTE
Direction of Rotation is either left hand (LH) rotation
(CCW)or right hand(RH) rotation (CW)viewed looking
into the output (shaft) end of the motor.
CAUTION
Exceeding the Maximum Operating Pressure rating
shown on starter nameplate may result in damage
to the motor or damage to the driven equipment.
NOTE
Maximum Operating Pressure is indicated on the
nameplate. This can (should) be measured at the
pressure check port below starter inlet port, and
dynamically (while the motor is in operation).
IMPORTANT
Optimum(correct) Maximum OperatingPressure isnot
necessarily the dynamic motor supply pressure
recommended for your application. Starter supply
pressure regulation, byapplication, has beenproven to
maximize the service life and reliability ofthe starter(s)
in most all applications. (See section 1.2)
NOTE
Proof Pressure, if shown on the nameplate, indicates
the maximum static pressure rating at which starter
turbine motor housing(s) will not burst in operation.
1.4STARTER MOTOR OUTPUT AND
PERFORMANCE
Please refer to specific Performance Graphs of the
model being applied which illustrate:
StarterOutput (shaft HP/Torque)over range of
dynamic supply pressures, 0 RPM (stall) to
maximum free speed.
AirConsumption Rates over rangeof dynamic
supply pressures (consumption is constant at
dynamic inlet pressures indicated on
performance charts).
Starter output & operating speed vary
considerably on DIFFERENT drive mediums
(e.g. air vs. methane gas).
Onmethane gas, starterproduces significantly
more HP, at higher speeds, so inlet supply
pressuresmayneed to be reduced (regulated)
to prevent excessive engine cranking speeds
(flame out).
In all cases, indicated performance assumes
exhaust routed to a safe location, through
system & piping that minimizes back
pressure not to exceed 15 psig.

TDI TURBOTWIN™
FROM TECH DEVELOPMENT
Publication: T1-795
Issued: August 1, 2008
Page 4
2.0 INSTALLING THE MOTOR
TDI T100-MS starters feature a turbine type
air motor that does not require lubrication in
the supply air. This is a separate
consideration from the lubrication of the
starter motor gearbox, a discrete oil sump
which requires oil maintenance (oil fill,
checks & changes).
If a vane-type starter motor is being replaced
by a TDI turbine type starter, TDIrecommends
removal of in-line/mist type lubricators to
minimize their inherent flow restriction to the
starter and eliminate this maintenance item.
CAUTION
All T100-MS/CS motors should be installed with the
inlet either straight down (6o’clock or180 degrees)or
straight up (0 degrees or 12 o’clock). In all cases,
orientation of gearbox sight glass must be just
below the motor/starter centerline, toinsure proper
indication/maintenance of gearbox oil level (see
section 2.1).
Model: T115-MS Performance Curve
15 Nozzles, Natural Gas 9.0:1
0
100
200
300
400
500
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
Output Speed - RPM
0
30
60
90
120
150112
90
68
45
22
0
POWER
HP KW
TORQUE
Nm LB.FT
408
680
272
544
136
0
90 Psig
60 Psig
150 Psig Inlet Flow
Pressure (Scfm) (Nm3/h)
150 Psig 2307 3921
120 Psig 1886 3206
90 psig 1466 2493
60 Psig 1047 1779
120 Psig

TDI TURBOTWIN™
FROM TECH DEVELOPMENT
Publication: T1-795
Issued: August 1, 2008 Page 5
2.1 PROPER INSTALLATION, ORIENTATION & OIL LEVEL MAINTNENACE
SOLAR P/N: 1078362-100 SOLAR P/N1078362-200
Motor/Starter Gearbox must be filled w/ (150ML) of Approved Oil Type** & Level Maintained
** Oil Type Recommended: Spec MIL-L-7808H, MIL-L-23699 (or equivalent synthetic grade turbine oil)
OIL FILL PORT
½”-14 NPT
OIL LEVEL
SIGHT GLASS
ORIENTATION
Viton O-ring
seal beneath 2”
NPT inlet flange
Viton O-ring seal
beneath 3”
exhaust adapter
flange
NOTE: PROPER INSTALLATION -
OIL LEVEL SIGHT GLASS
POSITIONED PARALEL TO
GROUNDLINE & BELOW
STARTER/MOTOR CENTERLINE
Starter
Output Shaft
& Mating
Spline
Engine Aux.
Gearbox
Splash-lube
Gearbox

TDI TURBOTWIN™
FROM TECH DEVELOPMENT
Publication: T1-795
Issued: August 1, 2008
Page 6
NOTE
TDI recommends synthetic grade oil (turbine oil) is
used in the starter gearbox sump. Use of either
improper synthetic or mineral based oils may
compromiseunit service life, manufacturer’s warranty,
and will increase the frequency of maintenance
intervals required.
WARNING
Donot operate this starter unless gearbox has been
filled to the proper oil level and maintained at this
level.
WARNING
Do not operate this starter unless it is properly
connected to an engine or load (see below).
2.2 SUPPLY LINE & EXHAUST LINE
INSTALLATION
WARNING
Be sure to either bleed the pressurized air reservoir
and/or safety the system such as closing all air/gas
supply valves, prior to installing motor or a new
supply line.
T100 TURBOTWIN T100-MS starter motors come
standard with a 2" NPT female pipe thread adapter for
theinlet connection port& various 3”exhaust adapters.
Various flange or thread adapters may be utilized at
these joints. Supplied adapters are sealed to the
motor housing with Viton O-rings (see section 2.1).
Hard piping may be used on supply/exhaust lines. A
section of flexible tubing may also be use/installed at
the starter inlet/outlet, to prevent leaks or wobble out
due to vibration.
The supply line consists of the line from the air/gas
supply source (via a pressure regulator when
necessary) through filters, manual and/or automatic
relay valves, to the starter inlet.
The exhaust line consists of the line from the motor
exhaust to a “safe” location. Turbine exhaust (air) is
typically plumbed away from the engine area.
Both supply & exhaust lines and components should
bedry-fitted for proper alignment/location,priortofinal
assembly.
All pipe threaded joints should be sealed with Loctite
Pipe Thread Sealant (TDI P/N 9-94085) or equivalent,
for leak tight joints prior to final assembly. Be sure to
tighten all joints to proper torque after final assembly.
The installation of the motorusingnatural gasis similar
to the air installation except all fittings, piping, valves
and regulators must be compatible with natural gas.
WARNING
When using natural (or combustible) supply gas
(e.g.methane gas) must be piped to a safe location,
routed and terminated according to industry codes
and local regulations.
NOTE
If the supply line is longer than 40 feet, the line piping
size may need to be increased to 2" diameter, to
minimize dynamic flow losses through piping and
ensure specified output. Similarly, if exhaust piping is
longer than 40 ft. in length, it may be necessary to
increase its diameter from 3” to 4” to minimize motor
exhaust back pressure and insure specified output.
On T115-MS applications, valves or regulators on the
supply side, having a Cv of 40 or higher, are
recommendedfor starter having15 nozzles (T115-MS)
Care must be taken to insure all inlet supply line piping
& components are capable of passing the required air
flow needed to produce specified power levels (motor
output).
See motor performance chart for specific
flow rates.
WARNING
Be sure that any/all piping &/or tubing used, meets
applicable requirements and that no leaks are
present following line installation or thereafter.
CAUTION
Although the light weight of these motors is easily
supported by their mounting flange designs, TDI
recommendsproperly bracing allrigid piping attached
to the motors… to eliminate axial strain on motor &
motormounting flanges. High axialloads (“over-hung
bending”) will greatly reduce motor life.

TDI TURBOTWIN™
FROM TECH DEVELOPMENT
Publication: T1-795
Issued: August 1, 2008 Page 7
CAUTION
There is often weld slag, grindings, thread shavings,
hardened compounds and other heavy debris in new
packagepiping & at new site installations. Therefore,
at commissioning (before running motors), TDI
recommendsa “blow-down”proceduretopurgemotor
supply lines of all hard debris that may otherwise
damage the motor severely. While T100
TURBOTWIN motors are highly tolerant of
contamination in the air/gas supply, motor life can be
greatlyincreased by usinga coarse meshstrainer. At
sites where dirty supply air/gas is present, use &
maintenance of a #40 mesh Y-strainer, upstream of
the motors, is highly recommended.
NOTE
Expensive moisture abatement (air/gas drying) is not
required, as this has no effect on the motors.
2.3 MOTOR CONTROLS
A preferred motor supply control valve is typically a
pilot-operated type, which can be pneumatically or
electrically actuated. The valve should be located
relatively close to the motor inlet, to prevent motor
over-running at the end of the cycle (especially on
starter applications).
CAUTION
Proper supply pressure “matching” and over-speed
control is highly recommended on all installations of
Models T100MS (See section 2.5)
Do not use supply pressure indications only as a
method to properly set the motors’ supply pressure. A
pressure regulator is required, where dynamic air/gas
motor supply pressure is great enough to exceed the
motor operating pressure (at the inlet port) and/or
where a “default” supply pressure would produce
motor output speeds beyond what is specified for
the application.(Result is over-speed, not
necessarily an indicated over-pressure). Both
over-pressure & over-speed will reduce life of the
motor & wastes supply air/gas (increases
operating costs).
2.4 INLET PRESSURE CHECK PORT
(checking dynamic operating pressures)
A 1/4" NPT port is located on the motor housing, under
the air inlet. This port can be used to check the supply
pressure at the motor when the motor is operating. To
check dynamic pressure, remove the 1/4" NPT pipe
plug and save for later use. Install a pressure gauge to
read at this port. Using Loctite Pipe Thread Sealant or
equivalent, replace ¼” NPTpipe plug whendone. This
pressure monitoring line/gauge may also be
permanently installed. Alternately, a pressure
transducer may be installed at the pressure check port
and electrical lines routed to a digital display at the
operator's station.
2.5 MATCHING MOTOR OUTPUT (SPEED)
TO LOAD
A hand held tachometer should be used to double-
check motor output speeds. Motor supply pressure
should be set at the minimum pressure required to
insure the motor runs the speed/load required by the
application.
It is recommended that all starters be installed with a
discrete supply pressure regulator. Do not use supply
pressure only, (such as the default fuel gas pressure
onthe package) as indicators ofmotor speed &output,
which typically do not account for:
Varyingfuel gas pressures (on variousturbine
engine models)
Varying compressor loads during start-up
Varying site conditions (temperatures, etc…)
Varying turbine engine ramp-up speeds (&
time) required.
NOTE
Starter motor over pressure (even where starter
supply pressure minimally exceeds that needed for
proper ramp-up speeds/times) may result in engine
turning too fast, too quickly… a.k.a. “flame-out.” In
these cases simply reducing starter supply
pressure will generally correct this.
3.0 MOTOR OPERATION
WARNING
Do not operate the TDI TURBOTWIN starter at
dynamic supply pressures greaterthan the pressure
rating on the nameplate. This dynamic pressure is
measured at the motor inlet while the motor is
running.
Static (non-flowing) supply pressure will
always be higher than theoperating (dynamic)
pressure.

TDI TURBOTWIN™
FROM TECH DEVELOPMENT
Publication: T1-795
Issued: August 1, 2008
Page 8
The maximum pressure limit (proof pressure)
that the TDI TURBOTWIN motor housings may
be subjected to is 600 PSIG (42 BAR).
Where system static pressure may exceedthe
600 PSIG (42 BAR) limit, in addition to
pressure reducing device, it a pressure relief
valveset below 600 PSIG (42 BAR) should be
used.
Where operating supply pressure exceeds
motors’ maximum operating pressure ratings,
or produces outputs above required by the
application, a pressure reducing device
(regulator) must be used.
All appropriate local pressure codes and pressure
limitations on other system components must be
adhered to and supersede the guidelines given in this
manual.
4.0 PREVENTIVE MAINTENANCE
IMPORTANT
All TURBOTWIN T100-MS/CS starter motors use
new oil-sump lubrication of the drive end (gearbox)
which must be properly maintained.
Severe Service ** & Required Field
Maintenance Procedures,to be performed
as preventative maintenance include:
oUtilize only oil types recommended
by the manufacturer (TDI), in the
starter gearbox.
oProperly orient the motors/starters
as described herein, to insure proper
oil levels can be easily maintained in
the starter gearbox (See section 2.1)
MAINTENANCE SCHEDULE
INTERVAL CHECKS MAINTENANCE
2,000
operating
hours (or
quarterly)
Check Oil
Level
Check oil
condition,
change oil if
using oil other
than
recommended
synthetic types
4,000
operating
hours (semi-
annually)
Check Oil
Level
Check oil
condition,
change oil if
using oil other
than
recommended
synthetic types
8,000
operating
hours
(annually)
Check Oil
Level Change Oil
(regardless of
type being used)
** Severe Service:is where motor(s) are cycled
longer than one (1) hour continuously or wherever
motor(s) can/may become unloaded for periods
longer than 30 seconds during cycle.
Repair technicians or un-authorized/un-trained service
organizations, without TDI TurboTech certification,
should not attempt to rebuildnor repair these products.
Proper maintenance, qualified maintenance repair of
your TDI TURBOTWIN starters & motors will assure
continued reliable and superior performance for many
years.

TDI TURBOTWIN™
FROM TECH DEVELOPMENT
Publication: T1-795
Issued: August 1, 2008 Page 9
5.0 TROUBLESHOOTING CHART
TROUBLE PROBABLE CAUSE SOLUTION
A. Valve not fully open. A. Repair or replace valve. 1. Motor does not run;
small air flow from
exhaust.
B. Nozzle blockage. B. Remove blockage or obstruction from nozzles.
A. Broken turbine rotor. A. Replace all damaged parts.
B. Broken gear train. B. Repair or replace gear train.
2. Motor does not run;
normal air flow from
exhaust.
C. Damaged motor drive. C. Repair or replace motor drive.
A. Inlet air pressure too low. A. Increase air pressure in 10 PSIG (0.6 BAR)
increments; DO NOT EXCEED OPERATING LIMIT.
B. Inlet supply piping too small. B. Supply piping must be a minimum of 1.5" diameter.
C. Pressure regulator orifice too
small.
C. Increase orifice size or replace pressure regulator
D. Inlet supply line valve (ball,
gate, relay, plug) too small.
D. Install larger valve.
E. In line lubricator installed in
supply line.
E. Remove lubricator.
F. Y-Strainer in supply line
clogged.
F. Clean strainer.
G. Excessive back pressure;
exhaust restricted.
G. Clean exhaust piping or increase size to at least the
minimum diameter recommended.
H. Damaged turbine nozzle. H. Replace turbine nozzle.
J. Wrong rotation motor. J. Replace with motor or proper rotation.
3. Reduced Motor
output power.
K. Wrong size motor. K. Check the Application Guide for the correct motor.
A. Motor Inlet air pressure too
high.
A. Decrease air pressure in 10 PSIG (0.6 BAR)
increments.
OR
If there is a manual shut-off valve in the supply line,
partially close it.
OR
Install a restriction orifice in the inlet supply line.
4. Engine cranks too
fast (flameout).
B. Wrong size motor. B. Check the Application Guide for the correct motor.

TDI TURBOTWIN™
FROM TECH DEVELOPMENT
Publication: T1-795
Issued: August 1, 2008
Page 10
6.0 WARRANTY
TDI TURBOTWIN ENGINE MOTOR WARRANTY
Tech Development (TDI) warrants to the original user of the TDI TURBOTWIN™ air starters to be free from defects in material
and workmanship for a period of one year (6 month for remanufactured units) from the date of installation. The warranty period
shall not extend beyond two years (12 months forfactoryremanufacturedunits) from thedate the unit was manufactured. (i.e.:a
unit with a manufactured date of July 1999 (SN: 9907-101) will not be covered under warranty after July2001). The conditions
of this warranty are: a) TDI is notified within this period by return of such product to TDI or its authorized distributor/dealer,
transportation prepaid by user; b) the starter has been installed according to TDI’s specifications; c) the starter has not been
misused, abused, or improperly maintained by user; d) the defect is not the result of normal wear and tear; e) the starter has
been repaired with parts manufactured or authorized by TDI; and f) TDI installation and repair procedures as outlined in the
appropriate manual were properly followed.
Tech Development will repair, or at its option, replace the unit during the warranty period at no charge to the customer,
provided it is returned to TDI with the proper return procedure.
Tech Development makes no other warranty, and implied warranties including any warranty or merchantability or fitness for a
particular purpose are hereby disclaimed.
This warranty constitutes the entire obligation of Tech Development relating to the sale and use of such product and TDI’s
maximum liability is limited to the purchase price of such product at the date of purchase. In no event shall TDI be liable for
incidental, indirect, consequential, or special damages of any nature arising from the sale or use of such engine starter
product.