TDI 56A User manual

AN 96-429 From Tech Development
6800 Poe Ave. •Dayton OH 45414
Tel: [phone] •Fax: [phone]
Website: www.tdi-turbotwin.com
Publication 56-711, Rev. 5
Dated: February 27, 2015
INSTALLATION AND OPERATING
MANUAL
MODELS: 56A / 56B / 56G / 56S
Gas Turbine Engine
Air Starter Motors

TDI TURBOSTART™
FROM TECH DEVELOPMENT
Page 1
1.0 GENERAL INFORMATION
This manual provides instructions for the
installation and operation of the TDI TURBOSTART
Model 56 series air starters. If there are
questions not answered by this manual, please
contact your TDI distributor or dealer for
assistance.
The 56 series models are turbine driven air
starters with a sprag-type over-running clutch.
They are best suited for use with industrial gas
turbine engines. Model 56A and 56K are
designed for installation on engines which use an
AND 20002 Type XII-S engine accessory drive
pad. Model 56B has a mounting flange per MS
3332-2(AS) with a Type G grooved pilot and a
splined output shaft per MS 3335(AS). The 56G
has a mounting flange and output spline shaft
that mates with the accessory drive assembly
starter mounting pad on General Electric LM1600
& LM2500 engines. Model 56S is designed for
use on the Solar Saturn starter mount pad.
The 56 Series air starters are suited to operate
within a wide range of inlet pressures and
ambient temperatures. These starters are
designed for operation with either compressed air
or natural gas; materials used are compatible
with "sour" natural gas and marine environments.
Small amounts of foreign matter or liquid in the
air stream will normally not adversely affect 56
Series air starters. As with all other TDI air starter
models, no lubrication is required in the supply
air.
The 56 Series air starters are normally supplied
for use within a dedicated start monitoring
system. Some models may be equipped with the
TDI Automatic Trip Valve (ATV) to shut off air to
the starter when a predetermined cranking speed
is reached. This prevents excessive cranking
speeds, which could damage the starter.
NOTE
Throughout this manual, the term "air" is used to
denote the starter drive medium. Unless
otherwise stated, "air" means either compressed
air or natural gas.
Please review the rest of this manual before
installing your TDI TURBOSTART 56 Series
starter.
1.1 WARNINGS, CAUTIONS, & NOTES
Throughout this manual, certain types of
information will be highlighted for your attention:
WARNING - used where injury to personnel or
damage to the equipment is likely.
CAUTION - used where there is the possibility
of damage to the equipment.
NOTE - used to point out special interest
information.
2.0 ORIENTATION OF THE
STARTER
If the factory orientation of the starter's turbine
housing assembly does not fit your engine
installation, this component can be re-oriented.
Determine the required orientation of the turbine
housing assembly and gearbox housing
assembly. The turbine housing assembly can
be rotated to six different positions relative to
the gearbox housing assembly.
CAUTION
The gearbox housing assembly must always be
installed so the oil drain is at the bottom (6
o'clock) position. This assures that the oil level
check plug is also in the correct position.
Remove the oil drain plug to assure that all oil is
drained from the gearbox housing.
Remove the six turbine housing assembly to
gearbox housing assembly socket head cap
screws.
Rotate the turbine housing assembly to the
desired position and reinstall the six cap
screws. Torque the six screws to 14 Lb.-Ft
(19.2 Nm).

TDI TURBOSTART™
FROM TECH DEVELOPMENT
Page 2
CAUTION
All screw threads are treated at the factory with a
fastener retention compound. Every screw and tapped
hole must be clean and have a drop of Loctite 290
applied to the threads before being reinstalled.
CAUTION
Ensure that the O-ring on the gearbox housing
assembly remains in position and is not cut.
Install the oil drain plug.
Remove the oil level check plug on the side of
the gearbox housing and the oil fill plug at the
top of the gearbox housing. Add oil to the
gearbox housing until it starts to run out of the oil
level check port. Install the oil fill plug and oil
level check plug.
3.0 INSTALLING THE STARTER
3.1 A turbine driven starter does not require
lubrication in the supply air. Therefore, if a
vane-type starter motor is being replaced,
TDI recommends that all lubrication devices
and lines be removed to minimize flow
restrictions.
WARNING
If a fuel (pulse) lubricator has previously been
installed in the system, disconnect and plug the
line to eliminate spraying diesel fuel on the
engine.
3.2 Liberally grease the starter's splined shaft
with chassis lube and then mount the 56
Series starter on the engine. Tighten all
mounting hardware as appropriate.
WARNING
The starter is shipped from the factory without oil
in the gearbox. Oil must be added before
operating the starter.
Remove the oil level check plug on the side of
the gearbox housing and check the oil level in the
gearbox housing.
NOTE
Use of a turbine engine oil conforming to
MIL-L-7808H, or equal, is recommended for -use
in the gearbox.
If oil needs to be added, remove the oil fill plug
at the top of the gearbox housing. Add oil to
the gearbox housing until it starts to run out of
the oil
level check port. Install the oil fill plug and oil
level check plug.
After adding oil to the starter, attach the supply
air line and all system monitoring and
shutdown devices.
3.3 Natural Gas Operation
Proper control of natural gas is a major
consideration when used in the starter system.
3.3.1 The turbine exhaust must be plumbed
away from the starter area and vented to
atmosphere. 3" NPT and 4" NPT exhaust
fittings are available from TDI; refer to
Section 4.6.
CAUTION
When an exhaust fitting and line are used, the
line must be supported to prevent load transfer
back to the starter and engine mounting pad.
3.3.2 There is a turbine housing natural gas
vent port that is plugged for compressed
air use. Remove this 3/8" NPT plug and
install a line to carry gas away from the
starter area and vent to atmosphere.
CAUTION
Do not connect the turbine housing vent line to the
turbine exhaust line; exhaust line gas can
pressurize the turbine housing.
3.3.3 If used, the oil fill vent stand pipe (1/2"
NPT) must be removed and a line installed
to locate this vent away from the
immediate vicinity of the starter system
monitors.
3.4 Because turbine starters such as the 56
Series are sensitive to flow restrictions,
care must be taken to use uniform hose or
tubing and fittings for connection of the
supply air line. Tees, elbows, and line
length must be kept to a minimum. TDI
recommends that hose or flex couplings
be installed to eliminate possible leakage
caused by strain on the supply air line.

TDI TURBOSTART™
FROM TECH DEVELOPMENT
Page 3
3.5 Normally an air strainer is not required. In
dirty environments, use of a #40 mesh
Y-strainer is recommended.
WARNING
Recheck all connections for a tight fit.
Fill the air system tank. The 56 Series starter is
now ready to operate.
4.0 STARTER OPERATION
The maximum operating pressure limit is the
inlet pressure when measured at the starter
inlet pressure check port and reflects all
supply air pipe and valving losses. In order to
check the starter inlet pressure, a %" NPT
pipe tap connection is provided in the inlet
housing to attach a pressure gauge; refer to
Figures 1 and 2. IN NO CASE Should INLET
OPERATING PRESSURE EXCEED 10.3
BAR (150 PSIG).
WARNING
Do not operate the TDI Turbostart 56 Series
air starter with air pressure greater than the
pressure rating on the nameplate. This
pressure is to be measured at the starter
-inlet while the starter is running.
The static supply pressure will always be
higher than the operating pressure. As a
guideline, the maximum pressure limit (proof
pressure) that the 56 Series air starter may
be subjected to is 600 PSIG (41.4 Bar).
System pressure that exceeds the maximum
operating limit must use a pressure reducer
device to ensure that the operating pressure
limit to the 56 Series air starter is maintained.
System pressure that exceeds the 600 PSIG
(41.4 Bar) limit must, in addition to a
pressure reducer device, incorporate a
pressure relief valve, set below 600 PSIG
(41.4 Bar), in the supply air line.
All appropriate local pressure codes and
pressure limitations on other system
components must be adhered to and would
supersede the guidelines given in this manual.
4.1 Follow the engine manufacturer's instructions
for starting the engine.
4.2 If a start is aborted before a successful
engine start, a restart may be attempted after
the starter turbine and engine have come to
rest. Refer to the Engine Operator's Manual if
the system continues to shut down before a
successful start.
4.3 If an Automatic Trip Valve (ATV) is used and
the ATV happens to trip before a successful
engine start, a restart may be attempted after
the starter turbine and engine flywheel have
come to rest. If the ATV continues to trip, it
indicates that the supply line pressure is too
high. Refer to the Operator's Trouble
Shooting Guide, Section 6.0.
4.4 If the starter fails to function properly when
first operated, or its performance deteriorates
with use, refer to the Operator's Trouble
Shooting Guide, Section 6.0. If you cannot
solve the problem, or repair is necessary,
contact your local TDI Turbostart distributor
or dealer.
4.5 Gearbox housing lubricant should be
checked every six months. Lubricant should
flow out of the oil level check port when the
plug is removed. If lubricant needs to be
added, remove the gearbox housing oil fill
plug / stand pipe and add lubricant until it
starts to flow from the oil level check port;
refer to Section 3.2.
4.6 Accessories
DESCRIPTION KIT P/N:
3" Marman inlet flange 55-119
6" Marman exhaust flange 55-120
3" NPT exhaust fitting 52-419
3" NPT exhaust elbow 52-403
4" NPT exhaust fitting 52-418

TDI TURBOSTART™
FROM TECH DEVELOPMENT
Page 4
5.0 WARRANTY
TDI TURBOSTART ENGINE STARTER WARRANTY
Tech Development (TDI) warrants to the original user of the TDI Turbostart 56 Series air starters that the starter and
related components manufactured by TDI will be free from defects in material and workmanship for a period of One (1)
Year from date of purchase by such user. The conditions of this warranty are: a) TDI is notified within this period by
return of such product to TDI or its authorized distributor or dealer, transportation prepaid by user, b) such product has
been installed according to TDI's specifications; c) such product has not been misused, abused or improperly
maintained by user, d) the defect is not the result of normal wear and tear, and e) such starter product has not been
repaired with parts not manufactured or authorized by TDI and that TDI installation and repair procedures as outlined in
the appropriate manual were properly followed.
Tech Development shall, at its option, either repair or replace, without charge, any such starter product found upon
TDI's examination to be so defective, or by mutual agreement, refund the user's purchase price in exchange for such
starter product. Repairs or replacements under this warranty are warranted for the remainder of the original warranty
period.
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.

TDI TURBOSTART™
FROM TECH DEVELOPMENT
Page 5
56-A Gas Turbine Air Starter

TDI TURBOSTART™
FROM TECH DEVELOPMENT
Page 6
56-B Gas Turbine Air Starter

TDI TURBOSTART™
FROM TECH DEVELOPMENT
Page 7
56-G Gas Turbine Air Starter

TDI TURBOSTART™
FROM TECH DEVELOPMENT
Page 8
56A Performance Curves
21 Nozzles, Methane Gas, 11.4 Gear Ratio
0 5 10 15 20 25 30 35 40 45
0
50
100
150
200
250
300
350
400
450
500
550
0
20
40
60
80
100
120
140
160
180
200
220
150psig
120psig
90 psig
60psig
68
136
272
340
408
476
204
Nm
LB-FT
TORQUE
544
612
680
0
15
30
45
60
75
HP KW
POWER
120
90
105
748
135
150
165
56A Performance Curves
21 Nozzles, Compressed Air, 11.4 Gear Ratio
0 5 10 15 20 25 30 35 40 45
0
50
100
150
200
250
300
350
400
450
500
550
0
20
40
60
80
100
120
140
160
180
200
220
150psig
120psig
90psig
60 psig
68
136
272
340
408
476
204
Nm
LB-FT
TORQUE
544
612
680
0
15
30
45
60
75
HP KW
POWER
120
90
105
748
135
150
165

TDI TURBOSTART™
FROM TECH DEVELOPMENT
Page 9
56B Performance Curves
21 Nozzles, Methane Gas, 9.0 Gear Ratio
0 5 10 15 20 25 30 35 40 45
0
50
100
150
200
250
300
350
400
450
500
550
0
20
40
60
80
100
120
140
160
180
200
220
150psig
120psig
90psig
60psig
68
136
272
340
408
476
204
Nm
LB-FT
TORQUE
544
612
680
0
15
30
45
60
75
HP KW
POWER
120
90
105
748
135
150
165
56B Performance Curves
21 Nozzles, Compressed Air, 9.0 Gear Ratio
0 5 10 15 20 25 30 35 40 45
0
50
100
150
200
250
300
350
400
450
500
0
20
40
60
80
100
120
140
160
180
200
150psig
120psig
90psig
60psig
68
136
272
340
408
476
204
Nm
LB-FT
TORQUE
544
612
680
0
15
30
45
60
75
HP KW
POWER
120
90
105
135
150

TDI TURBOSTART™
FROM TECH DEVELOPMENT
Page 10
56G Performance Curves
21 Nozzles, Methane Gas, 7.5 Gear Ratio
0 5 10 15 20 25 30 35 40 45 50 55
0
50
100
150
200
250
300
350
400
450
500
550
0
20
40
60
80
100
120
140
160
180
200
220
150psig
120psig
90psig
60psig
68
136
272
340
408
476
204
Nm
LB-FT
TORQUE
544
612
680
0
15
30
45
60
75
HP KW
POWER
120
90
105
748
135
150
165
56G Performance Curves
21 Nozzles, Compressed Air, 7.5 Gear Ratio
0 5 10 15 20 25 30 35 40 45 50
0
50
100
150
200
250
300
350
400
450
0
20
40
60
80
100
120
140
160
180
150psig
120psig
90psig
60psig
68
136
272
340
408
476
204
Nm
LB-FT
TORQUE
544
0
15
30
45
60
75
HP KW
POWER
120
90
105
135
612

TDI TURBOSTART™
FROM TECH DEVELOPMENT
Page 11
56S Performance Curves
7 Nozzles, Methane, 9.0 Gear Ratio
0 5 10 15 20 25 30 35 40 45 50
0
20
40
60
80
100
120
140
160
0
10
20
30
40
50
60
70
80
150psig
60psig
27
54
108
135
162
189
81
Nm LB-FT
TORQUE
216
0
8
15
22
30
38
HP KW
POWER
60
45
52
120psig
90psig
56S Performance Curves
7 Nozzles, Compressed Air, 9.0 Gear Ratio
0 5 10 15 20 25 30 35 40 45 50
0
20
40
60
80
100
120
140
160
0
10
20
30
40
50
60
70
80
150psig
60psig
27
54
108
135
162
189
81
Nm
LB-FT
TORQUE
216
0
8
15
22
30
38
HP KW
POWER
60
45
52
120psig
90psig

TDI TURBOSTART™
FROM TECH DEVELOPMENT
Page 12

TDI TURBOSTART™
FROM TECH DEVELOPMENT
Page 13