Emerson Vilter VSG, Installation, Operation & Maintenance Manual

Page 1: ...VSG VSSG compressor unit Installation operation maintenance manual FOR UNITS BUILT AFTER JULY 1 2013 ...

Page 2: ......

Page 3: ...r s instructions This warranty does not apply i to ordinary wear and tear damage caused by corrosion misuse overloading neglect improper use or operation including without limitation operation beyond rated capacity substitution of parts not approved by Seller accident or alteration as determined by Seller or ii if the product is operated on a gas with an H2S level above 100 PPM In addition Seller ...

Page 4: ...in shipment For this reason the equipment should be thoroughly inspected upon arrival Any damage noted should be reported immediately to the Transportation Company This way an authorized agent can examine the unit determine the extent of damage and take necessary steps to rectify the claim with no serious or costly delays At the same time the local Vilter representative or the home office should b...

Page 5: ...Oil Pressure Regulating 2 2 Control System 2 2 RTDs and Pressure Transducers 2 2 Section 3 Installation Delivery Inspection 3 1 Rigging and Lifting 3 1 Long Term Storage Recommendations 3 2 Compressor Motor 3 2 Air Cooled Oil Coolers 3 3 Compressor Unit Inspections Prior to Storage or Installation 3 3 Recommended Onsite Tools 3 3 Long Term Storage Log 3 4 Foundation 3 5 Piping 3 10 Header Piping a...

Page 6: ...ng Oil Filter Replacement 5 8 Oil Pump Strainer 5 9 Drive Coupling Form Flex BPU Installation 5 10 Drive Center Member Form Flex BPU Installation and Alignment 5 11 Drive Coupling Form Flex BPU Removal 5 13 Drive Coupling Type C Sure Flex Replacement 5 13 Compressor Replacement 5 15 Bare Shaft Compressor Lifting Points and Weights 5 17 Bare Shaft Compressor Center of Gravity Models 291 2101 5 18 B...

Page 7: ... Troubleshooting Guide General Problems Solutions 6 5 Section 7 Warranty and Parts Warranty Claim Processing 7 1 On Site Service Support 7 1 Remanufactured Bare Shaft Compressors Process 7 2 Explanation of Rebuild Levels 7 2 Bare Shaft Compressor Description 7 2 Appendices Appendix A Torque Specifications A Appendix B Oil Analysis Report B Appendix C Recommended Header Piping C Appendix D Recommen...

Page 8: ...igure 3 1 Rigging and Lifting Points 3 1 Figure 3 2 Concrete Pad with Compressor Unit Dimensions Side View 3 5 Figure 3 3 Concrete Pad with Compressor Unit Dimensions Front View 3 6 Figure 3 4 Interior Foundation Isolation 3 6 Figure 3 5 Foundation with Housekeeping Pads Dimensions Top View 3 7 Figure 3 6 Housekeeping Pad Dimension Detail Top View 3 9 Figure 3 7 Level Compressor Unit Using Top Sur...

Page 9: ...r Lifting Points and Component Weights 5 17 Figure 5 12 Bare Shaft Compressor Assembly Center of Gravity Models 291 2101 5 18 Figure 5 13 Bare Shaft Compressor Center of Gravity Discharge Manifold and Main Compressor Assembly Models 291 2101 5 18 Figure 5 14 Bare Shaft Compressor Assembly Center of Gravity Models 2401 3001 5 19 Figure 5 15 Bare Shaft Compressor Center of Gravity Discharge Manifold...

Page 10: ...Blank TOC VSG VSSG Installation Operation and Maintenance Manual Vilter Emerson 35391STG ...

Page 11: ...ation that shall be followed Not fol lowing such notices may result in void of warranty seri ous fines serious injury and or death WARNING Warning statements are shown when there are hazardous situations if not avoided will result in se rious injury and or death CAUTION Caution statements are shown when there are potentially hazardous situations if not avoided will result in damage to equipment NO...

Page 12: ...riable Frequency Drive EMD Electric Motor Drive ENG Engine Drive 7 Separator Type 16 16 inch diameter 36 36inchdiameter 20 20 inch diameter 42 42inchdiameter 24 24 inch diameter 48 48inchdiameter 30 30 inch diameter 54 54inchdiameter H Horizontal V Vertical SH Special Horizontal SV Special Vertical 8 Economizer NEC No Economizer Economizer Ports Plugged HEC Holes drilled in Economizer Plug for Oil...

Page 13: ...mpressor A bare shaft compressor is just the compressor with no coupling and motor nor foundation Compressor Unit A compressor unit consists of the bare shaft compressor with the coupling motor oil separator frame micro control ler system and oil system A compressor unit typically a single screw compressor unit is not mounted on a structural steel base Package Unit A package unit is a complete sys...

Page 14: ...ump Strainer 15 Oil Sight Glass 16 Oil Filter Optional Dual Oil Filters Shown 17 Discharge Connection 18 Oil Separator Inspection Port 19 Thermal Acoustic Oil Separator Blanket Optional Per Application 20 Nameplate 21 Heat Trace Insulation Optional Per Application 22 Frame 23 Oil Cooler Shell and Tube Heat Exchanger 2 3 4 6 8 10 13 16 1 17 7 11 12 14 15 11 Compressor Unit Component Identification ...

Page 15: ...SG Installation Operation and Maintenance Manual Vilter Emerson 35391STG Section 1 General Information 19 20 21 20 22 18 23 Figure 1 2 Gas Compressor Unit Components 2 of 3 Section 1 General Information 3 4 14 17 ...

Page 16: ...ure 27 RTD Suction 28 Volume Slide Valve Actuator 29 RTD Discharge 30 Capacity Slide Valve Actuator 31 Pressure Transducers Filter Inlet Oil Pressure Discharge 1 and 2 Component Identification Continued 32 Block Bleed Assembly 33 Remote Oil Cooler Finned Fan Heat Exchanger 34 Oil Separator Drain 35 RTD Oil Separator Figure 1 2 Gas Compressor Unit Components 3 of 3 33 24 26 29 30 32 35 28 31 OUTLET...

Page 17: ... Current IAH Amperage High IAHH Amperage High High Shutdown II Current Indication IT Current Transmitter Blind J Power JB Junction Box Wire Termination JI Power Indication JIT Power Indicating Transmitter JT Power Transmitter Blind K Time Schedule KC Time Controller Blind KI Time Indication KIC Time Indication Controller KR Time Recorder KY Time Relay Convertor L Level LAH Liquid Level High LAHH L...

Page 18: ...AHH Temperature High High Shutdown TAL Temperature Low TALL Temperature Low Low Shutdown TE Temperature Element RTD Thermocouple etc TG Temperature Gauge TI Temperature Indication Soft TIC Temperature Indicating Controller TIT Temperature Indicating Transmitter TRV Transfer Valve 3 Way TSH Temperature Switch High TSHH Temperature Switch High High Shutdown TTSL Temperature Switch Low TSLL Temperatu...

Page 19: ...Cover Manifold Gauge Valve M Motorized Ball Valve Needle Valve Orifice Plate G Pilot Light Pipe Plug Pipe Reducer Pneumatic Actuator Control Valve Relief Valve Regulating Valve Inlet Pressure Regulating Valve Outlet Pressure Rotary Valve Rupture Disc Schroder Valve S Solenoid Valve Spring Closing Drain Valve Stop Check Valve Strainer T Thermostatic Valve 3 Way Thermowell SW or NPT Thermowell SW or...

Page 20: ... Control Field Mounted SD Safety Instrumented System Field Mounted Programmable Logic Control DCS or Remote Control Panel Normally Accessible to Operator SD Safety Instrumented System Main Control Panel or DCS Programmable Logic Control Auxiliary Local Control Panel Normally Accessible to Operator SD Safety Instrumented System Auxiliary Local Control Panel Computer Function Field Mounted Computer ...

Page 21: ...Loop number or sequential number J Loop number or sequential number K Loop number or sequential number L Suffix SAMPLE TAG 105 LSH 300 A 1 First process cell or stage of compression 0 First unit number in process cell or stage of compression 5 Condensate service L Level S Switch H High 3 Loop number or sequential number 0 Loop number or sequential number 0 Loop number or sequential number A Anothe...

Page 22: ...Water Return CWR Cooling Water Return CWS Cooling Water Supply DR Drain ER Ethylene Refrigerant GLR Glycol Return GLS Glycol Supply H Hydrogen HR Hydrocarbon Refrigerant Pipe Line Data Identification IAS Instrument Air Supply LFG Land Fill Gas LO Lube Oil N Nitrogen NG Natural Gas NH Ammonia PC Process Condensate PG Process Gas PR Propylene Refrigerant Propane SV Safety Relief SO Seal Oil VC Vacuu...

Page 23: ...d scrubber for cooling while the oil is pumped or syphoned back to the compressor Check valves 3 and 6 are provided to stop the back flow of gas in the system when the compressor is shut down An equalizing line is also installed between the high pressure side oil separator and low pressure side suc tion to allow separator pressure to equalize to suction pressure at shutdown This is controlled by t...

Page 24: ...other option is to air cool oil remotely through a finned fan heat exchanger 8 Furthermore to collect oil from the coalescing side of the oil separator 12 a line is installed between the oil separator and the compressor By opening the needle valve 15 this will allow oil dripping off the coalescing filters to be fed back to the compressor 13 In addition the oil cooler 8 or 9 is piped in parallel to...

Page 25: ...actory However damage can occur in ship ment For this reason the units should be thoroughly inspected upon arrival prior to off loading Any dam age noted should be photographed and reported im mediately to the transportation company This way an authorized agent can examine the unit determine the extent of damage and take necessary steps to rectify the claim with no serious or costly delays At the ...

Page 26: ...g sheet to help with record keeping see section page 3 4 Warranty of the system remains in effect as described at the beginning of this manual section page i The following are recommendations regarding long term storage If the unit is designed for indoor duty it must be stored in a heated building If the unit is designed for outdoor duty and is to be stored outdoors a canvas tarp is recommended fo...

Page 27: ...5 0 020 Range 12 blade length Infrared Heat Gun Oil Pump maximum of 2 3 GPM with motor ap proved for Division 1 or Division 2 and with ability to overcome suction pressure Sockets and wrenches up to 2 1 2 63 5 mm Torque Wrenches with ranges from 0 to 600 ft lbs Voltmeter AIR COOLED OIL COOLERS The following are general recommendations Refer to specific air cooled oil cooler manufacturer instructio...

Page 28: ...ning to atmo sphere are to be open Space Heater Panel Components Ensure space heater is energized and panel components are rust free Name Please Print Initial Date M D Y PSI Nitrogen Pressure Current PSI Nitrogen Pressure Recharged If pressure is low identify and fix leak prior to recharging see Compressor Unit Leak Check procedure in Section 5 Nitrogen Leak Location Briefly explain nature of leak...

Page 29: ... compacted sand four inches thick for the foundation to rest on see Figure 1 Con crete Pad with Compressor Unit Dimensions Side View The rebar required is ASTM 615 grade 60 sizes 4 and 6 Wires will also be needed to tie the rebar together The recommended grout is Masterflow 648CP high performance non shirk grout to provide at least a 1 thick pad under each foot The recommended an chors are 5 8 Dia...

Page 30: ...the compressor unit is correctly placed on the foundation Once placed use the spherical wash ers directly under the compressor as the surface to level the compressor unit see Figure 3 7 Place shims under the feet of the compressor unit as needed until it is leveled see Figure 3 8 Select the correct drill bit and drill thru the anchor bolt hole in the mounting feet of the compressor unit to the dep...

Page 31: ...erior Foundation Isolation Leveling and Grouting The unit should be level in all directions Wet the concrete pad according to the grout manufacturer s directions Mix a sufficient amount of grout The grout must be an expanding grout rather than shrinking to provide a tighter bond Follow the manufacturer s recommendations for setting precautions mixing and grout placement finishing and curing The gr...

Page 32: ... 3600 Soil bearing capacity 1 500 lbs sq ft Wind speed 120 MPH Exposure factor D Wind importance factor 1 15 Concrete poured on and permanently cast against the earth General Design Requirements The compressor foundation is designed to Maintain the compressor in alignment and at proper elevation Minimize vibration and prevents its transmission to other structures Provide a permanently rigid suppor...

Page 33: ...ekeeping Pad Dimension Detail Top View 5 8 DIA HILTI HAS SSTHREADED ROD HAS E RODS ARE ACCEPTABLE FOR INTERIOR INSTALLATIONS INSTALLED USING HIT ICE HIT HY 150 ADHESIVE ANCHORING SYSTEM 5 PROJECTION 12 3 8 EMBEDMENT HOLESTO BE INSTALLEDWITH HAMMER DRILL DO NOT DIAMOND CORE TYP CENTER LINE G A G A G A G A G A 2 G A G A 1 TYP 5 6VERT WITH STD 90 HOOK AT BOTTOM EACH FACE 2 4 CLOSEDTIES COMPRESSOR UNI...

Page 34: ...en the job is complete In no case shall the attached piping be allowed to cause more than 0 002 movement at the compressor shaft If more than 0 002 movement is detected the piping must be adjusted to reduce the compressor shaft move ment to less than 0 002 For example the compressor shaft should not move more than 0 002 when piping is removed or connected to the compressor IMPORTANT piping element...

Page 35: ...R SUPPORT HANGER CHECK VALVE CUSTOMER SUPPORTS WHEN CHECK VALVE IS MOUNTED HERE 5 PIPE DIAMETERS 5 PIPE DIAMETERS Nozzle Dia in Fz lbf Fy lbf Fx ft lbf Mzz ft lbf Myy ft lbf Mxx ft lbf 4 400 400 400 300 300 300 6 600 600 600 500 500 500 8 900 900 900 1000 1000 1000 10 1200 1200 1200 1200 1200 1200 12 1500 1500 1500 1500 1500 1500 14 2000 2000 2000 2000 2000 2000 Section 3 Installation Table 3 2 Ma...

Page 36: ...e an intake velocity equal to or below 500FPM as the discharge velocity is above 500FPM We will look at each rule and provide pictorials and calculations for each guideline Let s assume the follow ing coolers are being installed in a common area Cooler 1 7 wide x 10 long with a 6 fan moving 55 000CFM of air Face velocity is 785FPM Cooler 2 8 wide x 12 long with a 7 fan moving 72 000CFM of air Face...

Page 37: ...d next to the building as in Figure 3 12 Based on the information above we are going to solve for the leg height that will provide an intake velocity of 500FPM We know the following The total airflow of the installation is 247 000CFM We have an intake perimeter of 3 sides 16ft 16ft and 25ft which totals 57 Our intake velocity guideline is 500FPM The equation used to calculate the leg height in Fig...

Page 38: ...his calculation please contact engineering As you can see in Figure 3 13 in the not preferred con figuration the leg height requirement in the first cal culation is satisfied However the coolers are not at the same discharge elevation This could be an issue if there is a cross wind from left to right Cooler 3 could block the discharge air flow from coolers 1 and 2 and recirculate it back down to t...

Page 39: ...allation Operation and Maintenance Manual Vilter Emerson 35391STG Figure 3 13 Discharge Elevation of Coolers Section 3 Installation NOT PREFERRED PREFERRED Figure 3 14 Cooler Placement and Spacing PREFERRED NOT PREFERRED ...

Page 40: ...17 1 At initial start up compressor unit must be off and depressurized prior to initial oil charging 2 Using a properly selected oil pump connect oil pump to oil separator drain valve 4 For oil separa tor drain valve location see Figure 3 16 3 Open oil separator drain valve 4 and fill oil separa tor 3 to Maximum NON Operating Level 4 Once Maximum NON Operating Level has been reached shut off oil p...

Page 41: ...ng Levels Normal Operating Level Maximum NON Operating Level Minimum Operating Level Figure 3 16 Suction Oil Charging Valve Oil Cooler Drain Valve and Oil Filter Shut Off Valves Suction Oil Charging Valve View Rotate 180 Oil Drain Valve Oil Separator Bypass Valve Oil Cooler View From Back View Rotate 180 Oil Filter Shut Off Valves ...

Page 42: ...il mixing valve 7 via control panel In Manual Mode change Manually Open value to 100 14 Run oil pump 6 for approximately 20 seconds only 15 Stop oil pump 6 and wait for a minimum of 30 min utes This will allow oil in the compressor 2 to drain and oil level 9 in oil separator 3 to settle NOTE Oil mixing valve can remain in Manual Mode since the setpoint will change the mode to Auto when reached For...

Page 43: ...R DRAIN DRAIN VENT COOLING WATER DISCHARGE OUTLET SUPPLY RETURN PT 004 BLEED PT 005 BLEED Figure 3 18 Priming Compressor with Shell Tube Oil Cooler and Piping Section 3 Installation NOTE Oil separator does not need to be filled again until oil level reaches Minimum Operating Level Every size of compressor will hold different amounts of oil so amount of oil draining back into oil separator will var...

Page 44: ... instructions will result in bearing damage and compressor seizing and will void any and all warranties that may apply NOTE This procedure is for remote oil coolers only Piping of oil must enter bottom connection of remote oil cooler and leave from top connection For remote air cooled oil cooler piping see Piping section Reference Figure 3 19 1 Verify oil level 8 is at Maximum Non Operating Oil Le...

Page 45: ...to suction oil charging valve 1 For suction oil charging valve location see Figure 3 16 16 Open suction oil charging valve 1 and fill oil separa tor 3 to Normal Operating Level 17 Once the Normal Operating level has been reached shut off the oil pump and close the suction oil charg ing valve 1 Disconnect and remove oil pump NOTE Oil separator does not need to be filled again until oil level reache...

Page 46: ...n a vessel before the compressor are hardwired and able to shut off the compressor should be wired to Aux on micro controller and starter 4 The suction and discharge line must be piped and properly supported independent of the unit 5 The discharge stop and check valve is shipped loose and must be installed During off periods liquid can condense in the line downstream of the discharge stop and chec...

Page 47: ... bearings and motor 14 The center section of the coupling should be left out to allow the start up technician to verify the final alignment and motor rotations 15 Verify that all valves are in the open position 16 Verify that the visual indicator on the Oil Temperature Control Valve Oil Mixing Valve position corresponds with OPEN on the control panel CLOSE position is 0 OPEN OPEN position is 100 O...

Page 48: ... Cold and hot alignment Verify with manufacturer s limits 5 Verify capacity slide calibration and correct command shaft rotation even though it is factory calibrated 6 Verify volume slide calibration and correct command shaft rotation even though it is factory calibrated 7 Check motorized oil mixing valve for proper setup 8 Starter set up by vendor technician 9 Blower set up by vendor technician 1...

Page 49: ...condensate or oil Wear rubber gloves and a face shield when working with condensate or oil Failure to comply may result in serious injury or death Inspect oil level through sight glasses on the oil Figure 4 1 Oil Operating Levels Normal Operating Level Maximum NON Operating Level Minimum Operating Level separator see Figure 4 1 Oil Operating Levels Drain or fill oil as required For oil draining an...

Page 50: ...onal information on Low Oil Pressure at Start see Troubleshooting Guide General Problems and Solutions in Section 6 If the compressor is in the automatic mode it will now load and unload and vary the volume ratio in response to the system demands Stopping Restarting Stopping the compressor unit can be accomplished a number of ways Any of the safety setpoints will stop the compressor unit if an abn...

Page 51: ...hed to the connector on the actuator cover Handle actuator cover with care to prevent damage to wires Failure to comply may result in damage to equipment 3 Carefully lift actuator cover from actuator assem bly and tilt towards Turck connectors Raise cover high enough to be able to press the blue calibration button and be able to see the red LED on the top of assembly 4 On the main screen of the PL...

Page 52: ...4 4 VSG VSSG Installation Operation and Maintenance Manual Vilter Emerson 35391STG Section 4 Operation Figure 4 3 Overview Main Menu and Instrument Calibration Screens Compact Logix PLC ...

Page 53: ...n calibration mode it outputs 0V when the actuator is running and 5V when it is still Thus as stated earlier the actuator voltage will fluctuate during calibration After the actuator has been calibrated 0V output will correspond to the minimum position and 5V to the maximum position 9 Quickly press and release the blue push button on the actuator one time This places the actuator in calibration mo...

Page 54: ...1 VSG 2101 CCW CW CCW CW 1 48 533 5 823 0 87 313 3 433 VSG 2401 VSG 2601 VSG 2801 VSG 3001 CCW CW CCW CW 1 80 648 7 072 1 36 490 5 341 Table 4 1 Command Shaft Rotation Specifications Section 4 Operation The large gear on the command shaft has 50 teeth The teeth are counted when moving the command shaft from the minimum stop position to the maximum stop position The manual operating shaft on the ge...

Page 55: ... now calibrated and knows the minimum and maximum positions of the slide valve it controls Now the capacity or volume chan nel of the PLC can be calibrated 16 Use the DOWN button to move the actuator to wards its minimum position while watching the mV readout on the Control Panel screen Discontinue pressing the DOWN button when the mV reading the Current window above the Set Min button is approxim...

Page 56: ...ction temperature does not become too cold When the compressor stops the valve returns to fully open 100 Figure 4 6 Oil Temperature Control Valve Oil Mixing Valve FAIL POSITION The temperature control valve remains in the last po sition when power is removed SCREEN DISPLAY The oil temperature control valve identified as OIL MIX on the main PLC display screen shows a numer ical value with as units ...

Page 57: ...discharge shut off valves to isolate the compressor unit from house system Lockout tagout valves 4 Close any other valves that may feed gas or oil to Figure 4 7 PLC Main Screen Stop Button Discharge Status the compressor and oil separator 5 Slowly open suction oil charging valve to depres surize compressor unit to atmosphere see Figure 4 9 Keep valve in open position NOTE Plugs are installed on bl...

Page 58: ...qualizing Solenoid Figure 4 9 Suction Oil Charging Valve and Discharge Bleed Valve 12 Once pressure is reached stop purging and close suction oil charging valve If pressure is greater than 10 psig crack open discharge bleed valve as needed to slowly bleed the system to approxi mately 10 psig 13 Wait 10 minutes to make sure there are no leaks and that the pressure is holding If the unit does not ho...

Page 59: ...as Purging is recommended if the compressor will be inactive for 12 hours or more For additional long term storage information refer to Long Term Storage Recommendations in Section 3 PREPARATION WARNING When working with LFG NG or other dangerous or flammable gases ensure there are adequate ventilation and vapor detectors Refer to national fire and building codes Failure to comply may result in se...

Page 60: ...oil return valves 16 Remove purging hose from suction oil charging valve CAUTION With a purged system when getting the compressor unit ready for start up it is important to slowly open the suction valve to prevent a sudden rush of gas and oil Failure to comply may result in damage to equipment NOTE Plugs are installed on bleed valves Remove and install plugs prior to and after bleeding Ensure to k...

Page 61: ...Operation and Maintenance Manual Vilter Emerson 35391STG Figure 4 13 Suction Oil Charging Valve Section 4 Operation Equalizing Solenoid for Suction Bypass Figure 4 12 Equalizing Solenoid View Rotate 90 Suction Oil Charging Valve ...

Page 62: ...ide and compres sor to return this oil back to the compressor To adjust the return flow proceed with the follow procedure NOTE Do not fully open the needle valve unless directed by Vilter Customer Service Leaving the needle valve fully open will reduce efficiency of the compressor unit 1 Open shut off valve on coalescing side of oil separa tor see Figure 4 14 2 While the unit is in operation crack...

Page 63: ...lignment and Integrity I I I I I I I I I I I I I I Motor Compressor See Motor Manual for proper lubrication procedures and service intervals Control Calibration Transducers I I I I I I I I I I I I I I RTDs I I I I I I I I I I I I I I Slide Valve Motors Slide valve calibration should be inspected monthly Inspections can be performed through the control panel If a Non Movement Alarm appears calibrat...

Page 64: ...lation for Maintenance Service WARNING When working with LFG NG or other dangerous or flammable gases ensure there are adequate ventilation and vapor detectors Refer to national fire and building codes Failure to comply may result in serious injury or death WARNING Avoid skin contact with any condensate or oil Wear rubber gloves and a face shield when working with condensate or oil Failure to comp...

Page 65: ...e checked for leaks after servicing to ensure a tight system For additional leak testing information refer to Chapter VI of ASME B31 3 Process Piping Code CAUTION Do not hydro test compressur unit Failure to comply may result in damage to equipment 1 If servicing the compressor unit was completed proceed to step 2 Otherwise isolate the compres sor unit from the house system see Compressor Unit Iso...

Page 66: ...e 5 2 Fill out label for bottle Place in mailing tube and seal with the preaddressed mailing label Below are a few points to remember when taking a sample Sample running compressor units not cold units Sample upstream of the oil filter Create specific written procedures for sampling Ensure sampling valves and devices are thoroughly flushed prior to taking a sample Ensure samples are taken as sched...

Page 67: ...intain proper operation Never allow the oil to reach a level higher than the Maximum Operating Level since this may impair the operation and efficiency 1 Using a properly selected oil pump connect oil pump to suction oil charging valve see Figure 5 3 2 Open suction oil charging valve and fill oil separator to Normal Operating Level 3 Once the Normal Operating Level has been reached shut off the oi...

Page 68: ... Piping in Appendices NOTE Ensure to check the oil pressure drop and record it daily If the compressor unit is equipped with only a single oil filter the compressor unit must be shut down prior to servicing see Stopping Restarting procedure in Section 4 If the compressor unit is equipped with dual oil filters then one oil filter can be isolated and serviced one at a time during operation Each oil ...

Page 69: ...er element from oil filter canister 7 If equipped with dual oil filter elements remove two filter elements and filter element centering piece from oil filter canister Retain filter element centering piece 8 Thoroughly clean the oil filter canister spring plate and centering piece Inspect spring plate and Figure 5 5 Oil Filter Drain Vent and Shut Off Valves Drain Valve Inlet Shut Off Valves Vent Va...

Page 70: ...Isolate the compressor unit see Compressor Unit Isolation procedure 2 If required install lifting eyes on oil separator man hole cover see Figure 5 6 3 Secure appropriate lifting device to oil separator manhole cover 4 Remove all bolts except top four bolts securing oil separator manhole cover to oil separator vessel 5 Adjust lifting device as needed to hold weight of oil separator manhole cover 6...

Page 71: ...Close strainer drain valve 13 Open shut off valves 14 Check replaced components for leaks 15 Turn disconnect switches to the ON position for the compressor unit and oil pump motor starter if equipped 16 Start compressor unit Oil Pump Strainer To clean the oil pump strainer proceed with the following steps NOTICE Dispose of the oil in a appropriate manner following all Local State and Federal ordin...

Page 72: ...Hub Installation On all single screw units the coupling assembly is shipped loose and will have to be installed and aligned on site This is to allow a check of proper electrical phas ing and direction of motor rotation The motor and compressor have been aligned from the factory with the coupling hubs already installed Using a dial indicator for aligning is recommended NOTE Drive coupling type and ...

Page 73: ...unt of waviness in the flex disc pack when viewed from the side This will result in a flex disc pack that is centered and parallel to its mating flange faces Move the motor to obtain the correct axial spacing see Table 5 3 and Figure 5 8 21 Angular Alignment Rigidly mount a dial indicator on one hub or shaft reading the face of the other hub flange Rotate both shafts together making sure the shaft...

Page 74: ...aight 29 Install bolts and locking nuts to secure disc pack to motor hub 30 Tighten locking nuts see Table 5 4 Coupling Size Lock Nut Size Tightening Torque ft lbs Nm BP38U 5 16 24 22 30 BP41U 7 16 20 55 75 BP47U 9 16 18 120 163 BP54U 9 16 18 120 163 BP56U 9 16 18 120 163 Table 5 5 Disc Pack Installation Torque Specifications 31 Perform hot alignment Run compressor unit and allow to warm up comple...

Page 75: ...mber 9 For straight bore hubs remove clamping bolts and hub from shaft 10 For tapered bore hubs remove bolt lock washers large washer and hub from shaft Drive Coupling Type C Sure Flex Replacement Drive couplings that are the Type C Sure Flex type are always installed with a C flange between the compres sor and motor The coupling assembly alignments are built into the design and therefore should n...

Page 76: ...n clamping bolts see Table 5 6 16 Install key and hub on motor shaft as noted during removal Allow gap to install coupling sleeve 17 Install coupling sleeve on hubs Position hub on motor shaft on coupling sleeve as noted during removal 18 Install set screw in compressor hub to secure key in keyway Tighten set screw see Table 5 6 19 Install clamping bolts to secure hub to motor shaft Tighten clampi...

Page 77: ...ling Installation and Alignment procedure 28 Install coupling guard 29 Install nuts and bolts to secure discharge pipe to oil separator and compressor 30 Tighten nuts on discharge pipe to compressor flange first then tighten nuts on discharge pipe to oil separator flange see Appendix A Compressor Replacement Notify Vilter prior to performing a compressor replace ment See Warranty instructions in S...

Page 78: ... Washer Nut Shim Frame Compressor 31 Install nuts to secure suction strainer check valve assembly to compressor and suction stop valve 32 Tighten nuts on suction strainer check valve as sembly to compressor first then tighten nuts on suction strainer check valve assembly to suction stop valve refer to Appendix A 33 Install all lines to compressor 34 Install all cables to sensors on compressor and ...

Page 79: ...B 3 4 10 UNC 2B 5 8 11 UNC 2B Models Component Weights Gate Rotor Bearing Housing Gate Rotor Bearing Housing Cover Discharge Manifold Main Compressor Assembly ONLY Gate Rotor Cover 291 601 19 lbs 9 kg 11 lbs 5 kg 125 lbs 57 kg 1105 lbs 502 kg 46 lbs 21 kg 751 901 28 lbs 13 kg 11 lbs 5 kg 177 lbs 80 kg 1450 lbs 658 kg 33 lbs 15 kg 1051 1301 37 lbs 17 kg 13 lbs 6 kg 274 lbs 125 kg 2006 lbs 910 kg 42...

Page 80: ...101 Shown Center of Gravity Main Lift Point Lifting Eyes Figure 5 13 Bare Shaft Compressor Center of Gravity Discharge Manifold and Main Compressor Assembly Models 291 2101 Main Lift Point Lifting Eyes Discharge Manifold Main Compressor Assembly Center of Gravity Range Center of gravity may differ slightly between models 291 2101 Adjust main lift point within the range to keep bare shaft compresso...

Page 81: ...ty Models 2401 3001 Figure 5 14 Bare Shaft Compressor Assembly Center of Gravity Models 2401 3001 Center of Gravity Main Lift Point Lifting Eyes Figure 5 15 Bare Shaft Compressor Center of Gravity Discharge Manifold and Main Compressor Assembly Models 2401 3001 Discharge Manifold Main Compressor Assembly Center of Gravity Main Lift Point Lifting Eyes ...

Page 82: ...spection Compressor Shaft Bearing Float Inspections If float measurements are out of tolerance contact Vilter Customer Service for further assistance BEARING AXIAL FLOAT INSPECTION CAUTION When taking the measurements do not exceed 300 lbs of force at point of contact or damage may result to the bearings DETERMINE MAXIMUM APPLIED FORCE To determine maximum applied force take maximum applied force ...

Page 83: ...Blade Main Rotor Float Damper Pin and Bushing Bushing Damper Pin Table 5 9 Maximum Bearing Float Compressor Model Max Axial Float in mm Max Radial Float in mm Max Force at Hub Shaft lbf N Max Applied Force 36 Lever 6 Pivot lbf N All 0 002 0 051 300 1335 60 267 151 181 201 152 182 202 301 361 401 0 006 0 152 100 444 20 89 501 601 701 0 007 0 178 150 667 30 133 291 341 451 601 0 007 0 178 150 667 30...

Page 84: ...r at no time should the blade uncover the support 5 Inspect main rotor and gate rotor for abnormal wear due to dirt or other contaminants If dam aged replace gate rotor and or main rotor GATE ROTOR BEARING FLOAT INSPECTION 6 Using dial indicator position a dial indicator on the gate rotor see Figure 5 19 Side View Wooden block to prevent damage to gate rotor blade Direction of rotor movement Axial...

Page 85: ...ate rotor against the pin to remove float 1 Place a straight edge along the side of the gate ro tor see Figure 5 21 2 Measure the gap from the straight edge to the peak of the gate rotor support For minimum distance see Figure 5 20 3 Repeat steps 1 to 2 to check gap along entire gate rotor edge on both sides Figure 5 20 Gate Rotor and Support Clearance Minimum Clearances ...

Page 86: ...nce Manual Vilter Emerson 35391STG Section 5 Maintenance Service Figure 5 21 Gate Rotor and Support Clearance Measuring Gate Rotor Support Gate Rotor Straight Edge Gate Rotor Support Gate Rotor Straight Edge Gate Rotor Support Gate Rotor Straight Edge ...

Page 87: ...nstall thrust bearing removal and installation tool with smaller puller shoe Turn the jacking screw clockwise The thrust bearings and housing assembly will be pulled off the shaft and out of the frame 12 Remove bolts from roller bearing housing 13 Re install two bolts into jack bolt holes provided in housing to aid in removal 14 To remove the gate rotor support carefully move support in the opposi...

Page 88: ...precisely the same dimensionally as blades installed originally at factory Therefore the same amount of shims will be required for replacement blades 901C 90 1B 90 1A Figure 5 22 Gate Rotor Assembly Removal and Tools Figure 5 23 Gate Rotor Assembly Removal Use flats provided on gate rotor support to prevent rotation when removing bearing retainer For VSSG 291 601 compressors do not use side rails ...

Page 89: ...lade and the shelf rotate the gate rotor to find the tightest spot It should be between 0 003 0 004 0 076 0 102 mm Make adjustments if neces sary It is preferable to shim the gate rotor blade looser rather than tighter against the shelf see Figure 5 25 24 After clearance has been set install a new O ring 143 on bearing housing cover install cover and tighten the bolts to the recommended torque val...

Page 90: ...hould have the suction line properly supported before the bolts securing the line to the cover can be removed After the line is removed the cover can be removed per paragraph B 5 Turn the main rotor so the driving edge of the groove is between the top of the shelf or slightly below the back of the gate rotor support At this point install the gate rotor stabilizing tool 6 Remove plug on the thrust ...

Page 91: ...lf 14 Once the clearance is set remove the spindle Install new O ring apply Loctite 242 thread locker to the socket head cap screw clamping the thrust bear ings to the spindle Torque all bolts see Appendix A 15 Install side covers with new gaskets Tighten bolts see Appendix A The unit can now be evacuated and leak checked Check for 0 003 0 004 0 076 0 102 mm clearance between gate rotor blade and ...

Page 92: ...lly seated 5 Place blade assembly on gate rotor support Locating damper over pin 6 Install washer 119 and snap ring 130 on gate ro tor assembly The bevel on the snap ring must face away from the gate rotor blade After the gate rotor blade and support are assembled there should be a small amount of rotational movement between the gate rotor and support Figure 5 30 Gate Rotor Blade Installation Gate...

Page 93: ... thrust bearings on VSG 301 701 units 15 Install retainer in the back of the inner race of one of the thrust bearings The back of the inner race is the narrower of the two sides 16 The bearing with the retainer should be placed in the housing first retainer towards the support Install the second bearing The bearings should be positioned face to face This means that the larger sides of the inner ra...

Page 94: ...r starter if equipped 3 Allow compressor motor and surrounding compo nents to cool prior to servicing 4 Disconnect connectors from actuator NOTE Noteorientationofcomponentstoaidininstallation 5 Remove screws and lock washers securing actuator assembly to actuator mount 6 Remove actuator assembly from actuator mount INSTALLATION CAUTION When installing the slide valve actuator assembly loosen locki...

Page 95: ...the bolts into the threaded jacking holes to assist in removing the cover There will be a small amount of oil drainage as the cover is removed 2 Remove the rotating portion of the shaft seal 219C 3 Remove oil seal 230 from cover 4 Remove the stationary portion of the shaft seal 219B from the seal cover using a brass drift and hammer to tap it out from the back side of the seal cover 5 Seal with st...

Page 96: ...ompressor lubricating oil do not wipe or touch the face of the rotating portion of the seal Align the slot in the rotating seal with the drive pin on the compressor input shaft see Figure 5 35 Carefully push the seal on holding onto the out side area of the seal until the seal seats against the shoulder on the input shaft Make sure the seal is seated against the shoulder If the seal is not fully s...

Page 97: ...ore that second when going through the calibration proce dure Depress the button quickly and then let go Each second the button is held down counts as another press The actuator goes into calibration mode spontaneously The white calibrate wire in the grey Turck cable is grounding intermittently Tape the end of the white wire in the panel and make sure that it cannot touch metal A very strong sourc...

Page 98: ...e Clean and tighten The position sensor has failed Replace the actuator There is a broken motor lead or winding Replace the actuator The motor will not move in either direction The thermal switch has tripped be cause the motor is overheated The motor will resume operation when it cools This could be caused by a malfunctioning control panel Consult the factory Any of the reasons listed in The mo to...

Page 99: ...ither of the optocoupler slots 2 Using a digital multi meter measure the DC voltage between terminal 3 of the small terminal block and TP1 on the circuit board see Note 1 You should measure between 0 1 and 0 2 Volts 3 Next measure the DC voltage between terminal 3 and TP2 on the circuit board You should measure between 0 1 and 0 2 Volts __________________ This indicates a skipped state in the patt...

Page 100: ...re available consult your Vilter authorized distributor for details Another possible cause for this error is a stuck motor thermal switch The ther mal switch can be tested by measuring the DC voltage with a digital multi meter between the two TS1 wire pads see Note 2 If the switch is closed normal operation you will measure 0 Volts The 24V supply is voltage is low This will occur momentarily when ...

Page 101: ...ratio to create differential pres sure otherwise oil pressure can t be maintained Oil pressure is manifold oil pressure minus the suction pressure It is a net pressure If the oil pump is selected to be a part time oil pump in the Setup menu then ensure that it only shuts off at an appropriate pressure ration that takes into account pressure drops through the oil cooler This is a set point in the C...

Page 102: ...matic oil mixing valve In the Vilter Only menu ensure that you select Yes this unit has the oil mixing valve to enable it If your are controlling a step type oil cooler or a VFD oil cooler verify the correct one is selected in the Vilter Only menu and the amount of steps are entered in the menu screen Oil Cooler Step Control menu Check the oil cooler and associated piping to make sure it is full o...

Page 103: ...pad or floor Check supported pipes i e suction and discharge pipe and make sure they are adequately supported Check for loose bolts and nuts Check condition of compressor and motor i e alignments Excessive Motor Backspin If there is more than normal motor backspin at shutdown check suction check valve for proper operation Table 6 3 Troubleshooting Guide General Problems Solutions 3 of 3 Section 6 ...

Page 104: ...6 8 Blank VSG VSSG Installation Operation and Maintenance Manual Vilter Emerson 35391STG ...

Page 105: ...replacing the warranty part Ship the part to Vilter per the instructions on the RMA document Please include a copy of the RMA document in the box for identification purposes when the part is received 4 Part to be evaluated 5 Warranty Consideration Acceptance A credit will be provided for the customer part sales order Denial Notification of denial will be provid ed to the customer COMPRESSOR Due to...

Page 106: ...tative for further details Submit a new PO for the amount that will be needed for the rebuild The inspection cost will be waived upon receipt of the new PO Make sure to provide your Ship to Address and Billing Address EXPLANATION OF REBUILD LEVELS Level 1 Compressor is in good condition Replace bearings gas kets shaft seal and o rings All hardware is intended to be re used when possible Parts are ...

Page 107: ...r specific torque specifications when supplied 2 When using loctite torque values in this table are only accurate if bolts are tightened immediately after loctite is applied The proof strength of Grade 2 bolts is less for sizes 7 8 and above and therefore the torque values are less than smaller sizes of the same grade Torque Specifications for 17 4 Stainless Steel Fasteners ft lbs Type Bolt Nut He...

Page 108: ...T ANALYSIS REPORT Report Number Report Date 3 4 2013 Evaluation Physical Properties Results Spectrochemical Analysis 21 20 16 0 077 64 23 19 5 Feb 21 2013 6049 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Wear Metals ppm Contaminant Additive Metals ppm 21 19 16 0 106 64 47 147 7 Oct 19 2012 4809 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 21 19 14 0 080 66 00 41 4 Jul 26 2010 5190 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0...

Page 109: ...C VSG VSSG Installation Operation and Maintenance Manual Vilter Emerson 35391STG Appendix C Recommended Header Piping ...

Page 110: ...nochoiceandtheverticaldropsneedtobehigher thenanelectronicservice valve needs to be installed in the return line at the compressor Consult Factory If ambient temperatures get below 50 F heat trace and insulation on oil lines and air cooler headers needs to be used Maximum pressure drop on oil lines to and from air cooler and compressor should not exceed anymore than 5 to 10 psi Recommended locatio...

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Page 112: ...35391STG Rev 0 8 13 Emerson and Vilter are trademarks of Emerson Electric Co or one of its affiliated companies 2013 Emerson Climate Technologies Inc All rights reserved Printed in the USA ...