Emerson Vilter VSH, Installation, Operation & Maintenance Manual

Page 1: ...VSS VSM VSH VSSH Compressor Unit Installation Operation Maintenance Manual FOR UNITS BUILT AFTER JANUARY 1 2015 ...

Page 2: ......

Page 3: ...s to Vilter To the extent the Buyer has supplied specifications information representation of operating conditions or other data to Seller in the selection or design of the Products and the preparation of Seller s quotation and in the event that actual operating conditions or other conditions differ from those represented by Buyer any warranties or other provisions contained herein which are affec...

Page 4: ...cts found by Seller to be defective Failure by Buyer to give such written notice within the applicable time period will be deemed an absolute and unconditional waiver of Buyer s claim for such defects Buyer assumes all other responsibility for any loss damage or injury to persons or property arising out of connected with or resulting from the use of the Products either alone or in combination with...

Page 5: ...re must be exercised in properly designing and maintaining the system to prevent conditions that could lead to liquid carry over Vilter Manufacturing is not responsible for the system orthecontrolsneededtopreventliquidcarryoverandassuchVilterManufacturingcannotwarrantequipment damaged by improperly protected or operating systems VilterTM screw compressor components are thoroughly inspected at the ...

Page 6: ...g transposed harmonised European Standards have been used EN ISO 12100 1 2010 Safety of Machinery General principles for design Risk assessment and risk reduction EN ISO 13857 2008 Safety of Machinery Safety distances to prevent danger zones being reached by the upper and lower limbs EN349 1993 A1 2008 Safety of Machinery Minimum gaps to avoid crushing hazards EN ISO 13850 2015 Safety of Machinery...

Page 7: ... 2 Theory Of Operation Refrigerant Flow 2 1 Oil Life and Oil Flow 2 1 Oil Cooling 2 2 Water Cooled Oil Cooling 2 2 Liquid Injection Oil Cooling 2 2 V Plus Oil Cooling 2 2 Thermosyphon Oil Cooling 2 2 Control System 2 3 Temperature Elements Pressure Transmitters and Indicators 2 3 Section 3 Installation Delivery Inspection 3 1 Rigging and Lifting of Compressor Unit 3 1 Compressor Unit Inspections P...

Page 8: ...peration 4 3 Calibrate Slide Valve Actuators For Units Using Vission20 20 4 4 Calibrate Slide Valve Actuators For Units Using Compact Logix PLC 4 10 Compressor Control with Vission20 20 Micro Controller No Slide Operation 4 15 Coalescing Oil Return Line Setup 4 16 Suction Equalizing Line Setup For VSS VSM Compressors 4 17 Dual Oil Filter Setup For Oil Filters With Filter Head Assemblies 4 18 Stop ...

Page 9: ... Element Removal For 3111A Oil Filter Housing 5 19 Oil Filter Element Removal For 3110A or 3112A Oil Filter Housing 5 20 Oil Filter Element Installation For 3111A Oil Filter Housing 5 20 Oil Filter Element Installation For 3110A or 3112A Oil Filter Housing 5 20 Oil Separator Coalescing Filter Replacement 5 21 Removal 5 21 Installation 5 21 Oil Separator Heater Cartridge Replacement 5 23 Parts Requ...

Page 10: ...r Bearing Installation 5 52 Gaterotor Disassembly VSM 97 127 Compressors Only 5 53 Gaterotor Blade Removal 5 53 Gaterotor Blade Installation 5 53 Gaterotor Thrust Bearing Removal 5 54 Gaterotor Thrust Bearing Installation 5 54 Gaterotor Roller Bearing Removal 5 54 Gaterotor Roller Bearing Installation 5 54 Compressor Shaft Seal Replacement 5 55 Shaft Seal Assembly 5 55 Handling Seal Face with Care...

Page 11: ... 3001 Only 8 16 Slide Valve Carriage Assembly 8 18 Actuator and Command Shaft 8 21 Miscellaneous Frame Components 8 22 Miscellaneous Frame Components Tubing and Fittings 8 25 Replacement Tools 8 25 Replacement Parts 8 28 VSM 301 701 Recommended Spare Parts List 8 31 Gaterotor Assembly 8 31 Shaft Seal 8 34 Main Rotor 8 35 Slide Valve Cross Shafts and End Plate 8 36 Slide Valve Carriage Assembly 8 3...

Page 12: ...5 42 Table 5 15 Shaft Seal Tool Kits 5 56 Table 5 16 VSH VSSH Shaft Seals 5 58 Table 5 17 Coils For Solenoid Valves ICFE 5 67 Table 5 18 Parts For Motorized Valve Station ICF 5 67 Table 5 19 Torque Specifications ft lbs 5 68 Table 6 1 Slide Valve Actuator Troubleshooting Guide 1 of 3 6 1 Table 6 2 Slide Valve Actuator LED Blink Codes 1 of 2 6 3 Table 6 3 Troubleshooting Guide General Problems Solu...

Page 13: ...Taking Process 5 10 Figure 5 7 Oil Strainer Drain Valve and Oil Separator Drain Valve 5 11 Figure 5 8 Suction Oil Charging Valve 5 12 Figure 5 9 Filter Assembly and Oil Strainer Drain Valve VPN 3111A Oil Filter Housing Shown 5 14 Figure 5 10 Filter Assembly Vpn 3112A Oil Filter Housing Shown 5 15 Figure 5 11 Duplex Oil Filter Assembly VPN 3110A Double Oil Filter Housing Shown 5 16 Figure 5 12 Dual...

Page 14: ... Clearance 5 50 Figure 5 50 Gaterotor Blade Assembly 5 50 Figure 5 51 Gaterotor Blade Installation 5 51 Figure 5 52 Gaterotor Thrust Bearing 5 51 Figure 5 53 Thrust Bearing Installation 5 51 Figure 5 54 Roller Bearing Assembly 5 52 Figure 5 55 Gaterotor Support VSM 97 127 5 53 Figure 5 56 Gaterotor Blade Installation 5 53 Figure 5 57 Gaterotor Thrust Bearing VSM 97 127 5 54 Figure 5 58 Shaft Seal ...

Page 15: ...areincludedtoillustratekeyconcepts Safety precautions are shown throughout the manual They are defined as the following NOTICE Notice statements are shown when there are important information 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 avo...

Page 16: ...with Oil Pump HN High Stage No Oil Pump SOI Suction Oil Injection B Booster S Swing Driver V Variable Frequency Drive E Electric Motor Drive G Engine Drive Economizer N No Economizer Economizer Ports Plugged E Economizer Connection Ports Piped to Single Flange F Economizer Flanges Flanged Port Covers piping by others Oil Filter S Single Filter D Dual Filter Oil Cooler PL Plate ST Shell and Tube Li...

Page 17: ...e 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 system mounted on...

Page 18: ...l Pump 20 Oil Sight Glass 21 Oil Pump Strainer 22 Oil Pressure Relief Valve 23 Oil Temperature Control Valve Oil Mixing Valve 24 Oil Cooler Plate Heat Exchanger 25 Oil Separator 26 Discharge Connection 27 Coalescing Oil Return Line 28 Heater Wiring Panel 29 Economizer Connection Flange 30 Nameplate 31 Suction Equalizing Line 32 Oil Separator Certification Plate Compressor Unit Component Identifica...

Page 19: ... VSM VSH VSSH Installation Operation and Maintenance Manual Emerson 35391SD 26 21 29 28 2 Figure 1 1 Refrigeration Compressor Unit Components 2 of 3 Section 1 General Information 5 7 27 1 19 18 30 30 32 17b 31 ...

Page 20: ...cer Suction Pressure 37 Pressure Transducer Discharge Pressure 38 Temperature Element Oil Separator 39 Temperature Element Oil Injection Compressor Unit Component Identification Continued 40 Capacity Slide Valve Actuator 41 Volume Slide Valve Actuator 42 Temperature Element Discharge Figure 1 1 Refrigeration Compressor Unit Components 3 of 3 Section 1 General Information 42 33 34 35 36 37 38 39 41...

Page 21: ... 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 Liquid Level High High Shutdown LAL Liquid Lev...

Page 22: ...tdown 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 Temperature Switch Low Low Shutdown TT...

Page 23: ...otorized 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 NPT Venturi Injector Nozzle V...

Page 24: ... 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 25: ...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 26: ...ter 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 Vacuum ...

Page 27: ...Flow Oil in the refrigeration system serves three primary pur poses They are compressor lubrication sealing clear ances between moving parts and heat removal result ing from heat of compression and friction Initially oil flow is driven by a mechanical gear pump 3 Once the system reaches design conditions the oil pump is shut off and oil flow is maintained by differential pressure As the oil is sep...

Page 28: ...the following manner Using high pressure liquid the point of injection can be the discharge line and no horsepower penalty is paid by injecting liquid into the compressor discharge line The high pressure gas source normally used for the pressure regulator would be compressor discharge pressure Since on a booster unit this intermediate pressure is very rarely as high as the nominal setting of 70 ps...

Page 29: ...re to comply may result in serious injury or death Temperature Elements Pressure Transmitters and Indicators Temperature elements TE pressure transmitters PT and pressure indicators PI are instruments used to measure temperatures and pressures at specific loca tions on the compressor unit Temperature elements are typically mounted on the compressor suction pipe dis charge pipe oil separator oil fi...

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Page 31: ...ring the compressor unit Ensure there is plenty of space to maneuver the com pressor unit and a clear path to its location NOTICE Vilter compressors are to be installed and connected to the customer provided piping Vilter expects this piping to be designed and built following ASME B31 3 Process Piping Guide plus any other local applicable codes and that the installation will be performed by qualifi...

Page 32: ...ry nitrogen Look into the suction and discharge connections and inspect for any signs of corrosion on parts Prelube the compressor with the main oil pump and rotate by hand several revolutions prior to start Notify Vilter Service and Warranty Department when the compressor is started NOTE For Pre Start Up and Start Up checklists please contact Vilter Service and Warranty Department CAUTION Before ...

Page 33: ...sing the grease specified on the motor lubrication nameplate Long Term Storage Recommendations The procedure described is a general recommendation for long term storage over one month of no operation of Vilter compressor units It is the responsibility of the installation firm and end user to address any unusual conditions Use the supplied long term storage log sheet to help with record keeping see...

Page 34: ...ther valves except those venting and draining 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 Lea...

Page 35: ...gate to build the foundation Also there should be enough sand to provide a base of compacted sand four inches thick for the foundation to rest on see Figure 1 Concrete 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 recom mended grout is Masterflow 648CP high performance non shrink grout to ...

Page 36: ...O FROST DEPTH AS REQ D AND BACKFILL WITH CLSM OR NON FROST SUSCEPTIBLE FILL 4 COMPACTED SAND G A CLEARANCE FOR REPLACING ELEMENTS Figure 3 2 Concrete Pad with Compressor Unit Dimensions Side View VilterTM foundation drawing When all rebars are in place the concrete can be poured The concrete must then be trolled level and a surface texture etched in place Leave the concrete to cure for at least 28...

Page 37: ...ighter bond Follow the manufacturer s recommenda tions for setting precautions mixing and grout place ment finishing and curing The grout must be worked under all areas of the feet with no bubbles or voids If the grout is settled with a slight outside slope oil and water can run off of the base Once the grout has cured torque the anchor bolts as per HILTI instructions Figure 3 3 Concrete Pad with ...

Page 38: ...it weight 20 000 lbs RPM 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 ...

Page 39: ...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 40: ...3 10 Section 3 Installation VSS VSM VSH VSSH Installation Operation and Maintenance Manual Emerson 35391SD Figure 3 8 Concrete Pad Housekeeping Detail ...

Page 41: ...ring towards the bottom see Figure The drill fixture is designed so that the hole for the spring will always be drilled on the opposite side from the cast in Vilter name on the bon net From the outside of the valve the casting numbers must always be towards the top of the valve 1 For VSM 97 VSM 113 and VSM 127 this is just a Stop Valve Correct Wrong Wrong Correct Verify the location of the Spring ...

Page 42: ... prevent vibration being transmitted through the pipe lines to the buildings One method of provid ing the needed flexibility to absorb the vibration is to provide long lines that are broken by 90 Ells in three directions A second method would be to install flexible pipe couplings as close to the compressor unit as possible with connections run in two different directions 90 apart These flexible co...

Page 43: ...taken from ASHRAE 15 89 and ANSI ASME B31 5 The installing contractor should be thor oughly familiar with these codes as well as any local codes CAUTION Accumulated liquid in the suction header can damage the compressor if not drained Always drain headers suction and discharge headers prior to start ups Failuretocomplymayresultindamagetoequipment Flange Loads The ideal load applied to flanges of t...

Page 44: ...d discharge headers prior to start ups Failuretocomplymayresultindamagetoequipment Remote Air Cooled Oil Cooler Piping If equipped with a remote air cooled oil cooler it is im portant that the piping be installed correctly to and from the compressor unit and remote air cooled oil cooler Outlet must be on top inlet on bottom Vertical drops should be no higher than 8 to 10 feet If there is no choice...

Page 45: ...n compressor see Figure 3 12 2 An auxiliary contact from compressor motor starter is required Connect isolated contact to terminal blocks 1 and 31 3 A dry contact from control relay CR11 must be wired to compressor motor starter coil This dry contact is wiredtoterminalblocksaccordingtosupplieddraw ing Control power for this coil should come from a source which will be de energized with compressor ...

Page 46: ...R CONTROL IF REQUIRED CONTROL POWER DISCONNECT AND BRANCH CIRCUIT PROTECTION TO BE SIZED PER THE NATIONAL ELECTRIC CODE INCOMING POWER SUPPLIED FROM REMOTE CUSTOMER SUPPLIED UL LISTED FUSED DISCONNECT OR BREAKER FLA X X AMPS 115VAC 60HZ HL SHUTDOWN AUX 1 1 INPUT OUTPUT RS 50 24 RD 35 A GND 1 1B OUTPUTS GND HP1 5 12 COM 12VDC 5VDC OUTPUT 2 1C INPUT DIGITAL OUTPUT BOARD 1 PLUG X2 DIGITAL OUTPUT BOAR...

Page 47: ...00 WATT 8 7 AMPS 750 WATT 6 5 AMPS OIL PUMP MOTOR FEED 480 VAC OIL SEPARATOR HEATER FEED 120VAC OIL SEPARATOR HEATER FEED 120VAC OIL SEPARATOR HEATER FEED 120VAC EQUIPMENT GROUND 1T1 1T2 1T3 N OIL SEPARATOR HEATER 52 GND N OIL SEPARATOR HEATER 54 N OIL SEPARATOR HEATER 56 GND GND T1 T2 T3 52 N 54 N 56 N INTERNAL PANEL WIRING FACTORY VILTER SHOP WIRING FIELD WIRING BY OTHERS Figure 3 13 Example Int...

Page 48: ...use the machine to freeze and clog the strainer A mixture of four parts water to one part liquid soap with a few drops of glycerin added makes a good solu tion Apply this mixture with a one inch round brush at all flanges threaded joints and welds Repair all visible leaks If possible leave the pressure on over night A small pressure drop of 5 lbs Over this period indicates a very tight system Reme...

Page 49: ...m gauge to the system in accordance with the manufacturer s instructions A single evacuation of the system does not satisfac torily remove all of the non condensable air and wa ter vapor To do a complete job a triple evacuation is recommended 2 Information taken from Commercial CO2 Refrigeration Systems Guide for Subcritical and Transcritical CO2 Applications by Emerson When the pump is first turn...

Page 50: ...ng WARNING Avoid skin contact with oil Wear rubber gloves and a face shield when working with oil Failure to comply may result in serious injury or death NOTICE Failure to follow these instructions will result in bearing damage and compressor seizing and will void any and all warranties that may apply NOTICE Do not put oil under vacuum Use an oil pump to charge oil Typically the compressor unit is...

Page 51: ...posi tion In this case make sure valves 2 3 5 6 and 7 are in the open position 16 Energize compressor unit Vission 20 20 will ener gize oil heaters 17 Run oil pump 4 for 15 seconds only 18 Wait minimum of 30 minutes to allow oil to drain from compressor 8 19 If compressor unit is not being started right away repeat steps 6 to 9 prior to starting Figure 3 16 Oil Drain Valve Oil Drain Valve Oil Sepa...

Page 52: ...quid refrigerant or oil Wear rubber gloves and a face shield when working with liquid refrigerant or oil Failure to comply may result in serious injury or death CAUTION Ensure compressor unit has been charged with the correct amount of oil prior to initial refrigerant charging Failure to comply may result in damage to equipment CAUTION Do not apply flame or steam directly to drum as this can produc...

Page 53: ... no bubbles and there will be a liquid seal in the re ceiver If these two conditions are not satisfied ad ditional refrigerant must be added 6 When sufficient refrigerant has been charged into the system close the charging and drum valves Then remove the drum from the system 7 During the charging period observe the gauge carefully to insure no operating difficulties Watch head pressures closely to...

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Page 55: ...when working with liquid refrigerant or oil Failure to comply may result in serious injury or death WARNING Avoid skin contact with oil Wear rubber gloves and a face shield when working with oil Failure to comply may result in serious injury or death Inspect oil level through sight glasses on the oil separa tor see Figure 4 1 Oil Operating Levels Drain or fill oil as required For oil draining and ...

Page 56: ...NING Software programming credentials shall only be made available by the supplier The user will only have access to operational features established by the supplier Failure to comply may result in serious injury or death Starting Before the screw compressor unit can start certain con ditions must be met All of the safety setpoints must be in a normal condition and the suction pressure must be abo...

Page 57: ... one side of the slot and a phototransistor on the other The phototransistor behaves as a light controlled switch When the photochopper fence is blocking the slot light from the LED is prevented from reaching the phototransistor and the switch is open When photochopper fence is not blocking the slot the switch is closed As the motor turns the photochopper fence alternately blocks and opens the opt...

Page 58: ...age to wires Failure to comply may result in damage to equipment Blue Calibrate Button Red LED Actuator Plastic Cover Actuator Assembly Figure 4 2 Actuator Assembly View Rotate 180 Calibrate Slide Valve Actuators For Units Using Vission20 20 1 Slide valve actuators must be installed prior to calibra tion Refer to Slide Valve Actuator Installation proce dure The following steps pertain to calibrati...

Page 59: ...bly and tilt towards connectors Raise cover high enough to be able to press the blue calibration but ton and be able to see the red LED on the top of assembly Figure 4 3 Slide Valve Calibration Screen Vission 20 20 Calibration Buttons 4 Logging on into the Vission20 20TM with high level access will prompt the Calibration buttons to ap pear see Figure 4 3 ...

Page 60: ...enu then press the Slide Calibration button to enter the slide calibra tion screen see Figure 4 4 6 If the compressor unit is starting for the first time or a new actuator was installed connect connec tors of power cable and position transmitter cable to new actuator Figure 4 4 Menu Screen and Slide Calibration Button Vission 20 20 ...

Page 61: ...the blue push button on the actuator one time This places the actuator in calibration mode The red LED will begin flashing rapidly CAUTION DO NOT CONTINUE TO ENERGIZE THE ACTUATOR MOTOR AFTER THE SLIDE HAS REACHED THE MECHANICAL STOP Doing so may cause mechanical damage to the motor or shear the motor shaft key When the slide has reached the mechanical stop position press the button in the center ...

Page 62: ... CW CCW CW 1 48 533 5 823 0 87 313 3 433 VSS 1801 CCW CW CCW CW 1 36 490 5 325 0 82 295 3 200 VSS 1851 VSS 2101 CCW CW CCW CW 1 48 533 5 823 0 87 313 3 433 VSS 2401 VSS 2601 VSS 2801 VSS 3001 CCW CW CCW CW 1 80 648 7 072 1 36 490 5 341 Table 4 1 Command Shaft Rotation Specifications The large gear on the command shaft has 50 teeth The teeth are counted when moving the command shaft from the minimu...

Page 63: ...t to disengage the brake slowly releasing tension from the motor mount Use the button to pulse the actuator to where the slide is just off of its mechani cal stop and there is no tension on the motor shaft NOTE After the blue button is pressed for the third time an mV reading will be displayed in the Current field Make sure the mV value is at least 150 to 200 mV higher than the max setpoint on the...

Page 64: ...motor has been installed There is an error code flashing on the actuator s circuit board an attempt to recalibrate should be made The range of travel is not correct and the command shaft travel is physically correct The compressor is pulling high amperage the cali bration of the volume slide should be checked An actuator does not unload below 5 or an actua tor that doesn t move Something is not wo...

Page 65: ...y release the tension on the actuator motor NOTE The Slide calibration screen on the Control Panel has a Current window which displays twice the actuator output voltage This value the volume and the capacity displayed in the Current Vol and Current Cap Windows are meaningless until calibration has been completed 10 Use the DOWN button on the Control panel to drive the slide valve to its minimum me...

Page 66: ...4 12 Section 4 Operation VSS VSM VSH VSSH Installation Operation and Maintenance Manual Emerson 35391SD Figure 4 8 Overview Main Menu and Instrument Calibration Screens Compact Logix PLC ...

Page 67: ...tallation Operation and Maintenance Manual Emerson 35391SD Figure 4 9 Slide Calibration Screen Compact Logix PLC Press down on Photo chopper to release tension from mo tor shaft Figure 4 10 Photo chopper Screen colors inverted for ease of reading ...

Page 68: ... 300 mV below recorded maximum mV 21 Press the Set Max button 22 Press the Main button to complete calibration and exit the Slide Calibration screen The con troller will automatically energize the actuator and drive it back to its minimum position below 5 for pre start up NOTE Now the Current Cap or the Current Vol value will be displayed in the window on the Main screen and the Slide Calibration ...

Page 69: ... select either VSG VSH or VSM from the Compressor combo box in page 2 of the Configuration Menu and then the Model from the next box The choice of this type of compressor will cause the re frigerant combo box to be grayed out Once the compressor has been selected the Vission 20 20 panel touchscreen will show an indicator of VFD speed percentage and buttons to increase and decrease it For more info...

Page 70: ...e NOTE Do not fully open the needle valve unless directed by VilterTM Technical Support 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 13 2 While the unit is in operation crack open needle valve and observe oil flow through sight glass 3 Slowlyopenneedlevalvemoreuntilasmallamount of oil is se...

Page 71: ...he oil separator the longer system pressure will take to equalize to suction pressure 1 To open valve turn counterclockwise To close valve turn clockwise Figure 4 14 Suction Equalizing Line and Valve Suction Equalizing Line Suction Equalizing Valve 2 Fully close valve to a stop 3 Turn valve to fully open position while counting number of turns to fully open Note total number of turns 4 Adjust valv...

Page 72: ...with the following steps NOTE Inlet Oil Pressure Transducer should only read oil pressure from active oil filter 1 Decide which oil filter will be active in use Outlet Oil Filter Shut Off Valves Inlet Oil Filter Shut Off Valves Inlet Oil Pressure Shut Off Valves 2 Open inlet and outlet oil filter shut off valves to active oil filter 3 Open inlet oil pressure shut off valve for active oil filter 4 ...

Page 73: ...ze 1 5 2 2 5 3 4 5 6 8 Number of Turns Open From Closed Position 2 2 25 2 75 3 25 4 5 3 75 5 75 7 75 Auto In the Auto Position the stop valve is operating as a check valve allowing flow in the directions of the arrows To set the valve to the automatic position fully close the valve and turn the stem out as indicated by the chart below Open In the manually Open Position with the valve stem fully ba...

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Page 75: ...arm appears calibrate immediately Compressor Compressor w Slides 4 I I I I I I I Compressor w o Slides 5 I I I I I I I I I I I I Inspect for Back Spin Inspect Every 5 000 Hours or As Needed Inspect for Leak Check Monthly Bearings I I Inspect S Sampling R Replace 1 The oil should be changed at these intervals unless oil analysis results exceed the allowable limits The frequency of changes will depe...

Page 76: ...edures and service intervals Control Calibration Transducers I I I I I I I I I I I I I I RTDs TTs 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 calibrate immediately Compressor Compressor See Table 5 2b for Service Schedule Timeline details Inspect for Back Sp...

Page 77: ...0 I I I R I I R I I R I 500 600 I I I R I I R I I R I I R I Inspect R Replace Bearings Inspect per Chart Table 5 2b Maintenance Service Schedule For VSH VSSH Compressor Only NOTE Upon Inspection if any component shows wear beyond what is allowed in the Service section of this document the component s must be replaced Notes Inspection includes Gaterotor Inspection backlash measurement shelf clearan...

Page 78: ...libration and operation of all controls par ticularly safety controls 12 Check oil cooler for any evidence of corrosion scal ing or other fouling 13 Operate compressor capacity and volume ratio controls through their range both automatically and manually Trimonthly Approximately 2000 operating hours A Check movement of compressor rotor at drive cou pling end to determine bearing float see Compress...

Page 79: ...ces before opening any part of the package unit to atmosphere The compressor unit must be isolated and depressurized to atmosphere prior to servicing 1 Shut down the compressor unit refer to Stopping Restarting procedure in Section 4 2 Turn motor and oil pump starter disconnect switch es into the OFF position Lock out tag out discon nect switches 3 If suction equalizing valve is not open open it t...

Page 80: ...e cautious when isolating sections of CO2 piping CO2 has a very steep pressure curve and as sections containing CO2 warm up pressures can rise dramatically well beyond system design 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...

Page 81: ...g 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 Improper selection or application of fluid diagnostic products can cause serious injury or damage The user is solely responsible for making the final selectionofproduc...

Page 82: ...sis lab immediately af ter sampling do not wait 24 hours Figure 5 2 Oil Analysis Kit VPN 3097A Figure 5 3 Oil Sampler Valve VPN 3708A For Gas Compression Applications Sampling Procedure THE SAMPLING PRESSURE RANGE IS LIMITED BETWEEN 5 TO 750 PSI 0 03 5 17 MPa IF THE OPERATING PRESSURE IS ABOVE 750 PSI 5 17 MPa THE OIL SAMPLING MUST BE DONE WHEN THE COMPRESSOR IS NOT RUNNING AND ENSURE THE SYSTEM P...

Page 83: ...e 5 4 Oil Sampling Valve VPN 3709A For Ammonia and Refrigerant Compressors a Oil Sampler Valve for Ammonia and Other Re frigerants Applications b Valve shown ready for oil sampling c Valve shown in lockout position Figure 5 5 Operating the Oil Sampling Valve Button being pressed valve open Button released valve closed ...

Page 84: ...hen wait for thefoamtodissipate Repeatthisstepasmanytimes as necessary around 4 to 6 times until the clear oil level reaches full see sequence in Figure 5 6 4 After all the foam dissipates tighten the sample bottle cap 5 Tighten the oil sampling valve cap 6 For valve 3709A only back seat the knurled lock nut by turning it counter clockwise This is to pre vent any accidental release see Figure 5 4 ...

Page 85: ... WARNING Donotdrainoilfromdrainvalvewhilethecompressor unitisrunning Shutdowntheunitandallowpressures to equalize to suction pressure prior to draining Failure to comply may result in serious injury Thecompressorunitmustbeshutdownpriortodraining due to high pressures in the oil system see Compressor Unit Isolation procedure Draining can be performed through the drain valve lo cated underneath the ...

Page 86: ...ntil the oil level reaches the normal operating level Watch this level carefully to maintain 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 2 Open suction oil charging valve and fill oil separator to Normal Operating L...

Page 87: ...nly replace with O ring VPN 3111AB after removing drain plug Drain plug and O ring are not shown in this procedure Drain Oil From Isolated Oil Line 1 Isolate the compressor unit see Compressor Unit Isolation procedure 2 Close oil supply valve and oil filter outlet valve to isolate oil filter assembly and oil pump strainer for servicing 3 Remove plug from drain valve on oil pump strainer 4 If neede...

Page 88: ...using cover and O ring from oil filter housing Discard O ring 14 Remove filter element from internal port of head assembly 15 Clean filter element connection area of head as sembly and interior of filter housing and cover Oil Pump Strainer Screen Removal and Service 16 Remove four bolts and strainer cover from strainer body 17 Remove screen from strainer body 18 Clean screen and interior of strain...

Page 89: ...all plug on bleed valve of filter housing 33 Slowly open oil supply valve and allow oil to fill oil line 34 Open filter outlet valve 35 Check oil level and fill oil separator to non operat ing level see Oil Charging procedure Oil Filter Element Installation For 3110A OR 3112A Oil Filter Housing See Figure 5 10 36 Install new filter element on internal port of head assembly Make sure filter element...

Page 90: ...s ensure there is adequate ventilation and refrigerant vapor detectors as per ASHRAE standards Failure to comply may result in serious injury or death WARNING Avoid skin contact with oil Wear rubber gloves and a face shield when working with oil Failure to comply may result in serious injury or death Change the oil filter as outlined in the Maintenance and Service Interval see Table 5 1 Maintenanc...

Page 91: ...is only one oil filter head assembly for both oil filters See Table 5 3 for the parts required for an oil filter re placement with their part numbers To replace an oil filter element continue with the follow ing steps NOTE For filter housings with drain plugs only replace with O ring VPN 3111AB after removing drain plug Drain plug and O ring are not shown in this procedure Installation 8 Before re...

Page 92: ...for oil filter to allow oil pressure to be read from oil filter that is now active 3 Slowly open outlet oil filter shut off valve to oil filter that is now active Outlet Oil Filter Shut Off Valves Inlet Oil Filter Shut Off Valves Inlet Oil Pressure Shut Off Valves Figure 5 12 Dual Oil Filter 3111A Oil Filter Housings Shown Oil Filters Plugs and Bleed Valves Plug 4 Slowly close inlet and outlet oil...

Page 93: ...all Local State and Federal laws and ordinances 9 Remove locking ring and filter housing from head assembly 10 Remove filter element from internal port of head assembly 11 Clean filter element connection area of head as sembly and interior of filter housing 12 Remove head to housing O ring from inside of filter head Discard O ring Oil Filter Drain Valve OIL OUTLET TO COMPRESSOR Oil Filter Head Ass...

Page 94: ...000 mi crons and close bleed valve 23 Install plug on bleed valve of filter housing 24 Slowly open oil supply valve and allow oil to fill oil line 25 Open filter outlet valve 26 Check oil level and fill oil separator to non operat ing level see Oil Charging procedure Oil Filter Element Installation For 3110A OR 3112A Oil Filter Housing See Figure 5 14 27 Install new filter element on internal port...

Page 95: ...e 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 Remove remaining four bolts and oil separator manhole cover from oil separator vessel 7 Remove nuts flat washer and cover plate securing coalescing oil filter to hold down rod 8 With ...

Page 96: ...lter Assemblies Oil Separator Vessel Vertical Oil Separator Manhole Cover Hold Down Rod Coalescing Filter Centering Strap Flat Washers Nuts Gasket Oil Separator Manhole Cover Centering Strap Nuts Coalescing Filter Hold Down Rod 3 4 in O D Tubing 6 ft long Flat Washer Oil Separator Vessel Horizontal Pipe Stub Pipe Stub Horizontal Oil Separator Vertical Oil Separator Gasket ...

Page 97: ...ctors 4 Disconnect Turck connector Heater Cartridges with loose wires 5 Remove junction cover to gain access to heater car tridge wires NOTE Note location of wires to aid in installation 6 Disconnect wires 7 Remove cable connector 8 Remove cable and wires from junction 9 Remove junction from heater cartridge 10 Remove heater cartridge from thermowell Installation 11 Apply anti seize to threads of ...

Page 98: ...crew 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 size can be determined by the in...

Page 99: ...will provide longer service with smoother operation The flex disc pack is designed to an optimal thickness and is not to be used for axial adjustments 21 Axial Spacing The axial spacing of the shafts should be positioned so that the flex disc packs are flat when the equipment is running under normal op erating conditions This means there is a minimal amount of waviness in the flex disc pack when v...

Page 100: ...emove the disc pack alignment bolt Proceed to mount the second disc pack to the other hub in the same way Ensure that the beveled part of the washer is against the disc pack 24 Install bolts and locking nuts to secure both disc packs to center member 25 Tighten locking nuts 26 If room is required to install center member adjust hub position accordingly If both the motor and compressor hubs are str...

Page 101: ...emove center member 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 the...

Page 102: ...e 5 7 15 Install clamping bolts to secure hub on compressor shaft Tighten clamping bolts see Table 5 7 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...

Page 103: ...at washers 2 and screws 1 to se cure upper guard 7 to ring mounting guard 5 16 Install eight flat washers 2 and screws 1 to se cure upper guard 7 to lower guard 8 17 Return compressor unit to service Coupling Guard Replacement NOTE Coupling guards may differ slightly but this replacement procedure can be used to remove and installthem Thecouplingguardassemblydescribed in this procedure is VPN A274...

Page 104: ...points 16 Installappropriateliftingeyesontopofcompressor 17 Using appropriate lifting device and additional per sonnel remove compressor from frame Figure 5 20 Compressor Replacement and Hardware Assembly VSS 2401 3001 Shown Nut Lock Washer Flat Washer Spherical Washer Assembly Stud Flat Washer Lock Washer Nut Shim Frame Compressor Compressor Replacement Notify VilterTM prior to performing a compr...

Page 105: ...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 34 Install all lines to compressor 35 Install all cables to sensors on compressor and actuator 36 Perform leak check see Compressor Unit Leak Check procedure Bareshaft Compressor Lifting Points and Weights Models Component Weights Gaterotor Bearing...

Page 106: ... Main Compressor Assembly Gaterotor Cover Gaterotor Bearing Housing Cover Gaterotor Bearing Housing Model 1551 2101 Shown MAIN HOUSING LIFTING POINT 1 2 13 UNC Main Lift Point Center of Gravity Lifting Eye Lifting Eye Lifting Point A 1 2 13 UNC Lifting Point B 1 2 13 UNC ROLLER BEARING HOUSING GATEROTOR BALL BEARING SUPPORT GATEROTOR COVER Figure 5 22 Bareshaft Compressor Assembly Center of Gravit...

Page 107: ...101 Shown Center of Gravity Main Lift Point Lifting Eyes Figure 5 24 Bareshaft 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 bareshaft compressor ...

Page 108: ...ity Models 2401 3001 Figure 5 25 Bareshaft Compressor Assembly Center of Gravity Models 2401 3001 Center of Gravity Main Lift Point Lifting Eyes Figure 5 26 Bareshaft 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 109: ...View Wooden block or fulcrum Direction of shaft movement Rigidly attach dial indicator Position on axis of compressor Applied Force Shaft being pushed by use of lever Figure 5 27 Bearing Axial Clearance Inspection Compressor Inspection Compressor Shaft Bearing Clearance Inspections If clearance measurements are out of tolerance contact Vilter Technical Support for further assistance CAUTION When t...

Page 110: ...terTM Technical Support Side View Rigidly attach dial indicator Direction of shaft movement Applied Force Shaft being pushed by use of lever Figure 5 28 Bearing Radial Clearance Inspection Compressor Model Max Axial Clearance in mm Max Radial Clearance in mm Max Force at Hub Shaft lbf N Max Applied Force 36 Lever 6 Pivot lbf N 97 127 0 002 0 051 0 004 0 102 100 444 20 89 151 181 201 152 182 202 30...

Page 111: ...rotor axial bearing clear ance position a dial indicator on the gaterotor as shown in Figure 5 29 b Figure 5 29 Gaterotor Bearing Clearance Force to be determined by length of lever arm Use bolt for fulcrum Rigidly attach dial indicator Side View Wooden block to prevent damage to gaterotor blade Showing gaterotor bearing clearance being measured Direction of gaterotor movement Axial force at gater...

Page 112: ...ut moving the feeler gauge slowly rotate the gaterotor so that the feeler gauge tip stays between the gaterotor and the shelf See Figure 5 31 c CAUTION Do not over rotate If the rotor catches the feeler gauge apiececanbreakandfallintotherotorgroove 3 Gently pull the feeler gauge out in the direction shown in Figure 5 31 d Figure 5 30 Gaterotor and Shelf Clearance Check for 0 003 0 004 0 076 0 102 ...

Page 113: ... if there is any noticeable clearance between the gaterotor and its bushing see Figure 5 32 If there is noticeable clearance please contact Vilter Service Department NOTE The number of bushings on a gaterotor can be anywhere from one to three 2 To measure the float between the gaterotor bush ing and the support damper pin see Figure 5 34 position a dial indicator at the tip of the support as shown...

Page 114: ...hat a tooth in the rotor is perpendicular to the Main Axis as shown in Figure 5 35 The tooth should be in the center axis of the housing 2 A dial indicator with magnetic base can be used Vilter part numbers 9994ARE or 9994ARJ for the dial indicator and 9994ARD for the magnetic base See Figure 5 36 for location Figure 5 34 Gaterotor Float Figure 5 35 Alignment of Gaterotor Inside Tooth is Perpendic...

Page 115: ...terotor with two fingers back and forth rapidly several times while reading the dial indicator to see what the displacement range is This displacement range will be the total backlash Contact Vilter Service Department if the measurement is above the ranges shown on Table 5 13 Table 5 13 Backlash Range Figure 5 38 Measuring Backlash Displacement Range Fingers Positioning to Move the Gaterotor Back ...

Page 116: ...e unit can be evacuated and leak checked before starting Figure 5 39 Chipped Edge of Gaterotor Gaterotor Assembly Replacement All Compressors Except VSM 301 701 and VSM 97 127 Compressors Table 5 14 lists the gaterotor tool sets needed to remove and install gaterotor assemblies Table 5 14 Gaterotor Tool Kits Model Tool Set VPN VSM 97 VSM 127 N A VSM 71 VSM 401 N A VSM 501 701 A25205B VSS VSSH 291 ...

Page 117: ...pport in the opposite direction of rotation and tilt roller bearing end towards the suction end of the compressor The compressor input shaft may have to be turned to facilitate the removal of the gaterotor support On dual gate compressor units repeat the procedure for the remaining gaterotor support assembly Installation 15 Install gaterotor support by carefully tilting the roller bearing end of t...

Page 118: ...crew clockwise This will push the thrust bearings onto the shaft and push the housing assembly into the frame Install the inner retainer 115 and bolts 151 us ing Loctite 242 thread locker Tighten bolts see Appendix A 19 Set clearance between gaterotor blade and shelf 20 Place a piece of 0 003 0 004 shim stock between gaterotor blade and shelf NOTE This measurement determines the amount of shims ne...

Page 119: ... the gaterotor blade looser rather than tighter against the shelf see Figure 5 43 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 value 25 Install side cover with a new gasket Tighten the bolts to the recommended torque value The unit can then be evacuated and leak checked Figure 5 42 Gaterotor Assembly...

Page 120: ...properly supported before the bolts securing the line to the cover can be removed After the line is removed the cover can be removed as described above 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 gaterotor support At this point install the gaterotor stabilizing tool 6 Remove plug on the thrust bearing housing Loosen the ...

Page 121: ...s sary It is preferable to shim the gaterotor blade looser rather than tighter against the shelf 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 bearings 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 ...

Page 122: ... Installation 1 Install gaterotor support by carefully tilting the roller bearing end of the gaterotor support towards the suction end of the compressor The compressor input shaft may have to be rotated to facilitate the installation of the gaterotor support Install gatero tor stabilizer The gaterotor stabilizer 901 will hold the gaterotor support in place as the thrust bearing housing is being in...

Page 123: ...5 49 Section 5 Maintenance Service VSS VSM VSH VSSH Installation Operation and Maintenance Manual Emerson 35391SD Figure 5 48 Gaterotor Assembly VSM 97 127 Compressors ONLY ...

Page 124: ... and bushing for excessive wear Replace if required Figure 5 49 Gaterotor and Shelf Clearance Check for 0 003 0 004 0 076 0 102 mm clearance between gaterotor blade and partition Figure 5 50 Gaterotor Blade Assembly 7 Check the clearance between the entire gatero tor blade and the shelf rotate the gaterotor to find the tightest spot It should be between 0 003 0 004 0 076 0 102 mm Make ad justments...

Page 125: ...ade Installation 13 Install damper pin bushing 120 in gaterotor blade 111 from the back side of the blade Be sure bush ing is fully seated 14 Place blade assembly on gaterotor support Locating damper over pin 15 Install washer 119 and snap ring 130 on gatero tor assembly The bevel on the snap ring must face away from the gaterotor blade After the gaterotor blade and support are assembled there sho...

Page 126: ...ease the installation of the bear ings into the gaterotor support 26 Install the bearing retaining snap ring Gaterotor Roller Bearing Removal 27 Remove the snap ring 131 which retains the roll er bearing in the bearing housing see Figure 5 54 28 Remove the roller bearing 125 from the bearing housing 112 29 Use a bearing puller to remove the roller bearing race 125 from the gaterotor support 110 Ga...

Page 127: ... Figure 5 55 3 Check damper pin and bushing for excessive wear Replace if required Figure 5 55 Gaterotor Support VSM 97 127 Gaterotor Blade Installation 4 Install damper pin bushing 120 in gaterotor blade 111 from the back side of the blade Be sure bush ing is fully seated see Figure 5 56 5 Place blade assembly on gaterotor support Locating damper over pin see Figure 5 55 6 After the gaterotor bla...

Page 128: ... onto the gaterotor support 15 Install the outer bearing into the bearing housing so the numbers match the numbers on the inner race Install the snap ring retainer in the housing The bevel on the snap ring must face away from the roller bearing 101 104 103 Install Retainer Ring With Beveled Facing Away From Gaterotor Gaterotor Thrust Bearing Removal See Figure 5 57 7 Remove retaining ring from gat...

Page 129: ...n the shaft Figure 5 58 Shaft Seal Assembly Figure 5 59 Handling Seal Face with Care Carbon or SC component is the stationary part of the seal and is installed into the shaft seal housing using an O ring The shaft seal housing with the stationary part is assem bled in the compressor main housing using an O ring see Figure 5 58 The shaft seal needs to be carefully handled and installed to function ...

Page 130: ...he cup assembly 219B the Anti rotation pin in the housing must be removed See Figure 5 61 Suggestion A spray bottle filled with clean compressor oil may be used to lubricate the faces of the seals without touching the seal 7 Install a new oil seal 230 in seal housing 218 8 To install the carbon cartridge part of the seal in the seal housing clean inside shaft seal housing 218 where cup assembly 21...

Page 131: ...61 Compressor Shaft Seal Installation Tapered and Straight Shafts 17 Install a new O ring 260 on the seal housing 218 making sure the O ring is placed in the O ring groove and not the oil gallery groove See Figure 5 61 18 Lubricate both seal faces with clean compressor lu bricating oil 19 Carefully install the seal housing 218 on the com pressor shaft evenly tightening the bolts 281 to the recomme...

Page 132: ...readed jacking holes to assist in removing shaft seal housing 218 3 Remove silicon carbide rotating face 219 6 O ring 219 7 from shaft 4 Remove spring holder 219 8 from shaft 5 Removeoilseal 230 fromshaftsealhousing 218 6 Remove retaining ring 219 5 from seal housing 7 Flip the seal housing over and carefully tap the stationary silicon carbide piece 219 3 retainer 219 4 and O ring 219 2 out of the...

Page 133: ...rom other area of manual 2 Loosen and remove screws 281 mounting shaft seal housing 218 to main compressor housing 3 Carefully thread three screws 281 into the jacking holes in the shaft seal housing 218 to push it out of the main compressor housing Do not go more than one half turn on any screw at a time 4 Once the shaft seal housing 218 has been re moved from the compressor housing loosen the 4 ...

Page 134: ...ge the O ring on the inner diameter of the shaft seal see Figure 5 64 Figure 5 65 Shaft Seal Housing Figure 5 64 Shaft with Pin Drive Pin on Shaft Lead Chamfer on Outer Diameter of Shaft Shoulder to Which Seal Will Bottom on Figure 5 66 The Alignment of Compressor Shaft and Mating Ring Shoulder on Compressor Shaft Align slot in mating ring 219C with drive pin on compressor shaft 219C O ring 2 Chec...

Page 135: ... isfullyseatedagainst the shoulder of the compressor shaft If the spring holder 219 8 is not fully seated against the shoulder the carbon component of the stationary assembly 219B will be damaged when the shaft seal housing 218 is installed 3 Place O ring 219 7 inside rotating silicon carbide piece 219 6 and carefully assemble onto shaft You should feel some resistance in sliding this onto the sha...

Page 136: ...to main compressor shaft taking care to align the drive pin in the main shaft with the keyway on the rotating face support 301C 6 Using a small amount of Flowserve supplied grease carefully re assemble O ring 301B and rotating face 301A over the compressor shaft onto the rotating face support 301C 7 Moving onto the stationary portion of the seal 219B gently press the stationary face 305 into the s...

Page 137: ...onentstoaidininstallation 5 First remove E clips then remove Locking Retainers next loosen and remove Grooved Bolts and Washes that securing actuator assembly to ac tuator mount See Figure 5 67 for parts details 6 Remove actuator assembly from actuator mount Installation CAUTION When installing the slide valve actuator assembly loosen locking collar down the shaft Do not use a screwdriver to pry l...

Page 138: ...o line A and B then the retainer will drop on easily If required tighten bolt further for this alignment GrooveLok Bolt Retainer Many Shapes Available E clip Assembled A B 2 Position Locking Retainer over Grooved Bolt with the shallow curved edge toward the center of the command shaft housing See figure 5 67 b NOTE The locking retainer hex hole is offset 3 so flipping it over gives it new position...

Page 139: ...nstall a new o ring 446 into the groove on the compressor discharge manifold You may use clean compressor lubricating oil on the o ring 6 Install the command shaft onto the compressor discharge manifold Ensure that the command shaft tongue is engaged in the cross shaft slot in side the compressor discharge manifold Rotate the command shaft assembly so that the vent holes point downward This will p...

Page 140: ...liquid injection control operation refer to Section 2 For additional information regarding setup installation programming and troubleshooting refer to Appendices The liquid injection control valve station ICF consists of these parts Danfoss part acronyms are shown in parentheses Liquid Injection Control Valve Station ICF Inlet Connection Sight Glass Shown with Covers Shut off Valves ICFS Inlet and...

Page 141: ...TION 3389EA ICAD 600 MOTOR ACTUATOR W 10M CABLES 3389EE ICAD 900 MOTOR ACTUATOR W 10M CABLES 3389AE1 CABLES 10M FOR ICAD ACTUATOR 3389AE2 TOP COVER FOR ICAD ACTUATOR 3389EB CONTROLLER EKC 347 LIQUID LEVEL 3389FD MODULE B66 FUNCTION FOR ICF VALVE STATION 3389FA MAGNETIC TOOL FOR ICM VALVE MANUAL OPERATION 20 25 AND 32 3389FC MAGNETIC TOOL FOR ICM VALVE MANUAL OPERATION 40 50 AND 65 3389FB ICM 20 SE...

Page 142: ... UNC 5 10 18 29 44 63 87 155 150 SAE GRADE 5 COARSE UNC 8 16 28 44 68 98 135 240 387 SAE GRADE 5 FINE UNF 16 SAE GRADE 8 COARSE UNC 11 22 39 63 96 138 191 338 546 SOCKET HEAD CAP SCREW ASTM A574 COARSE UNC 5 13 26 46 73 112 155 215 380 614 NOTES 1 Torque values on this sheet are not to override those given on the individual drawings 2 When using loctite the torque value on this sheet are only accu...

Page 143: ...eads are required to be lubricated prior to tightening the bolt nut Whether a lubricant is used or not has considerable impact on the amount of torque required to achieve the proper preload in the bolt stud Use a lubricant if required or not if so specified D Unlike a ratchet wrench a torque wrench is a calibrated instrument that requires care Recalibration is required periodically to maintain acc...

Page 144: ...5 70 Blank VSS VSM VSH VSSH Installation Operation and Maintenance Manual Emerson 35391SD ...

Page 145: ...re the motor brake operates freely and the photo chopper will not contact the optocouplers when the shaft is pressed down The white calibrate wire in the grey Turck cable is grounded Tape the end of the white wire in the panel and make sure that it cannot touch metal Dirt and or condensation on the position sensor boards are causing it to malfunction Clean the boards with an electronics cleaner or...

Page 146: ...otor brake to where it operates freely and recalibrate The position sensor s EEPROM memory has failed Replace the actuator The actuator does not transmit the cor rect position after a power loss The motor was manually moved while the position sen sor was not powered Recalibrate The motor brake is not work ing properly Get the motor brake to where it operates freely and recalibrate The position sen...

Page 147: ... See above The command shaft is jammed Free the command shaft Broken gears in the gear motor Replace the actuator Blown relays or fuses Check and replace blown relays and or fuse The motor operates intermittently several minutes on several minutes off Motor is overheating and the thermal switch is tripping This could be caused by a malfunctioning control panel Consult the factory The motor runs sp...

Page 148: ...e motor shaft until the aluminum photo chopper fence is not blocking either of the optocoupler slots 2 Using a digital multimeter measure the DC voltage between termi nal 3 of the small terminal block and TP1 on the circuit board see Note 1 The measurement should be 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 be tween 0...

Page 149: ...a tors reposition often Solutions are available consult your VilterTM authorized distributor for details Another possible cause for this error is a stuck motor thermal switch The thermal switch can be tested by measuring the DC voltage with a digital multimeter be tween the two TS1 wire pads see Note 2 If the switch is closed normal operation you will measure 0 Volts The 24V supply voltage is low ...

Page 150: ...oil filter pressure drop Check Prelube Oil Pressure Safety Changeover setpoint is sufficient in Timers Screen Prelube Oil Pressure is Manifold Pressure minus Discharge Pressure Low Run Oil Pressure Check solutions in Low Oil Pressure at Start Check that there is proper discharge pressure ratio to create differ ential pressure otherwise oil pressure can t be maintained Oil pressure is manifold oil ...

Page 151: ...etting of all manual values Check for correct operation of 3 way oil mixing valve If you are controlling a step type oil cooler or a VFD oil cooler verify the correct one is selected in the Configuration Screen and the amount of steps are entered in the Remote Oil Cooler Control Screen Check the oil cooler and associated piping to make sure it is full of oil before starting Check the oil strainer ...

Page 152: ...e slide Vibration Check that unit is leveled and secured to mounting 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 suc tion check valve for proper operation Table ...

Page 153: ...n STEP 2 Return the parts freight prepaid to VILTER MANUFACTURING CORPORATION 5555 South Packard Avenue Cudahy WI 53110 8904 STEP 3 Upon receipt of the returned part s Vilter will complete a timely evaluation of the part s STEP 4 You will be contacted with Vilter s decision once the final report is completed STEP 5 If approved the approved warranty will be credited excluding freight to your accoun...

Page 154: ...our area The shop will diagnose the root cause submit a report to the OEM and the motor OEM will make the determination of warranty coverage If warranty is approved the OEM will either have the motor repaired by the motor shop or send a new replacement motor to the site Note Motor warranty is a pass thru warranty as stated in Vilter Manufacturing s standard warranty statement which means that the ...

Page 155: ...st fee A Return Material Authorization RMA number will be provided Send the compressor to Vilter in the condition as stated on the Rebuild Form i e no oil in the compres sor Charges may apply if conditions are not met A report will be sent to you after the inspection has been completed explaining what level of rebuild is necessary along with the cost NOTE Inspection and rebuild times will vary con...

Page 156: ...7 4 Blank VSS VSM VSH VSSH Installation Operation and Maintenance Manual Emerson 35391SD ...

Page 157: ...ual is still the best for your compressor Parts that appear on diagrams might be shown separately for reference but are sold as an assembly or kit only 8 1 VSH VSSH Recommended Spare Parts List For VSH VSSH compressor spare parts please contact Vilter Engineering Service for the list Note Please have your Model and Sales Order available when ordering These are found on the compressor s Name Plate ...

Page 158: ...8 2 Blank VSS VSM VSH VSSH Installation Operation and Maintenance Manual Emerson 35391SD ...

Page 159: ...ed in your manual is still the best for your compressor Parts that appear on diagrams might be shown separately for reference but are sold as an assembly or kit only 8 3 VSS Recommended Spare Parts List Refer to the Custom Manual Spare Parts Section for Specific Applications Please have your Model and Sales Order available when ordering These are found on the compressor s Name Plate ...

Page 160: ...erson 35391SD Vilter parts get renewed from time to time so be sure to ask if the part listed in your manual is still the best for your compressor Parts that appear on diagrams might be shown separately for reference but are sold as an assembly or kit only Gaterotor For VSS Models from 451 to 2101 ...

Page 161: ...HOUSING 2 25517A 2 25517A N A 114 RETAINER 2 25008A 2 25008A N A 115 RETAINER 2 25009A 2 25009A N A 116 BALL BEARING COVER 2 25258A 2 25258A N A 117 Gaterotor COVER 2 25519A 2 25519A N A 118 Gaterotor COVER GASKET 2 25259A 2 25259A 2 25088A 119 WASHER 2 25007A 2 25007A 2 25086A 120A BUSHING SMALL DOWEL PIN 2 25006A 2 25006A 2 25087A 120B BUSHING LARGE DOWEL PIN 2 25760A 2 25760A 2 25760B 121 SHIM ...

Page 162: ...SET 2 121 2 122 1 123 1 124 2 A25165C 2 A25165C 2 A25165C 2 A25165C 110 SUPPORT 2 25553A 2 25614A 2 25587A 2 25587A 111 Gaterotor 2 25554A 2 25610A 2 25588A 2 25588F 118 Gaterotor COVER GASKET 2 25088A 2 25132A 2 25132A 2 25132A 119 WASHER 2 25086A 2 25086A 2 25086A 2 25086A 120A BUSHING SMALL DOWEL PIN 2 25087A 2 25104A 2 25104A 2 25104A 120B BUSHING LARGE DOWEL PIN 2 25760B 2 25760B 2 25760B 2 2...

Page 163: ...9A 114 RETAINER 2 25141A 2 25141A 2 25141A 115 RETAINER 2 25789A 2 25789A 2 25789A 116 BALL BEARING COVER 2 25351A 2 25351A 2 25351A 117 Gaterotor COVER 2 26508B 2 25354A 2 25354A 118 Gaterotor COVER GASKET 2 26509A 2 25790A 2 25790A 119 WASHER 2 25788A 2 25788A 2 25788A 120A BUSHING SMALL DOWEL PIN N A 2 25104A 2 25104A 120B BUSHING LARGE DOWEL PIN 2 25760C 2 25104A 2 25104A 121 SHIM 0 002 AR 257...

Page 164: ...5E 110 SUPPORT 2 25665E 2 25665D 111 Gaterotor 2 25645A 2 25744D 112 SMALL BEARING HOUSING 2 26507A 2 26507A 113 LARGE BEARING HOUSING 2 26506A 2 26506A 114 RETAINER 2 25141A 2 25141A 115 RETAINER 2 25789A 2 25789A 116 BALL BEARING COVER 2 25351A 2 25351A 117 Gaterotor COVER 2 26508B 2 26508B 118 Gaterotor COVER GASKET 2 26509A 2 26509A 119 WASHER 2 25788A 2 25788A 120A BUSHING SMALL DOWEL PIN N A...

Page 165: ...Parts that appear on diagrams might be shown separately for reference but are sold as an assembly or kit only 8 9 Gaterotor VSS 2401 thru VSS 3001 Only 12 8 14 5 15 9 4 1 6 10 3 7 11 13 TIGHTEN TO 19 FT LBS USE BLUE LOCTITE USE SHIMS TO ACHIEVE 0 003 0 004 SHELF CLEARANCE TIGHTEN TO 78 FT LBS TIGHTEN TO 54 FT LBS INSTALL RETAINER WITH BEVEL FACING GATEROTOR TIGHTEN TO 33 FT LBS TIGHTEN TO 154 FT L...

Page 166: ...ATEROTOR 1 00 A25164F A25164F A25164F A25164F 003 SHIM 1 00 A25165F A25165F A25165F A25165F 004 SUPPORT 1 00 A25222FH A25222FG A25222FF A25222FE 005 BEARING HOUSING 1 00 26089B 26089B 26089B 26089B 006 GATEROTOR BEARING HOUSING COVER 1 00 25789B 25789B 25789B 25789B 007 GATEROTOR COVER 1 00 26087B 26087B 26087B 26087B 008 RETAINING RING 3 346 X 0 109 BEVELED 1 00 26132C 26132C 26132C 26132C 009 HE...

Page 167: ...might be shown separately for reference but are sold as an assembly or kit only 8 11 Shaft Seal 230 260 219 Shaft Seal With Stationary Carbon Face ITEM DESCRIPTION MODEL NUMBER QTY VSS 291 thru VSS 601 VSS 751 thru VSS 1301 VSS 1551 thru VSS 2101 VSS 2401 thru VSS 3001 SHAFT SEAL AMM KIT 219 230 260 1 KT709A KT709B KT709E KT709F SHAFT SEAL R22 KIT 219 230 260 1 KT781A KT781B KT781C KT781F 230 OIL ...

Page 168: ...ly for reference but are sold as an assembly or kit only Main Rotor For VSS Models from 451 to 2101 201 DESCRIPTION ROTOR ASSEMBLY A25226BB A25226BA A25226CB A25226CA A25226DB A25226DA A25752HA A25226EB A25226EC A25226EA A25226ED A25226EE 207 SHIM PACK A25177B A25177B A25177C A25177C A25177D A25177D A25177D A25177E A25177E A25177E A25177E A25177E ITEM QTY 1 1 1 1 1 1 1 1 1 1 1 1 MODEL NUMBER VSS 4...

Page 169: ...sted in your manual is still the best for your compressor Parts that appear on diagrams might be shown separately for reference but are sold as an assembly or kit only 8 13 Main Rotor ITEM DESCRIPTION MODEL NUMBER QTY VSS 2401 VSS 2601 VSS 2801 VSS 3001 ROTOR ASSEMBLY 1 A25226AN A25226AM A25226AL A25226AK 102 SHIM PACK 1 A25177G A25177G A25177G A25177G VSS 2401 thru VSS 3001 Only ...

Page 170: ...Vilter parts get renewed from time to time so be sure to ask if the part listed in your manual is still the best for your compressor Parts that appear on diagrams might be shown separately for reference but are sold as an assembly or kit only Slide Valve Cross Shafts and End Plate For VSS Models from 451 to 2101 ...

Page 171: ...u VSS 1301 QTY VSS 1501 VSS 1801 QTY VSS 1551 thru VSS 2101 221 SHAFT 2 25843A 2 25844A 2 25845A 2 25793A 2 25793A 222 GEAR 4 25027A 4 25027A 4 25027A 4 25027A 4 25027A 226 RACK CLAMP 2 25913A 4 25913C 4 25913C 4 25913C 227 RACK CLAMP 2 25913B N A N A N A 228 SPACER 2 25847A 4 25033C 4 25033C 4 25033C 4 25033C 267 DOWEL PIN N A 2 2868B 2 2868B 2 2868B 2 2868B 268 EXPANSION PIN 4 1193D 4 1193D 4 11...

Page 172: ...al Emerson 35391SD Vilter parts get renewed from time to time so be sure to ask if the part listed in your manual is still the best for your compressor Parts that appear on diagrams might be shown separately for reference but are sold as an assembly or kit only End Plate VSS 2401 VSS 3001 Only ...

Page 173: ...401 thru VSS 3001 Quantity DESCRIPTION 018 PIPE PLUG SOCKET HEX 2 13163F 019 O RING 1 609 X 1 887 NEOPRENE 2 2176X 270 FLUSH SEAL PLUG 3 4 14 NPTF SOCKET HEAD 2 2606A 269 ROLL PIN M2 5 X 26 STEEL 4 2981AA 286 SCREW 1 4 20 NC X 2 CAP SOCKET HEAD ASTM A574 8 2795Q 226 RACK CLAMP 4 25913E 298 SET SCREW 10 32 NF X 3 16 CUP PNT HEX 4 2060H 222 GEAR 4 25027A 220 END PLATE ASSEMBLY 1 A25849FA A25849FAAF ...

Page 174: ...newed from time to time so be sure to ask if the part listed in your manual is still the best for your compressor Parts that appear on diagrams might be shown separately for reference but are sold as an assembly or kit only Capacity Slide Volume Slide Carriage Assembly Slide Valve Carriage Assembly For VSS Models from 451 to 2101 ...

Page 175: ...CAPACITY PISTON SHAFT N A 2 25078A 2 25078E 2 25784A 342 VOLUME PISTON SHAFT N A 2 25078B 2 25078F 2 25783A 343A COVER SEPARATE VOL CAP 4 25022A 2 25123B 4 25123D N A 343B COVER ONE PIECE CAST 2 25399D 2 25279A 2 25401A 2 25690A 344 COVER SEPARATE VOL CAP N A 2 25123A N A N A 345A GASKET SEPARATE VOL n a CAP COVERS 4 25021A 2 25124B 4 25124C N A 345B GASKET ONE PIECE CAST COVER 2 25900A 2 25902A 2...

Page 176: ...ON 1 A25184GS 104 SMALL PISTON SEAL 1 A25200FS 105 PISTON COVER 1 A25220F 106 SMALL CAPACITY PISTON SLEEVE 1 26113E 107 PISTON SHAFT GUIDE WASHER CAP SM 1 26115D 108 PIPE NIPPLE 1 2 X 2 1 2 1 13189D 109 PIPE SOCKET PLUG HEX 3 13163F 110 SCREW 5 8 16 NC X 4 CAP SOCKET 3 2795BE 111 NORD LOCK WASHER 625 PER MANENTLY TIGHT 3 3004H 112 RETAINING RING 2 875 X 0 093 INT BEVELED 2 2867AQ 113 RETAINING RIN...

Page 177: ...ppear on diagrams might be shown separately for reference but are sold as an assembly or kit only 8 21 Actuator Command Shaft ITEM DESCRIPTION MODEL NUMBER QTY VSS 291 thru VSS 601 VSS 751 thru VSS 901 VSS 1051 VSS 1201 VSS 1301 VSS 1551 thru VSS 2101 VSS 2401 thru VSS 3001 400 COMMAND SHAFT ASSEMBLY 2 A25994B A25994C A25994D A25994E A25994F 401 SLIDE VALVE ACTUATOR 2 25972D 25972D 25972D 25972D 2...

Page 178: ...parts get renewed from time to time so be sure to ask if the part listed in your manual is still the best for your compressor Parts that appear on diagrams might be shown separately for reference but are sold as an assembly or kit only VSS Screw Compressor Miscellaneous Frame Components For VSS Models from 451 to 2101 ...

Page 179: ...N A 1 A25243ED 511 DISCHARGE MANIFOLD 1 25502A 1 25540A 1 25597A 1 25663A 512 MANIFOLD GASKET 1 25503A 1 25541A 1 25324A 1 25324A 1 25676A 1 25676A 513A FLANGE 1 25058ASW 1 25058ASW 1 25058B 1 25058ASW 1 12477C 1 12477C 513B FLANGE 2 25058B 2 25058ASW 2 25058B 2 25058B N A 2 25058ASW 514A GASKET 1 11323D 1 11323D 1 11323E 1 11323D 1 11323F 1 11323F 514B GASKET 2 11323E N A 2 11323E 2 11323E N A 2 ...

Page 180: ...ately for reference but are sold as an assembly or kit only Miscellaneous Frame Components VSS 2401 thru VSS 3001 Only NOTES Not Shown ITEM DESCRIPTION QTY VSS 2401 thru VSS 3001 504 FLANGE SET 1 250 VSS 401MM 1 A25190EA 505 TUBING VSS2401 3001 1 A25201F 536 PLUG 1 2 14NPTF FLUSH SEAL SOC HD 2 2606E 538 PLUG 3 4 14NPTF FLUSH SEAL SOC HD 3 2606A 539 PLUG LIQUID INJECTION 4 26293A 540 O RING 0 171X0...

Page 181: ...till the best for your compressor Parts that appear on diagrams might be shown separately for reference but are sold as an assembly or kit only 8 25 VSS 451 THRU VSS 1801 VSS 451 THRU VSS 1201 VSS 1501 VSS 1801 VSS 451 VSS 601 VSS 751 VSS 901 VSS 1051 VSS 1201 Miscellaneous Frame Components Tubing and Fittings Gaterotor BEARING SUPPLY LINES SEAL CHAMBER OIL LINE SLIDE VALVE BALANCE PISTON EQUALIZI...

Page 182: ... MALE 5 13375D 5 13375D 3 13375D 2 13375D 556 STRAIGHT 1 4 ODT X 1 4 MPT 1 13229D 1 13229D 2 13229D N A 557 TEE RUNNING 1 4 OD X 1 4 MPT MALE 1 1509A 1 1509A 1 1509A 1 13376D 558 HEX BUSHING 1 13231AA 1 13231AA 1 1101H 1 13231AA 559 HEX BUSHING N A N A 1 1101K 1 1101K 560 ELBOW 3 8 ODT X 1 2 MPT 90 MALE 1 13375Z 1 13375Z 1 13375Z 1 13375Z 561 ELBOW 3 8 OD X 1 4 MPT 90 MALE 1 13375F 1 13375F 1 1337...

Page 183: ...mbly or kit only 8 27 Miscellaneous Frame Components Tubing and Fittings VSS 2401 VSS 3001 ITEM DESCRIPTION QTY VSS 2401 VSS 3001 555 MALE ELBOW 3 8 ODX 1 4MPT 90 2 00 13375F 557 BRANCH MLE TEE 1 4ODTX1 4ODTX1 4MPT 1 00 13376D 560 MALE ELBOW 1 4ODTX1 4MPT 90 2 00 13375D 567 COMPRESSION CONNECTOR 3 8 ODT X 1 8MPT 1 00 13229W 568 BUSHING 1 X 1 4 HEXAGON 2 00 1101M 570 UNION TUBE TEE 3 8 1 00 13239E ...

Page 184: ...CRIPTION MODEL NUMBER QTY VSS 291 thru VSS 601 VSS 751 VSS 901 VSS 1051 VSS 1201 VSS 1301 VSS 1551 thru VSS 2101 VSS 2401 thru VSS 3001 900 Gaterotor TOOLS 1 A25205B A25205C A25205C A25205E A25205F 901A Gaterotor STABILIZER SET 901A 901B 901C 1 A25698A A25698A A25698A N A N A 901B Gaterotor STABILIZER SET 901A 901B 901C 901D 1 N A N A N A A25699A N A ...

Page 185: ...er Cover Gasket 2555E 1 4 5 Suction Strainer Strainer Cover Gasket 2555F 1 6 Suction Strainer Strainer Cover Gasket 2555G 1 8 Suction Strainer Safety Relief Valves 300 Psig R 717 Relief Valve 1498GG 2 300 Psig R 717 Dual Relief Valve 250 Psig R 717 Relief Valve 1498EE 2 250 Psig R 717 Dual Relief Valve 300 Psig Halocarbon Relief Valve 1 2 x 5 8 1498GA 2 300 Psig Halocarbon Dual Relief Valve 300 Ps...

Page 186: ...n R 717 Liquid Injection System 10 Ton R 717 Thermostatic Expansion Valve 2629B 1 10 Ton R 717 Liquid Injection System 15 Ton R 717 Thermostatic Expansion Valve 2629C 1 15 Ton R 717 Liquid Injection System 20 Ton R 717 Thermostatic Expansion Valve 2629D 1 20 Ton R 717 Liquid Injection System 30 Ton R 717 Thermostatic Expansion Valve 2629E 1 30 Ton R 717 Liquid Injection System 50 Ton R 717 Thermos...

Page 187: ... your manual is still the best for your compressor Parts that appear on diagrams might be shown separately for reference but are sold as an assembly or kit only 8 31 VSM 301 701 Recommended Spare Parts List Refer to the Custom Manual Spare Parts Section for Specific Applications Please have your Model and Sales Order available when ordering These are found on the compressor s Name Plate ...

Page 188: ...8 32 Section 8 Spare Parts List VSS VSM VSH VSSH Installation Operation and Maintenance Manual Emerson 35391SD Gaterotor Assembly ...

Page 189: ...6R 2176R 106 SHIM GATEROTOR 1 A25165A A25165A A25165A 1 A25165B A25165B A25165B 108 SUPPORT GATEROTOR 1 A25222AB A25222AA A25222AC 1 A25222BB A25222BA A25222BC 108 1 SUPPORT GATEROTOR 1 A25161AB A25161AA A25161AC 1 A25161BB A25161BA A25161BC 108 2 BALL BEARING 1 A25163A A25163A A25163A 1 A25163B A25163B A25163B 108 3 ROLLER BEARING 1 2864F 2864F 2864F 1 2864B 2864B 2864B 108 4 RETAINING RING 0 781...

Page 190: ...on diagrams might be shown separately for reference but are sold as an assembly or kit only Shaft Seal ITEM DESCRIPTION MODEL NUMBER QTY VSM 301 401 VSM 501 701 SHAFT SEAL KIT AMM 219 230 260 1 KT709D KT709A SHAFT SEAL KIT HALO 219 230 260 1 KT781D KT781A 219 SHAFT SEAL 1 A A 230 OIL SEAL 1 2930C 25040A 244 TEFLON SEAL 1 25939A 25939A 252 RETAINER RING 1 2928M 2928M 260 O RING 1 2176U 2176F 261 O ...

Page 191: ...sor Parts that appear on diagrams might be shown separately for reference but are sold as an assembly or kit only 8 35 Main Rotor Models VSM 301 401 Counter Clockwise ONLY Models VSM 501 701 Clockwise ONLY ITEM DESCRIPTION MODEL NUMBER QTY VSM 301 VSM 361 VSM 401 QTY VSM 501 VSM 601 VSM 701 MAIN ROTOR ASSEMBLY 1 A25226AB A25226AA A25226AC 1 A26010BB A26010BA A26010BC 201 ROTOR 1 A25716AB A25716AA ...

Page 192: ...on 8 Spare Parts List VSS VSM VSH VSSH Installation Operation and Maintenance Manual Emerson 35391SD Slide Valve Cross Shafts End Plate Models VSM 301 401 Counter Clockwise ONLY Models VSM 501 701 Clockwise ONLY ...

Page 193: ... 227 CLAMP 4 25913A 25913A 25913A N A N A N A 228 SPACER 4 25847A 25847A 25847A 4 25847A 25847A 25847A 293 SHIM 0 002 AR 25409AA 25409AA 25409AA 2 26027BA 26027BA 26027BA 294 SHIM 0 003 AR 25409AB 25409AB 25409AB 2 26027BB 26027BB 26027BB 295 SHIM 0 005 AR 25409AC 25409AC 25409AC 1 26027BC 26027BC 26027BC 296 SHIM 0 010 AR 25409AD 25409AD 25409AD 1 26027BD 26027BD 26027BD 244 TEFLON RING 1 25939A ...

Page 194: ...ed from time to time so be sure to ask if the part listed in your manual is still the best for your compressor Parts that appear on diagrams might be shown separately for reference but are sold as an assembly or kit only Volume Ratio Capacity Slide Carriage Assembly Slide Valve Carriage Assembly Assembly Includes Carriage and Slides ...

Page 195: ... and Capacity slide valves The above totals are per side of the compressor double the quantities if both slide valve carriages are being worked on Not Pictured ITEM DESCRIPTION MODEL NUMBER QTY VSM 301 401 VSM 501 701 300 CARRIAGE ASSEMBLY 1 A25179A A26012B 304 CAPACITY PISTON 340 341 350 355 1 A25183A A25183B 305 VOLUME PISTON 340 342 350 355 1 A25184A A25184B 316 CAPACITY RACK 1 25023BH 25024AH ...

Page 196: ... the part listed in your manual is still the best for your compressor Parts that appear on diagrams might be shown separately for reference but are sold as an assembly or kit only Actuator Command Shaft ITEM DESCRIPTION MODEL NUMBER QTY VSM 301 401 VSM 501 701 400 COMMAND SHAFT ASSEMBLY 2 A25994A A25994B 401 SLIDEVALVE ACTUATOR 2 25972D 25972D 446 O RING SEAL 2 2176X 2176X ...

Page 197: ...SD Vilter parts get renewed from time to time so be sure to ask if the part listed in your manual is still the best for your compressor Parts that appear on diagrams might be shown separately for reference but are sold as an assembly or kit only 8 41 VSM 501 701 Miscellaneous Frame Components VSM 301 401 ...

Page 198: ...r kit only Miscellaneous Frame Components ITEM DESCRIPTION MODEL NUMBER QTY VSM 301 401 QTY VSM 501 701 512 MANIFOLD GASKET 1 25737A 1 26037A 514 ECON O MIZER GASKET 2 11323G 2 11323D 522 COUPLING LOCK PLATE N A 1 25004D 523 LOCK WASHER N A 1 3004H 528 ECON O MIZER PLUG 2 25419A 2 25397K 530 O RING N A 2 2176BF 540 DOWEL PIN 2 2868B 2 2868B 542 PIPE PLUG 3 2606C 10 2606B 551 HEX HEAD CAP SCREW N A...

Page 199: ...t appear on diagrams might be shown separately for reference but are sold as an assembly or kit only 8 43 Housing Accessories Housing Accessories ITEM DESCRIPTION MODEL NUMBER QTY VSM 301 701 117 Gaterotor COVER 1 25416B 118 COVER GASKET 2 25259B 129 GASKET 1 11323T 180 INLET SCREEN 1 25920A 343 PISTON COVER 1 25724B NOTES Not Pictured ITEM DESCRIPTION MODEL NUMBER QTY VSM 301 401 VSM 501 701 345 ...

Page 200: ...the part listed in your manual is still the best for your compressor Parts that appear on diagrams might be shown separately for reference but are sold as an assembly or kit only Replacement Tools ITEM DESCRIPTION MODEL NUMBER QTY VSM 301 401 VSM 501 701 900 GATEROTOR TOOLS 1 A25205B A25205B 901 GATEROTOR STABILIZER 1 25742A 25742B 902 SEAL INSTALLATION TOOL 1 25455A 25455B ...

Page 201: ... assembly or kit only 8 45 ITEM DESCRIPTION QTY PART NUMBER GATEROTOR TOOL SET 1 A25205B 1 STABILIZER GATEROTOR ASSEMBLY 1 A25698A 2 BAR BEARING PULLER 1 25204A 3 SHOE PULLER 1 875 1 25157A 4 SHOE PULLER 2 500 1 25157B 5 JACKSCREW 1 A25156B 6 STUD 375 16 X 4 9 2 25908A 7 STUD 250 20 X 4 4 2 25908B 8 STUD 312 18 X 7 5 2 25908C SCREW 1 4 20 NC X 1 3 4 CAP SOCK 2 2795W 9 PLAIN NUT 5 16 18NC 2B HEX 2 ...

Page 202: ...ted in your manual is still the best for your compressor Parts that appear on diagrams might be shown separately for reference but are sold as an assembly or kit only VSM 97 127 Recommended Spare Parts List Refer to the Custom Manual Spare Parts Section for Specific Applications Please have your Model and Sales Order available when ordering These are found on the compressor s Name Plate ...

Page 203: ...d in your manual is still the best for your compressor Parts that appear on diagrams might be shown separately for reference but are sold as an assembly or kit only 8 47 Kits Gaterotor Kits For VSM127 ITEM VPN QUANTITY DESCRIPTION KT759J 1 Blade Bearing KT1098G 1 Blade Shaft Seal Kit ITEM VPN QUANTITY DESCRIPTION KT709P 1 Shaft Seal Kit 143mm Compressor Contact Vilter for Other Sizes ...

Page 204: ...8 48 Blank VSS VSM VSH VSSH Installation Operation and Maintenance Manual Emerson 35391SD ...

Page 205: ...MBERS OR INCHES 10 1 4 5 16 3 8 7 16 1 2 9 16 5 8 3 4 7 8 SAE GRADE 2 COARSE UNC 5 10 18 29 44 63 87 155 150 SAE GRADE 5 COARSE UNC 8 16 28 44 68 98 135 240 387 SAE GRADE 5 FINE UNF 16 SAE GRADE 8 COARSE UNC 11 22 39 63 96 138 191 338 546 SOCKET HEAD CAP SCREW ASTM A574 COARSE UNC 5 13 26 46 73 112 155 215 380 614 NOTES 1 Torque values on this sheet are not to override those given on the individua...

Page 206: ...A 2 Blank VSS VSM VSH VSSH Installation Operation and Maintenance Manual Emerson 35391SD ...

Page 207: ...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 0 Accuracy of rec...

Page 208: ...zes appropriate to the compressor charge to avoid leaving partially filled containers open for long period of times Vilter B Type lubricant is available in 5 and 55 gallon contain ers Refrigeration systems using ester based lubricants will require suitable high capacity moisture filter driers to maintain low total moisture content in the refrigerant and lubricant Compatibility Misc Vilter Type B l...

Page 209: ...carbon natural gas Landfill gas Turbine feed gas 3143D PAO 68 METHANE 55 gallon drum Hydrocarbon natural gas Landfill gas Turbine feed gas 3143G PAO 150 METHANE 5 gallon pail Hydrocarbon natural gas Landfill gas Turbine feed gas 3143H PAO 150 METHANE 55 gallon drum Hydrocarbon natural gas Landfill gas Turbine feed gas 3143J PAO 100 DIGESTER 5 gallon pail Hydrocarbon natural gas Landfill gas Turbin...

Page 210: ...B 4 Blank VSS VSM VSH VSSH Installation Operation and Maintenance Manual Emerson 35391SD ...

Page 211: ...ringbroad bandrmsvibrationwithflatresponseovera frequency range of at least 10 Hz to 1000 Hz Depending on the vibration criteria this may require measurements of displacement or velocity or combinations thereof Care should be taken to ensure that the measuring sys tem is not influenced by environmental factors such as temperature variations magnetic fields sound fields power source variations tran...

Page 212: ...nd held instruments The use of computers for trend analy sis and warning against malfunctions is also becoming more common Operational Conditions Measurements shall be carried out when the compres sor has reached normal steady state operating tem peratures and with the machine running under specified conditions If the measured vibration is greater than the acceptancecriteriaallowedandanexcessiveba...

Page 213: ...are defined to permit a qualitative assessment of the vibration of a given ma chine and provide guidelines on possible actions Zone A The vibration of newly commissioned ma chines would normally fall within this zone Zone B Machines with vibration within this zone are normally considered acceptable for unrestricted long term operation Zone C machines with vibration within this zone are normally co...

Page 214: ...Support Class ZONE RMS Displacement RMS Velocity μmm mils mm s In sec A 0 30 0 1 15 0 2 3 0 09 B 30 57 1 15 2 25 2 3 4 5 09 18 C 57 90 2 25 3 55 4 5 7 1 18 28 D Above 90 Above 3 55 Above 7 1 Above 28 RMS 0 707 X peak sine wave only Setting of ALARMS The ALARM values may vary considerably up or down for different machines The values chosen will normally be set relative to a baseline value determine...

Page 215: ...ment should be individually mounted or attached to each specific piece of piping or tubing as required in the location of what is perceived as the maximum amplitude or worse vibration While there are references which specifically allow high er levels of vibration for piping the goals for the vibra tion levels of the piping and tubing on the compressor unit should still utilize the same criteria ou...

Page 216: ...C 6 Blank VSS VSM VSH VSSH Installation Operation and Maintenance Manual Emerson 35391SD ...

Page 217: ...ation Operation and Maintenance Manual Emerson 35391SD Appendix D Liquid Injection Valve Setup Instructions and Quick Start Guide Appendix D Liquid Injection Valve Setup Instructions and ICM ICAD Motorized Valve Quick Start Guide ...

Page 218: ...button when done 7 Press the Up arrow button until a value of 04 is shown on the screen 8 Press the Circle button There should be a value of 50 shown If not use the up down arrow buttons to change it to the correct value Press the Circle button when done 9 Press the Up arrow button until a value of 07 is shown on the screen 10 Press the Circle button There should be a value of 1 shown If not use t...

Page 219: ......

Page 220: ...ing and Troubleshooting DKRCI EI HT0 A1 5 0H1639 Danfoss USCO MKS 11 006 Contents Page Installation 3 Wiring the ICAD 5 ICAD Overview 8 ICAD Programming 9 Troubleshooting The Manual Tool 10 Service parameters 10 Alarms 11 Tips 11 Common questions 1 ...

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Page 222: ... ICM 65 110 81 7 Install the ICAD motor actuator on the ICM valve a The ICM valve must not be in its fully opened position while the ICAD motor is calibrated with the valve at a later step Therefore if the opening degree of the ICM valve was changed from the factory setting it should be set to an opening degree between 0 and 75 using the manual magnet tool To easily ensure correct positioning turn...

Page 223: ...ration White common alarm digital NPN transistor output when combined with yellow wire Brown indicates ICM is fully open digital NPN transistor output when combined with yellow wire Green indicates ICM is fully closed digital NPN transistor output when combined with yellow wire Supply voltage is galvanically isolated from input and output wires Supply voltage 4 V d c 10 15 Load ICAD 600 1 A ICAD 9...

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Page 227: ... installed 1 Close valve Open valve 3 Maintain valve position 4 Go to OD given by 12 Digital Input function 09 1 1 Define function when DI is ON short circuited DI terminals when 02 1 Open ICM valve DI OFF Close ICM valve Close ICM valve DI OFF Open ICM valve Password 10 0 199 0 Enter number to access password protected parameters 26 Password 11 Old Alarms 11 A1 A99 Old alarms will be listed with ...

Page 228: ... before using the manual tool and restore power afterward to ensure recalibration and trouble free operation The user will be able to troubleshoot and determine many of the conditions and set points within the ICAD by accessing the Service Menu A list of those service parameters follows below It is also possible to restore the original factory settings to the ICAD by the following procedure To res...

Page 229: ...ear to be opening or closing properly The ICAD was not mounted properly on the valve stem Solution Check to make sure that the ICAD was mounted evenly on the ICM valve The ICAD is not receiving a proper input signal Solution Use the service parameters 51 for a mA input or 52 for a voltage input to check the input signal that the ICAD is receiving 1 The valve position feedback signal is not working...

Page 230: ...inuous power supply It is used to change the valve position usually to close the valve in the event of a power failure Therefore the system is not to be run in the UPS mode Add a solenoid valve in front of the ICM This is a very simple solution provided that there is no issue associated with the additional pressure drop through the solenoid valve How much power do I need to supply to the ICAD The ...

Page 231: ... VSH VSSH Installation Operation and Maintenance Manual Emerson 35391SD Appendix E Liquid Injection Valve Station ICF 20 40 Installation Guide Appendix E Liquid Injection Valve Station ICF 20 40 Installation Guide ...

Page 232: ... When the valve is assembled make sure that some rust protective oil is supplied in the valve Before commissioning inlet and outlet valves must be closed at all time Fig 1a Fig 1b Fig 1c Fig 2 Fig 3 Danfoss M27H0049_1 Inlet and outlet stop valves must be closed all the time before commissioning of the installation in ordre to prevent rust formations in the valve The stop valves are closed when del...

Page 233: ... ft lbs 50 Nm 36 ft lbs For both ICF 20 and ICF 25 40 with ICM and ICFE 25 40 Please Note When used in CO2 the o rings see fig 4 on the ICM and ICFE 25 40 modules can swell grow At service it is recommend that new o rings are installed before the ICM and ICFE 25 40 function modules are reinstalled in the ICV valve body 2a 2b 4 12 o rings For the 4 bolts in all ICF modules ...

Page 234: ...not apply too much force Danfoss recommends that you conduct a stepwise tightening of the packing gland For each turn check for possible leaks Before remounting the cap on the modules ICFS stop valve module ICFR manual regulating valve module or ICFN stop check valve module please ensure that the gasket is present in the cap Then tighten the cap with 16 Nm 12 ft lbs Before remounting the cap on th...

Page 235: ...lockwise until the locking ring stops Do not force the spindle further If the locking ring is damaged or removed the spindle will start to leak The valve cannot be forced closed by the manual stem ICFE 25 40 solenoid valve module Locking ring Turn spindle counter clockwise to open Remove the cap on the side of the ICFE 20H At 9 o clock position the manual opener is disabled not active To force the...

Page 236: ...C 20 Check valve module ICFN 20 Stop check valve module ICM 20 A B or C Motor valve module ICFB 20 Blank top cover location not possible ICF 20 6 In order to supply the ICF valve station best suited for liquid lines and hot gas lines certain function modules are dedicated to specific module ports Function M1 M2 M3 M4 M5 M6 ICFS 20 Stop valve module ICFR 20A Manual regulating valve module ICFF 20 F...

Page 237: ...quid lines and hot gas lines certain function modules are dedicated to specific module ports Function M1 M2 M3 M4 ICFS 25 40 Stop valve module ICFR 25 40 A or B Manual regulating valve module ICFF 25 40 Filter module ICFE 25 40 Solenoid valve module ICFC 25 40 Check valve module ICFN 25 40 Stop check valve module ICM 25 A or C Motor valve module ICFB 25 40 Blank top cover ICFW 25 40 Welding module...

Page 238: ...at ICFO 20 manual opening module 1 Seal cap 2 Gland nut 3 Seal cap gasket 4 Sealing ring 5 Rubber gasket 6 Spindle 7 Hex head bolt 8 Flange ICFR 20 manual regulating valve module 1 Spindle 2 Thread part 3 AL gasket 4 Bonnet 5 Hex head bolt 6 Flange 7 Gasket 8 Seat ICFC 20 check valve module 1 Bonnet 2 Hex head bolt 3 Flange 4 Gasket ICM 20 A 20 B or 20 C motor valve module 1 Adapter 2 Hex head bol...

Page 239: ...asket ICFB 20 blank top cover module 1 Hex head bolt 2 Flange 3 Gasket ICFF 20E extended filter module 1 Dirt protection plug 2 Bonnet 3 Hex head bolt M12x80 4 Flange 5 Gasket 6 Filter element 7 Plug 3 8 NPT 8 Filter adaptor ICFS 25 40 stop valve module 1 Spindle 2 Thread part 3 O ring 4 Bonnet 5 Hex head bolt 6 Flange 7 Gasket ICFR 25 40 A or B manual regulating valve module 1 Spindle 2 Thread pa...

Page 240: ...O ring 4 Bonnet 5 Gasket 6 Seat ICFN 25 40 stop check valve module 1 Spindle 2 Thread part 3 O ring 4 Bonnet 5 Hex head bolt 6 Flange 7 Gasket ICFB 25 40 blank top cover module 1 Hex head bolt 2 Flange 3 Gasket ICFC 25 40 check valve module 1 Bonnet 2 Hex head bolt 3 Flange 4 Gasket ICFW 25 40 Welding module 25 DIN 1 Hex head bolt 2 Flange 3 Gasket 4 Weld connection 1 2 3 4 5 6 The function module...

Page 241: ...let side of the ICF must always be connected to the system or properly capped off for example with a welded on end plate Surface protection and identification The external surface is zinc chromated to provide corrosion protection according to EN 12284 2003 8 13 The Zinc Chromatization does not cover the welding connections After installation has been completed the external surface of the valve must...

Page 242: ...E 12 Blank VSS VSM VSH VSSH Installation Operation and Maintenance Manual Emerson 35391SD ...

Page 243: ...Appendix F Hand Held Slide Valve Calibration Tool F 1 VSS VSM VSH VSSH Installation Operation and Maintenance Manual Emerson 35391SD Appendix F Hand Held Slide Valve Calibration Tool ...

Page 244: ...check for the correct rotation see the Increase Direction for Single Screw Compressors Table on the next page to establish which one is the increase button and which one the decrease button for your compressor model Features The calibration procedure may be performed directly at the actuator so the operator can immediately de tect when the actuators start to slow down and reach the mechanical stop...

Page 245: ...ity Slide Valve Volume Slide Valve 151 VSM VSG CW CW 152 VSM VSG CW CW 181 VSM VSG CW CW 182 VSM VSG CW CW 201 VSM VSG CW CW 202 VSM VSG CW CW 291 VSS VSSH VSSG CW CW 301 VSM VSG CW CW 341 VSS VSSH VSSG CW CW 361 VSM VSG CW CW 401 VSM VSG CW CW 451 VSS VSSH VSSG CW CW 501 VSM VSG CCW CCW 601 VSM VSG CCW CCW 601 VSS VSSH VSSG CW CW 701 VSM VSG CCW CCW 751 VSS VSG CCW CCW 791 VSS VSH VSG CCW CCW 891...

Page 246: ...F 4 VSS VSM VSH VSSH Installation Operation and Maintenance Manual Emerson 35391SD Appendix F Hand Held Slide Valve Calibration Tool ...

Page 247: ...IMPORTANT FOR REMOTE OIL COOLERS ONLY READ BEFORE PROCEEDING G 1 VSS VSM VSH VSSH Installation Operation and Maintenance Manual Emerson 35391SD Appendix G Pre Start Up For Remote Oil Coolers ...

Page 248: ...G 2 Blank VSS VSM VSH VSSH Installation Operation and Maintenance Manual Emerson 35391SD ...

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Page 250: ...ity in cooling recovery and compression It combines best in class technology with proven engineering and design to create quality products and latest solutions for customers worldwide About Emerson Vilter Manufacturing LLC is a business segment of Emerson a global leader in bringing technology and engineering together to provide innovative solutions for customers in industrial commercial and consu...