Emerson Vsg Users Manual 35391SSG VSG/VSSG Compressor Unit Installation, Operation And Maintenance

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2015-01-05

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Front Cover
Vilter Warranty Statement
Table of Contents
Section 1 - General Information
Section 2 - Theory of Operation
Section 3 - Installation
Section 4 - Operation
Section 5 - Maintenance/Service
Section 6 - Troubleshooting
Section 7 - Warranty and Parts
Appendices
Back Cover

VSG/VSSG compressor unit

Installation, operation & maintenance manual

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Seller warrants all new single screw gas compression units and bareshaft single screw compressors

manufactured by it and supplied to Buyer to be free from defects in materials and workmanship for a period

of (a) eighteen (18) months from the date of shipment or (b) twelve (12) months from the date of

installation at the end user’s location, whichever occurs ﬁ rst.

If within such period any such product shall be proved to Seller’s satisfaction to be defective, such product

shall be repaired or replaced at Seller’s option. Such repair or replacement shall be Seller’s sole obligation

and Buyer’s exclusive remedy hereunder and shall be conditioned upon (a) Seller’s receiving written notice

of any alleged defect within ten (10) days after its discovery, (b) payment in full of all amounts owed by

Buyer to Seller and (c) at Seller’s option, Buyer shall have delivered such products to Seller, all expenses

prepaid to its factory. Expenses incurred by Buyer in repairing or replacing any defective product

(including, without limitation, labor, lost refrigerant or gas and freight costs) will not be allowed except by

written permission of Seller. Further, Seller shall not be liable for any other direct, indirect, consequential,

incidental, or special damages arising out of a breach of warranty.

This warranty is only applicable to products properly maintained and used according to Seller’s

instructions. This warranty does not apply (i) to ordinary wear and tear, damage caused by corrosion,

misuse, overloading, neglect, improper use or operation (including, without limitation, operation beyond

rated capacity), substitution of parts not approved by Seller, accident or alteration, as determined by Seller

or (ii) if the product is operated on a gas with an H2S level above 100 PPM. In addition, Seller does not

warrant that any equipment and features meet the requirements of any local, state or federal laws or

regulations. Products supplied by Seller hereunder which are manufactured by someone else are not

warranted by Seller in any way, but Seller agrees to assign to Buyer any warranty rights in such products

that Seller may have from the original manufacturer. Labor and expenses for repair are not covered by

warranty.

THE WARRANTY CONTAINED HEREIN IS EXCLUSIVE AND IN LIEU OF ALL OTHER REPRESENTATIONS AND

WARRANTIES, EXPRESS OR IMPLIED, AND SELLER EXPRESSLY DISCLAIMS AND EXCLUDES ANY IMPLIED WARRANTY

OF MERCHANTABILITY OR IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Any description of the products, whether in writing or made orally by Seller or Seller’s agents,

speciﬁ cations, samples, models, bulletins, drawings, diagrams, engineering sheets or similar materials used

in connection with Buyer’s order are for the sole purpose of identifying the products and shall not be

construed as an express warranty. Any suggestions by Seller or Seller’s agents regarding use, application or

suitability of the products shall not be construed as an express warranty unless conﬁ rmed to be such in

writing by Seller.

VSG/VSSG Standard Vilter Warranty Statement

ii VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSOR.

The following instructions have been prepared to assist in installation, operation and removal of Vilter Single Screw

Compressors. Following these instructions will result in a long life of the compressor with satisfactory operation.

The entire manual should be reviewed before attempting to install, operate, service or repair the compressor.

A compressor is a positive displacement machine. It is designed to compress gas. The compressor must

not be subjected to liquid carry over. Care 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 or the controls needed to prevent liquid carry over and as such Vilter Manufacturing cannot

warrant equipment damaged by improperly protected or operating systems.

Vilter screw compressor components are thoroughly inspected at the factory. However, damage can occur

in shipment. For this reason, the equipment should be thoroughly inspected upon arrival. Any damage

noted should be reported immediately to the Transportation Company. This way, an authorized agent

can examine the unit, determine the extent of damage and take necessary steps to rectify the claim with

no serious or costly delays. At the same time, the local Vilter representative or the home office should be

notified of any claim made.

All inquires should include the Vilter sales order number, compressor serial and model number. These can be

found on the compressor name plate on the compressor.

All requests for information, services or parts should be directed to:

Vilter Manufacturing LLC

Customer Service Department

P.O. Box 8904

5555 South Packard Ave

Cudahy, WI 53110-8904 USA

Telephone: 1-414-744-0111

Fax:1-414-744-3483

e-mail: info.vilter@emerson.com

Equipment Identification Numbers:

Vilter Order Number: _______________________Compressor Serial Number: _________________

Important Message

TOC - 1

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

VSG/VSSG Standard Vilter Warranty Statement .....................................................................................i

Important Message................................................................................................................................ ii

Section 1 • General Information

How To Use This Manual .........................................................................................................................1-1

Gas Compressor Unit Model Designations ..............................................................................................1-2

System Unit Identification .....................................................................................................................1-3

Compressor Unit Component Identification ...........................................................................................1-4

Piping & Identification Component Tags .................................................................................................1-7

Symbols and Identification .....................................................................................................................1-8

Section 2 • Theory of Operation

Gas Flow ................................................................................................................................................2-1

Oil Life and Oil Flow ................................................................................................................................2-1

Oil Pressure Regulating ..........................................................................................................................2-2

Control System ......................................................................................................................................2-2

RTDs and Pressure Transducers ..............................................................................................................2-2

Section 3 • Installation

Delivery Inspection ................................................................................................................................3-1

Rigging and Lifting .................................................................................................................................3-1

Short Term Storage Recommendations ..................................................................................................3-2

Long Term Storage Recommendations ...................................................................................................3-2

Compressor Motor .....................................................................................................................3-2

Air Cooled Oil Coolers ................................................................................................................3-3

Compressor Unit Inspections Prior to Stoarge or Installation ..................................................................3-3

Recommended Onsite Tools ..................................................................................................................3-3

Long Term Storage Log ..........................................................................................................................3-4

Foundation ............................................................................................................................................3-5

Piping .................................................................................................................................................. 3-10

Header Piping and Drains ...........................................................................................................3-10

Remote Air Cooled Oil Cooler Piping ..........................................................................................3-10

General Installation Guideline for Multiple Air Coolers Installed in a Common Area ................................ 3-12

Free Flow ...................................................................................................................................3-12

One Fan Diameter ......................................................................................................................3-12

Intake Velocity ...........................................................................................................................3-12

Hot Air Recirculation ..................................................................................................................3-14

Pressure Testing .....................................................................................................................................3-16

Initial Oil Charging .................................................................................................................................3-16

Using Non-Vilter Oils .................................................................................................................. 3-16

Unit Oil Charging and Priming .................................................................................................... 3-16

Priming Oil Cooler (Shell and Tube)and Piping............................................................................ 3-16

Priming Compressor and Oil Filters ............................................................................................3-18

Priming Remote Oil Cooler and Piping (Initial Oil Charging) ........................................................3-20

Priming Compressor and Oil Filters ............................................................................................3-21

Pre Start-Up ...........................................................................................................................................3-22

Start-Up .................................................................................................................................................3-24

Table of Contents

Section Title Section Number

TOC - 2 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 4 • Operation

Oil Inspection ........................................................................................................................................4-1

Dual Oil Filters........................................................................................................................................ 4-1

Control System Calibration ....................................................................................................................4-2

Starting, Stopping and Restarting the Compressor ................................................................................4-2

Calibrate Slide Valve Actualors ...............................................................................................................4-2

Oil Temperature Control Valve (Oil Mixing Valve) Operation ...................................................................4-7

Manual Override ........................................................................................................................4-8

Purging with Dry Nitrogen .....................................................................................................................4-9

Purging with Dry Gas .............................................................................................................................4-11

Coalescing Oil Return Line Setup ............................................................................................................4-14

Section 5 • Maintenance/Service

Maintenance and Service Schedule ........................................................................................................5-1

Maintaining Proper Operation ................................................................................................................5-2

Compressor Unit Isolation for Maintenance/Service ...............................................................................5-3

Compressor Unit Leak Check ..................................................................................................................5-3

Oil System Components .........................................................................................................................5-4

Oil Sampling............................................................................................................................... 5-4

Oil Charging ...............................................................................................................................5-5

Oil Draining ................................................................................................................................5-6

Oil Filter Replacement ................................................................................................................5-6

Coalescing Oil Filter Replacment ................................................................................................. 5-8

Oil Pump Strainer .......................................................................................................................5-9

Drive Coupling (Form-Flex BPU) Installation ...........................................................................................5-10

Drive Center Member (Form-Flex BPU) Installation and Alignment ......................................................... 5-11

Drive Coupling (Form-Flex BPU) Removal ...............................................................................................5-13

Drive Coupling (Type C Sure-Flex) Replacement .....................................................................................5-13

Compressor Replacement ......................................................................................................................5-14

Compressor Bearing Float Inspections ...................................................................................................5-16

Gate Rotor Float and Gate Rotor Bearing Float Inspection .......................................................................5-17

Gate Rotor and Support Clearance .........................................................................................................5-19

Gate Rotor Assembly Replacement (All VSG & VSSG Compressors Except VSG 301-701 Compressors) ....5-21

Gate Rotor Assembly Replacement (VSG 301-701 Compressors ONLY) ...................................................5-24

Gate Rotor Disassembly .........................................................................................................................5-26

Gate Rotor Blade Removal/Installation ....................................................................................... 5-26

Gate Rotor Thrust Bearing Removal/Installation .........................................................................5-27

Gate Rotor Roller Bearing Removal/Installation ...........................................................................5-27

Slide Valve Actuator Assembly Replacement .......................................................................................... 5-28

Command Shaft Assembly Replacement ................................................................................................5-29

Command Shaft Seal Replacement .........................................................................................................5-29

Section 6 • Troubleshooting

Table 6-1. Slide Valve Actuator Troubleshooting Guide ...........................................................................6-1

Table 6-2. Slide Valve Actuator LED Blink Codes ......................................................................................6-3

Table 6-3. Troubleshooting Guide - General Problems & Solutions ..........................................................6-5

Table of Contents

Section Title Section Number

TOC - 3

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Tables

Table 3-1. Long Term Storage Compressor Hardware .............................................................................3-2

Table 3-2. Maximum Allowable Flange Loads .........................................................................................3-11

Table 4-1. Command Shaft Rotation Specifi cations ................................................................................ 4-6

Table 5-1. Maintenance/Service Schedule ..............................................................................................5-1

Table 5-2. Oil Filter Elements and Compressor Models ............................................................................5-6

Table 5-3. Shaft and Hub Distances ........................................................................................................5-10

Table 5-4. Hub Clamp Bolt and Set Screw Torque Specifi cations .............................................................5-12

Table 5-5. Disc Pack Installation Torque Specifi cations ...........................................................................5-12

Table 5-6. Clamping Bolts and Set Screw Torque Specifi cations..............................................................5-14

Table 5-7. Maximum Bearing Float (Compressor Shaft) ..........................................................................5-17

Table 5-8. Gate Rotor Float .....................................................................................................................5-18

Table 5-9. Gate Rotor Tool Sets ...............................................................................................................5-21

Table 6-1. Slide Valve Actuator Troubleshooting Guide (1 of 2) ............................................................... 6-1

Table 6-2. Slide Valve Actuator LED Blink Codes* (1 of 2) ........................................................................6-3

Table 6-3. Troubleshooting Guide - General Problems & Solutions (1 of 3) ..............................................6-5

Figures

Figure 1-1. Gas Compressor Unit Model Designation ............................................................................. 1-2

Figure 1-2. Gas Compressor Unit Components .......................................................................................1-4

Figure 2-1. Gas Compressor Unit P&ID ...................................................................................................2-1

Figure 3-1. Rigging and Lifting Points .....................................................................................................3-1

Figure 3-2. Concrete Pad with Compressor Unit Dimensions - Side View ................................................3-5

Figure 3-3. Concrete Pad with Compressor Unit Dimensions - Front View ...............................................3-6

Figure 3-4. Interior Foundation Isolation ................................................................................................3-6

Figure 3-5. Foundation with Housekeeping Pads Dimensions - Top View ................................................3-7

Figure 3-6. Housekeeping Pad Dimension Detail - Top View ...................................................................3-9

Figure 3-7. Level Compressor Unit Using Top Surface of Spherical Washers ............................................3-9

Figure 3-8. Concrete Pad Housekeeping Detail .......................................................................................3-10

Figure 3-9. Maximum Allowable Flange Loads ........................................................................................3-11

Figure 3-10. Installation of Coolers - One Fan Diameter Next to Building ................................................3-12

Figure 3-11. Leg Height ..........................................................................................................................3-13

List of Tables and Figures

Table/Figure Section Number

Section Title Section Number

Section 7 • Warranty and Parts

Warranty Claim Processing ....................................................................................................................7-1

On Site Service Support .........................................................................................................................7-1

Remanufactured Bare Shaft Compressors Process ..................................................................................7-2

Explanation of Rebuild Levels .....................................................................................................7-2

Bare Shaft Compressor Description ............................................................................................7-2

Appendices

Appendix A Torque Specifications ......................................................................................................A

Appendix B Motor (Compressor) General Storage Instructions .......................................................... B

Appendix C Oil Analysis Report ..........................................................................................................C

Appendix D Recommended Header Piping ........................................................................................D

Appendix E Recommended Remote Air Cooled Oil Cooler Piping .......................................................E

TOC - 4 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Figure 3-12. Installation of Coolers - Next to Buildling ............................................................................3-13

Figure 3-13. Discharge Elevation of Coolers ............................................................................................3-15

Figure 3-14. Cooler Placement and Spacing ............................................................................................ 3-15

Figure 3-15. Oil Operating Levels ...........................................................................................................3-17

Figure 3-16. Suction Oil Charging Valve, Oil Cooler Drain and Oil Filter Shut-Off Valves ...........................3-17

Figure 3-17. Priming Oil Cooler (Shell & Tube) and Piping .......................................................................3-18

Figure 3-18. Priming Compressor (with Shell & Tube Oil Cooler) and Piping ............................................3-19

Figure 3-19. Priming Remote Oil Cooler and Piping ................................................................................3-20

Figure 3-20. Priming Compressor and Oil Filters .....................................................................................3-21

Figure 4-1. Oil Operatiing Levels .............................................................................................................4-1

Figure 4-2. Actuator Assembly ...............................................................................................................4-3

Figure 4-3. Menu Screen and Slide Calibraiton Button (Compact Logix PLC) ...........................................4-4

Figure 4-4. Slide Valve Calibraiton Screen (Compact Logix PLC) ..............................................................4-5

Figure 4-5. Photo-chopper .....................................................................................................................4-5

Figure 4-6. Oil Temperature Control Valve (Oil Mixing Valve) ..................................................................4-8

Figure 4-7. PLC Main Screen ................................................................................................................... 4-9

Figure 4-8. Suction Bypass Valve and Equalizing Solenoid .......................................................................4-10

Figure 4-9. Suction Oil Charging Valve and Discharge Bleed Valve .......................................................... 4-10

Figure 4-10. Customer Purge Line ..........................................................................................................4-11

Figure 4-11. PLC Main Screen ................................................................................................................. 4-12

Figure 4-12. Suction Bypass Valve and Equalizing Solenoid .....................................................................4-13

Figure 4-13. Suction Oil Charging Valve .................................................................................................4-13

Figure 4-14. Coalescing Oil Return Line .................................................................................................. 4-14

Figure 5-1. Suction Bypass Valve (Manual) Location (1 of 2) ....................................................................5-2

Figure 5-1. Suction Bypass Valve (Equalizing Solenoid) Location (2 of 2) ................................................. 5-3

Figure 5-2. Oil Analysis Kit ......................................................................................................................5-4

Figure 5-3. Suction Oil Charging, Oil Cooler Drain Valve and Oil Filter Shut-Off Valves ............................5-5

Figure 5-4. Oil Filter Assemblies (Single and Dual) ..................................................................................5-6

Figure 5-5. Oil Filter Drain, Vent and Shut-Off Valves ..............................................................................5-7

Figure 5-6. Oil Separator Manhole Cover and Coalescing Filter Assembly ................................................5-8

Figure 5-7. Oil Pump Strainer and Drain Valve ........................................................................................5-9

Figure 5-8. Hub Distance (Axial Spacing) ................................................................................................5-11

Figure 5-9. Angular Alignment and Parallel Offset ..................................................................................5-12

FIgure 5-10. Compressor Replacement and Hardware Assembly (Models 2401-3001 Shown) ................ 5-15

FIgure 5-11. Bearing Axial Float Inspection (Compressor) .......................................................................5-16

FIgure 5-12. Bearing Radial Float Inspection (Compressor) .....................................................................5-17

FIgure 5-13. Gate Rotor Float .................................................................................................................5-17

FIgure 5-14. Gate Rotor Bearing Float .....................................................................................................5-18

FIgure 5-15. Gate Rotor and Support Clearance - Minimum Clearances .................................................. 5-19

FIgure 5-16. Gate Rotor and Support Clearance - Measuring ...................................................................5-20

FIgure 5-17. Gate Rotor Assembly Removal and Tools ............................................................................5-22

FIgure 5-18. Gate Rotor Assembly Removal ............................................................................................5-22

FIgure 5-19. Gate Rotor Assembly and Tools ...........................................................................................5-23

FIgure 5-20. Gate Rotor and Shelf Clearance ...........................................................................................5-23

FIgure 5-21. Gate Rotor Assembly Breakdown ........................................................................................5-24

FIgure 5-22. Gate Rotor Thrust Bearing ..................................................................................................5-25

FIgure 5-23. Gate Rotor and Shelf Clearance ...........................................................................................5-25

FIgure 5-24. Gate Rotor Blade Assembly .................................................................................................5-26

FIgure 5-25. Gate Rotor Blade Installation ..............................................................................................5-26

FIgure 5-26. Gate Rotor Thrust Bearing ..................................................................................................5-27

FIgure 5-27. Thrust Bearing Installation ..................................................................................................5-27

FIgure 5-28. Roller Bearing Assembly ..................................................................................................... 5-28

FIgure 5-29. Command Shaft Seal ..........................................................................................................5-29

FIgure 5-30. Command Shaft Seal Installation ........................................................................................5-30

List of Tables and Figures

Table/Figure Section Number

1 – 1

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

How To Use This Manual

This manual contains instructions for gas compressor

units. It has been divided into eight sections:

Section 1: General Information

Section 2: Theory of Operation

Section 3: Installation

Section 4: Operation

Section 5: Maintenance & Service

Section 6: Troubleshooting

Section 7: Warranty and Parts

Appendices

It is highly recommended that the manual be reviewed

prior to servicing system parts.

Figures and tables are included to illustrate key concepts.

Safety precautions are shown throughout the manual.

They are deﬁ ned 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 ﬁ nes, serious injury and/or death.

WARNING - Warning statements are shown when there

are hazardous situations, if not avoided, will result in se-

rious injury and/or death.

CAUTION - Caution statements are shown when there

are potentially hazardous situations, if not avoided, will

result in damage to equipment.

NOTE - Notes are shown when there are addtional infor-

mation pertaining to the instructions explained.

Additional installation, operation and maintenance in-

structions can be found in the associated software man-

ual and bareshaft compressor manual.

Section 1 • General Information

1 – 2 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

1. Compressor Model

VSG = Vilter Single Screw Compressor

VSSG = Vilter Single Screw Compressor

(Compressor models 291, 341, 451 & 601 -

these are 240mm diameter rotors with

counter clockwise rotation)

VRSG = Vilter Twin Screw

2. Size

CFM - Nominal CFM displacement of the compressor at

3600 rpm

3. Slide Arrangement

VVR = Variable Volume Ratio; Parallex™

4. Gas Compressed

L = Landﬁ ll Gas

D = Digester Service Site Application

N = Natural Gas (Primarily Methane)

G = Other Gas Type

5. Application

HP = High Stage with Oil Pump

HN = High Stage no Oil Pump

6. Driver

VFD = Variable Frequency Drive

EMD = Electric Motor Drive

ENG = Engine Drive

7. Separator Type

16 = 16 inch diameter 36 = 36 inch diameter

20 = 20 inch diameter 42 = 42 inch diameter

24 = 24 inch diameter 48 = 48 inch diameter

30 = 30 inch diameter 54 = 54 inch diameter

H = Horizontal V = Vertical

SH = Special Horizontal SV = Special Vertical

8. Economizer

NEC = No Economizer, Economizer Ports Plugged

HEC = Holes drilled in Economizer Plug for Oil

or Unloading

9. Oil Cooler

PLT = Plate

ST = Shell and Tube

REM = Remote

10. Oil Cooling Medium

REF = Refrigerant

WTR = Water

GL = Glycol

AIR = Air

Gas Compressor Unit Model Designations

The compressor unit model designation can be found on the nameplate. For nameplate location, see Component

Identiﬁ cation on section page 1-4.

VSG-601-VVR-L-HP-VFD-36H-NEC-ST-WTR

1234567 8 9 10

Figure 1-1. Gas Compressor Unit Model Designation

Section 1 • General Information

1 – 3

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

System Unit Identiﬁ cation

To keep deﬁ nitions of units simple and consistent, Vilter has deﬁ ned the following three:

• Bare Shaft Compressor

• Compressor Unit

• Package Unit

Bare Shaft Compressor

A bare shaft compressor is just the compressor with no coupling and motor nor foundation.

Compressor Unit

A compressor unit consists of the bare shaft compressor with the coupling, motor, oil separator, frame, micro-control-

ler system and oil system. A compressor unit typically a single screw compressor unit, is not mounted on a structural

steel base.

Package Unit

A package unit is a complete system mounted on a structural steel base with interconnecting piping.

Section 1 • General Information

1 – 4 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

1 - Motor

2 - Coupling

3 - Suction Strainer

4 - Suction Check Valve

5a - Suction Stop Valve

5b - Suction Stop Butterﬂ y Valve

(Typically Shipped Loose)

6 - Compressor

7 - Discharge Pipe

8 - PLC Panel

9 - Block & Bleed Assembly

10 - Oil Pump

11 - Oil Heater

12 - Oil Separator

13 - Oil Temperature Control Valve

(Oil Mixing Valve)

14 - Oil Pump Strainer

15 - Oil Sight Glass

16 - Oil Filter

(Optional Dual Oil Filters Shown)

17 - Discharge Connection

18 - Oil Separator Inspection Port

19 - Thermal/Acoustic Oil Separator

Blanket

(Optional Per Application)

20 - Nameplate

21 - Heat Trace Insulation

(Optional Per Application)

22 - Frame

23 - Oil Cooler (Shell and Tube Heat

Exchanger)

23 4 5a

1013

1112141511

Compressor Unit Component Identiﬁ cation

Each gas compressor unit may differ, but below are typical components that can be found on each unit.

Figure 1-2. Gas Compressor Unit Components (1 of 3)

Section 1 • General Information

1 – 5

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

2021

Figure 1-2. Gas Compressor Unit Components (2 of 3)

Section 1 • General Information

1 – 6 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

24 - RTD (Oil Filter Outlet)

25 - Pressure Transducer (Oil Injection

Temperature)

26 - Volume Slide Valve Actuator

27 - RTD (Discharge)

28 - RTD (Suction)

29 - Capacity Slide Valve Actuator

30 - Pressure Transducers

(Discharge, Oil Filter Inlet and

Outlet)

Component Identiﬁ cation (Continued)

31 - Block & Bleed Assembly

32 - Remote Oil Cooler (Finned Fan

Heat Exchanger)

33 - RTD (Oil Separator)

Figure 1-2. Gas Compressor Unit Components (3 of 3)

Section 1 • General Information

25 27 28

OUTLET

INLET

1 – 7

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Piping & Identiﬁ cation Component Tags

Use this list to identify components shown in the Piping & Identiﬁ cation Diagram.

A Atmosphere

AN Anode - Sacriﬁ cial

AV Angle Valve

BFV Butterﬂ y Valve

BDV Automatic Blowdown

Valve

BV Ball Valve

C Compressor

CPL Coupling

CRR Cooling Refrigerant Liquid

Return

CRS Cooling Refrigerant Liquid

Supply

CS Carbon Steel or Cold Side

CV Check Valve

CWR Cooling Water Return

CWS Cooling Water Supply

D Drive Motor or Drain

E Heat Exchanger

EQ Equalizing Line

F Fan

FC Fail Closed or Flow

Controller

FG Flow Switch Indicator or

Glass

FI Flow Indicator

FIT Flow Indicating

Transmitter

FO Fail Open

FSI Flow Sight Indicator

FT Flow Transmitter (Blind)

FV Flow Control Valve

(Pneumatic Actuator)

GLV Globe Valve

GTV Gate Valve

HS Hand Switch or Hot Side

HEV Hand Expansion Valve

HV Hand Valve

IA Instrument Air

II Current Indicator

IT Current Transmitter

JB Electrical Terminal Box or

Junction Box

LC Level Control

LE Level Probe

LI Level Indicator or Gauge

LIT Liquid Level Indicating

Transmitter

LO Lube Oil or Lock Open

LP Local Panel

LSH Level Switch High

LSHH Level Switch Shutdown

High High

LSL Level Switch Low

LSLL Level Switch Shutdown

Low Low

LV Level Control Valve -

Pneumatic Actuator

MCC Motor Control Center or

Motor Starter

MV Motor Operated Valve

MGV Manifold Gauge Valve

MI Moisture Indicator

N Nitrogen

NC Normally Closed

NO Normally Open

NV Needle Valve

P Pump or Process

PDI Differential Pressure

Indicator - Gauge

PDIT Differential Pressure

Indicating Transmitter

PDSH Differential Pressure

Switch High

PDSHH Differential Pressure

Switch Shutdown High

High

PDSL Differential Pressure

Switch Low

PDSLL Differential Pressure

Switch Shutdown Low

Low

PDT Differential Pressure

Transmitter - Blind

PDV Differential Pressure

Control Valve - Pneumatic

Actuator

PI Pressure Indicator or

Gauge

PIT Pressure Indicating

Transmitter

PSH Pressure Switch High

PSHH Pressure Switch

Shutdown High High

PSL Pressure Switch Low

PSLL Pressure Switch

Shutdown Low Low

PSV Pressure Safety Relief

Valve

PT Pressure Transmitter

- Blind

PV Pressure Control Valve

QE Heater Element -

Immersion Heater

R Refrigerant

RD Rupture Disc

SDV Automatic Shut-off Valve

SG Sight Glass

SS Stainless Steel or Heat

Exchanger Shell Side

STR Strainer

SV Safety Relief or Slide Valve

SW Selector Switch

TE Temperature Element -

RTD or Thermocouple

Section 1 • General Information

1 – 8 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

TI Temperature Indicator or

Thermometer

TIT Temperature Indicator

Transmitter

TRV Transfer Valve - 3-way or

6-way Valve

TS Heat Exchanger Tube Side

TSH Temperature Switch High

TSHH Temperature Switch

Shutdown High High

TTSL Temperature Switch Low

TSLL Temperature Switch

Shutdown Low Low

TT Temperature Transmitter

- Blind

TV Temperature Control

Valve

TW Thermowell

V Vent

VG Gauge Valve

VTRI Venturi

VLV Stop Valve

XV Solenoid Valve

YE Vibration Probe

YSH Vibration Switch High

YSHH Vibration Switch

Shutdown High High

YT Vibration Transmitter

YU Vibration Monitoring

System

YZE Axial Proximitor Probe -

Axial Displacement

YZT Axial proximitor

Transmitter - Axial

Displacement

YZU Axial Proximitor

Monitoring System

ZE Position Element

- Positioner

ZI Position Indicator

ZIT Position Indicating

Transmitter

ZT Position Transmitter

- Blind

Symbols and Identiﬁ cations

Use this list to identify components shown in the Piping & Identiﬁ cation Diagram.

3-Way Valve

Angle Valve

Globe Valve

Gate Valve

Butterﬂ y Valve

Ball Valve

Schrader Valve

Pressure Safety Relief

Valve

Spring-Closing Drain

Valve

Block & Bleed Manifold

Solenoid Valve

3-Way Solenoid Valve

Needle Valve

Check Valve

Strainer

Suction Strainer

Motorized Valve

3-Way Thermostatic Valve

Hand Expansion Valve

Restriction Oriﬁ ce

Rupture Disc

Inlet Pressure Regulating

Valve

Outlet Pressure

Regulating Valve

Differential Pressure

Regulating Valve

Pneumatic Actuator

Control Valve Fail Close

Pneumatic Actuator

Control Valve Open

Diaphragm Actuator

Diaphragm

Spring-Opposed

Diaphragm

Pressure-Balanced

Vilter Venturi Injector

Nozzle

Flange Set

Pipe Reducer

Thermowell

Drive Coupling

Insulation Not by Vilter

Insulation by Vilter

Vibration Absorber

Heater

Heat Trace

Low Side Float Valve

Section 1 • General Information

1 – 9

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

High Side Float Valve

Steady-Mount

Bulb & Capillary

Thermostatic Expansion

Valve

Pilot Light (Color Inside)

Man-Way Cover

BY VILTER BY OTHERS

Scope of Supply

Economizer Regulator

Compressor

Motor

Heat Exchanger

Fan

Vertical Tank/Drum Vessel

Horizontal Tank/Drum

Vessel

Positive Displacement

Pump

Centrifugal Pump

Rotary Pump

Filter

Plate & Frame Heat

Exchanger

Discrete Instrument, Field

Mounted

Discrete Instrument,

Remote, Mount, Normally

Accessible to Operator

Discrete Instrument, Local

Rack Mounted, Normally

Accessible to Operator

Shared Display/Control,

Field Mounted

Shared Display/Control,

DCS or Remote Control

Panel Normally Accessible

to Operator

Shared Display/Control,

Local Control Panel

Normally Accessible to

Operator

Programmable Logic

Control, Field Mounted

Programmable Logic

Control, DCS or Remote

Control Panel, Normally

Accessible to Operator

Programmable Logic

Control, Local Control

Panel, Normally

Accessible to Operator

Pneumatic Signal

XXXXX

Capillary Tube

Electrical Signal

Internal System Link

(Software or Data Link)

Mechanical Link

LLLLL

Hydraulic Signal

V100

EQUIPMENT TYPE SERIES NUMBER

Equipment Number

Identiﬁ cation

Section 1 • General Information

1 – 10 / Blank VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

2 – 1

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 2 • Theory of Operation

The gas and oil systems work in unison, but each one

will be explained separately. Reference Figure 3 - Gas

Compressor Unit P&ID for gas and oil ﬂ ow descriptions.

Gas Flow

The gas compression process begins as processed gas

enters the suction inlet (1). The processed gas ﬂ ows

through a stop valve (2), check valve (3) then through

a suction line strainer (4) to the compressor (14). The

processed gas is then pressurized through the compres-

sor and discharged as high pressure gas vapor into the

oil separator (13). In the oil separator, the oil is then

separated from the discharged gas vapor by impinge-

ment separation. The high pressure gas ﬂ ows out to

the aftercooler and scrubber for cooling while the oil is

pumped or syphoned back to the compressor.

Moreover, check valves (3) and (6) are provided between

the oil separator to prevent gas vapor or liquid from ﬂ ow-

ing back to the compressor during shutdown periods.

An equalizing line is also installed between the high

pressure side (oil separator) and low pressure side (suc-

tion) to allow .

Oil Life and Oil Flow

The life of the oil is directly affected by the quality of the

gas. Proper separation of any liquids must be accom-

plished to prevent droplets of liquid at the compressor

OIL SEPARATOR

OPTIONAL DUAL OIL FILTERS

STANDARD SINGLE

OIL FILTER

COMPRESSOR

FILTER

DRAIN

BLEED

FILTER

BLEED

DRAIN

BLEED

SUCTION GAS

1/4” OIL CHARGING

1/4”

100#

DISCHARGE

STOP VALVE

MOTOR

BLEED

MOTOR

PUMP

CHECK

VALVE

OPTIONAL REMOTE AIR COOLED OIL COOLER

STANDARD WATER COOLED OIL COOLER

OIL COOLER

DRAIN

VENT

OIL

DRAIN

Figure 2-1. Gas Compressor Unit P&ID

1 2 3 4

14 13

2 – 2 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

suction. The discharge temperature of the compressor

must be kept a minimum of 30°F (or 17°C) above the dis-

charge gas dew point to prevent the condensing of liq-

uids in the oil separator. The oil separator shell and legs

must be insulated when the gas stream has a high prob-

ability of having condensables.

Oil in the gas compressor unit 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

ﬂ ow is driven by a mechanical gear pump (7). Once the

system reaches design conditions, the oil pump is shut

off and oil ﬂ ow is maintained by differential pressure in

the gas system.

As the oil is separated from the gas in the oil separator,

it is pumped or syphoned through an oil cooler (9), then

ﬁ ltered through a single (11) or dual oil ﬁ lters (15) and

back to the injection port of the compressor (14). The

standard oil cooler is a shell and tube water cooled heat

exchanger (9). The other option is to air cool oil remotely

through a ﬁ nned fan heat exchanger (8).

Furthermore, to collect oil from the coalescing side of

the oil separator (12), a line is installed between the oil

separator and the compressor. By opening the shut-off

valve (6), this will allow oil dripping off the coalescing ﬁ l-

ters to be fed back to the compressor. In addition, the oil

cooler (8 or 9) is piped in parallel to the oil temperature

control valve (oil mixing vlave) (10), which acts as a by-

pass valve.

On units with a full-time oil pump, oil pressure is regu-

lated by the oil pressure regulator (12). It controls up-

stream pressure to the compressor bearings and should

be adjusted to hold the oil pressure at 20 psig above suc-

tion pressure. Excess oil not required for bearing lubrica-

tion is passed through the regulator and back into the oil

separator (13).

This is a continuous cycle.

Control System

The gas compressor unit is controlled by a Programmable

Logic Controller (PLC) panel. This PLC panel’s main func-

tion is to control the gas compression system from the

data that it receives from the sensors around the unit.

Refer to Compact Logix PLC manual (35391CL) for addi-

tional information.

RTDs and Pressure Transducers

Resistance Thermometers (RTDs) and pressure trans-

ducers are instruments used to measure temperatures

and pressures at speciﬁ c locations on the gas compressor

unit, see Figure 1-2. Gas Compressor Unit Components.

RTDs are typically mounted on the suction pipe, dis-

charge pipe, oil separator and oil ﬁ lter outlet pipe.

Pressure transducers are typically mounted on the block

and bleed assembly and directly on the suction pipe. The

pressure transducers measure suction pressure, inlet

and outlet oil pressure, and oil separator pressure.

Section 2 • Theory of Operation

3 – 1

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Only qualiﬁ ed personnel shall operate rigging and lift-

ing equipment. Ensure that the lifting device is capable

of lifting the weight of the compressor unit, refer to the

supplied Vilter General Assembly (GA) drawing.

To lift the compressor unit, use lifting points on com-

pressor unit frame to attach the lifting device, see Figure

3-1. There are a few points to consider prior to moving

the unit:

• Ensure that the weight is evenly distributed amongst

the lifting device (i.e. lifting chains and spreader bar)

prior to lifting.

• Ensure that the lifting device is not obstructed by any

parts of the compressor unit to prevent damage to

components.

• Use additional personnel as needed to spot and aid in

maneuvering the compressor unit.

• Ensure there is plenty of space to maneuver the com-

pressor unit and a clear path to its location.

Delivery Inspection

All equipment supplied by Vilter are thoroughly inspect-

ed at the factory. However, damage can occur in ship-

ment. For this reason, the units should be thoroughly

inspected upon arrival, prior to off-loading. Any dam-

age noted should be photographed and reported im-

mediately to the transportation company. This way, an

authorized agent can examine the unit, determine the

extent of damage and take necessary steps to rectify the

claim with no serious or costly delays. At the same time,

the local Vilter representative or the home ofﬁ ce should

be notiﬁ ed of any claims made within ten (10) days after

its discovery. Refer to long term storage for additional

recommendations.

Rigging and Lifting of Compressor

Unit WARNING

When rigging and lifting a compressor unit, use proper

lifting device capable of lifting and maneuvering the

weight and size of the compressor unit. Use only

qualiﬁ ed personnel and additional personnel and

lifting equipment (i.e. spreader bar) as required.

Failure to comply may result in death, serious injury

and/or damage to equipment.

Figure 3-1. Rigging and Lifting Points

Section 3 • Installation

Lifting Point

Use lifting chains/straps and spreader bar. Evenly

distribute weight. Keep lifting chains and spreader

bar clear of components to prevent damage.

3 – 2 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

COMPRESSOR MOTOR

The following are general recommendations. Refer to

speciﬁ c motor manufacturer instructions for storage

recommendations.

• Remove the condensation drain plugs from those

units equipped with them and insert silica-gel into

the openings. Insert one-half pound bags of silica-

gel (or other desiccant material) into the air inlets and

outlets of drip-proof type motors.

NOTE

Bags must remain visible and tagged, so they will be

noticed and removed when the unit is prepared for

service.

• Cover the motor completely to exclude dirt, dust,

moisture, and other foreign materials.

• If the motor can be moved, it is suggested that the

entire motor be encased in a strong, transparent plas-

tic bag. Before sealing this bag, a moisture indicator

should be attached to the side of the motor and sev-

eral bags of silica-gel desiccant be placed inside the

bag around the motor. When the moisture indicator

shows that the desiccant has lost its effectiveness, re-

place desiccants.

• Whenever the motor cannot be sealed, space heat-

ers must be installed to keep the motor at least 10°F

above the ambient temperature.

• Rotate motor and compressor shafts several revolu-

tions (approximately 6) per month to eliminate ﬂ at

spots on the bearing surfaces. For motors utilizing

anti-friction bearings, the shaft should be rotated

once every 30 days by hand at 30 RPM for 15 seconds

in each direction. Bearings should also be re-lubricat-

ed at 2-year intervals using the grease speciﬁ ed on

the motor lubrication nameplate.

• If the compressor unit is installed, wired and charged

with oil, open all oil line valves and run the oil pump

for 10 seconds prior to rotating the compressor shaft.

Continue running the oil pump while the compressor

shaft is being turned to help lubricate the surfaces of

the shaft seal.

For additional storage information, refer to Appendices.

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 ﬁ rm and end user to address any unusual

conditions. Use the supplied long term storage log sheet

to help with record keeping, see section page 3-3.

Warranty of the system remains in effect as described at

the beginning of this manual, section page i.

The following are recommendations regarding long

term storage:

• If the unit is designed for indoor duty, it must be

stored in a heated building.

• If the unit is designed for outdoor duty and is to be

stored outdoors, a canvas tarp is recommended

for protection until installation. Adequate drainage

should be provided. Place wood blocks under the

base skid so that water does not collect inside the

base perimeter or low spots in the tarp.

• All compressor stop valves are to be closed to isolate

the compressor from the remainder of the system.

All other valves, except those venting to atmosphere,

are to be open. The unit is shipped with dry nitrogen

holding charge of approximately 5 psi above atmo-

spheric pressure. It is essential that the nitrogen hold-

ing charge be maintained.

• The nitrogen or clean dry gas holding charge in the

system and compressor are to be monitored on a

regular basis for leakage. If not already installed, it is

required that a gauge is to be added to help moni-

tor the nitrogen holding charge pressure. If a drop in

pressure occurs, the source of leakage must be found

and corrected. The system must be evacuated and

recharged with dry nitrogen to maintain the package

integrity.

• Cover all bare metal surfaces (coupling, ﬂ ange faces,

etc.) with rust inhibitor.

• Desiccant is to be placed in the control panel. If the

panel is equipped with a space heater, it is to be ener-

gized. Use an approved electrical spray-on corrosion

inhibitor for panel components (relays, switches,

etc.)

• All pneumatic controllers and valves (Fisher, Taylor,

etc.) are to be covered with plastic bags and sealed

with desiccant bags inside.

Section 3 • Installation

3 – 3

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Compressor Unit Inspections Prior to

Storage or Installation

The compressor unit must be inspected prior to instal-

lation since components could have come loose and/or

damaged during shipment or moving.

• Check for loose bolts, particularly the compressor

and motor mounting nuts.

• Check for bent or damaged components. The com-

pressor unit should have also been inspected prior to

off-loading, see Delivery Inspection.

• Check that the nitrogen pressure is still holding pres-

sure. The pressure gauge is located at the discharge

bleed valve on the block and bleed assembly. Any

leaks must be ﬁ xed and the system purged and re-

charged with dry nitrogen.

Recommended Onsite Tools

The tools recommended to have on site are important

for troubleshooting, inspections and compressor unit

operation. Besides general mechanic tools, these tools

are recommended:

• Oil Pump (maximum of 2-3 GPM with motor ap-

proved for Division 1 or Division 2 and with ability to

overcome suction pressure)

• Infrared Heat Gun

• Torque Wrenches (with ranges from 0 to 600 ft-lbs)

• Sockets and wrenches up to 2-1/2” (63.5 mm)

• Voltmeter

AIR COOLED OIL COOLERS

The following are general recommendations. Refer to

speciﬁ c air cooled oil cooler manufacturer instructions

for storage recommendations.

• If the coolers are to be stored or not operated for an

extended period of time, the fan motors may ingress

moisture if they are not protected or operated regu-

larly. In severe cases, the moisture will reduce the in-

sulation level of the windings or cause rusting of the

bearings necessitating removal for repairs at a motor

repair facility. This is a common problem with large

generating installations when the coolers are often

ready but commissioning of the main turbine-gener-

ator is delayed for several months.

• The simplest remedy for installed coolers is to oper-

ate the fan motors for a few hours every week dur-

ing the downtime period until regular operation

resumes. The fan motors on stored coolers must be

protected from the elements by covering them with

waterproof tarps.

Section 3 • Installation

3 – 4 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 3 • Installation

LONG TERM STORAGE LOG

Date: _______________________________

Name: _______________________________ Intial:_______________

Company:

Vilter Order No. _____________________________________________

Compressor Serial Number: ________________________________________________________

Was Compressor Shaft Rotated? _______YES _______ NO HOW OFTEN? __________

Was Air Cooled Oil Cooler Rotated? _______YES _______ NO HOW OFTEN? __________

Was Compressor Motor Rotated? _______YES _______ NO HOW OFTEN? __________

Was Compressor Motor Lubricated? _______YES _______ NO HOW OFTEN? __________

What was the Nitrogen pressure? _______PSIG

Was it necessary to recharge with Nitrogen? ________YES _______NO

If unit needed recharging, was the leak found? ________YES _______NO

Please briefly explain nature of leak:

Is compressor stored in a building that is heated and insulated to prevent condensation of moisture and freezing of Equipment?

___________YES _________NO

Are all machined surfaces exposed to atmosphere coated with a light grease to prevent rusting (compressor shaft)?

__________YES _________NO

Compressor has been placed in operation as of: DATE ______________

3 – 5

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 3 • Installation

Foundation

Vilter Single Screw compressor units are low vibra-

tion machines. Under most conditions, no elaborate

foundation is necessary. However a sound foundation

maintains motor alignment and proper elevation, and

is therefore required. Provided are recommendations

for the foundation and anchoring of the compressor

unit. The Vilter foundation supports the entire operating

weight of the unit and is suitable for years of continuous

duty. Included are speciﬁ cations for concrete, rebar, ag-

gregate, anchors and grout.

Considerations Prior to Starting

Consult professionals, such as building inspectors,

structural engineers, geotechnical engineers and/or

construction contractors prior to starting. Below are a

few points to consider:

Site Characteristics:

• Soil information

• Site drainage

• Wind data

• Seismic zone

• Ingress and egress

• Power and power lines

Site Layout:

• Plant elevations, grading, drainage and erosion

• Accessibility to compressors for service

• Location of surrounding buildings

• Property lines and roadways

• Power

• Fire safety

Safety:

NOTE

Always check with a safety engineer before proceeding.

• Arranging equipment with adequate access space for

safe operation and maintenance

• Wherever possible, arrange equipment to be served

by crane. If not feasible, consider other handling

methods

• Make all valves and devices safely accessible

• Use special bright primary color schemes to differen-

tiate service lines

• Lightening protection for outdoor installations

• Relief valve venting

Foundation Materials

Materials needed to build the foundation are forms,

concrete, sand, rebar, wire, grout, anchor bolts, ex-

pansion board and shims. A set of concrete forms will

need to be acquired; generally, these can be rented or

constructed from dimensional lumber. There should

be enough 4,000 psi concrete with one inch aggregate

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 - Con-

crete Pad with Compressor Unit Dimensions - Side

View. The rebar required is ASTM 615, grade 60, sizes

#4 and #6. Wires will also be needed to tie the rebar

together. The recommended grout is Masterﬂ ow 648CP

high performance non-shirk grout to provide at least

a 1” thick pad under each foot. The recommended an-

chors are 5/8” Diameter HILTI HAS SS threaded rod for

outdoor installations or HAS-E rods for indoor installa-

tions. Anchor bolts shall have a ﬁ ve inch projection and

12-3/8” embedment. The required adhesive is HIT-ICE/

HIT/HY 150 anchoring system. There should be enough

one inch expansion boards to go around the perimeter

of the foundation. Finally there should be enough shim

stock and extra anchor bolt nuts to level the compres-

sor unit.

Building the Foundation

Use the Vilter General Arrangement (GA) and founda-

tion drawings to help secure a building permit and

foundation construction. The Vilter GA drawing will

have the necessary dimensions required to determine

the overall foundation size and where to locate the

compressor unit on the foundation. It will also show the

dimensions required to form up the housekeeping piers

that the compressor unit rests on. The Vilter foundation

drawing lists the necessary information to construct a

suitable foundation. It includes the rebar requirements

and locations. It also shows anchor bolt locations,

grouting and the concrete speciﬁ cations. Using the

Vilter GA drawing, Vilter foundation drawing and the

information from site characteristics, site layout and

safety studies will provide enough data to allow build-

ing the foundation to proceed.

The foundation is to be cast and permanently exposed

against the earth. Therefore, if constructing on an exist-

ing ﬂ oor, typically indoors, the ﬂ oor will need to be bro-

ken up to get to the earth. If starting from undisturbed

soil, it must be also be prepared accordingly. In either

case, these are some check points to consider:

• Check the depth of your frost line to ensure

the foundation extends below it

• Ensure the foundation rests entirely on natural rock

or entirely on solid earth, but never on a combination

3 – 6 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

of both

• Check the ability of the soil to carry the load

• Check wet season and dry season soil characteristics

for static loading limits and elasticity

• Check local codes for Seismic Design requirements

For examples of foundation diagrams, see to Figure 3-2

and Figure 3-3.

CENTER LINE OF

GAS COMPRESSION

SYSTEM

EL. TOP OF

GRADE

# 6 @ 12"

EACH WAY

TOP & BOTTOM

3" CLR. 2" CLR.

1'-0"

COMPRESSOR UNIT

2" (TYP.)

G.A.

EXCAVATE TO FROST DEPTH AS REQ'D AND BACKFILL

WITH CLSM OR NON-FROST SUSCEPTIBLE FILL

4" COMPACTED

SAND

Figure 3-2. Concrete Pad with Compressor Unit Dimensions - Side View

trolled level and a surface texture etched in place. Leave

the concrete to cure for at least 28 days.

Compressor Unit Installation

Once the foundation has cured, the compressor unit

can be placed on the foundation, see Figure 3-5 and

Figure 3-6. With the appropriate material handling

equipment, lift the compressor unit by locations shown

on the Vilter GA drawing and slowly place it on the

foundation housekeeping piers. As per the Vilter GA

drawing, ensure the compressor unit is correctly placed

on the foundation. Once placed, use the spherical wash-

ers directly under the compressor as the surface to level

the compressor unit, see Figure 3-7. Place shims under

the feet of the compressor unit, as needed, until it is

leveled, see Figure 3-8. Select the correct drill bit and

drill thru the anchor bolt hole in the mounting feet of

the compressor unit to the depth called for on the Vilter

foundation drawing. Finally using the HILTI instructions,

put your anchor bolts in place and wait for them to cure.

Then place the nuts on the anchor bolts to ﬁ nger tight

and prepare to grout.

NOTE

In Figures 3-3 and 3-8, the recommended

housekeeping height of 6” is to allow maintenance/

service of the oil strainer and oil pump.

Once the site has been excavated and prepared, place

four inches of sand down on the bed where the founda-

tion will rest. The sand must be compacted before plac-

ing the forms and rebar. After the sand is compacted,

use the Vilter GA drawing to construct the forms for

the foundation. With forms in place, install expansion

boards on the inside of the forms, for example, see

Figure 3-4. Next, place your rebar in the forms as per the

Vilter foundation drawing. When all rebars are in place

the concrete can be poured. The concrete must then be

Section 3 • Installation

3 – 7

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

CENTER LINE OF

GAS COMPRESSION

SYSTEM

# 6 @ 12"

EACH WAY

TOP & BOTTOM

COMPRESSOR UNIT

G.A.

EL. TOP OF

GRADE

EXCAVATE TO FROST DEPTH AS REQ'D AND BACKFILL

WITH CLSM OR NON-FROST SUSCEPTIBLE FILL

Figure 3-3. Concrete Pad with Compressor Unit Dimensions - Front View

CONCRETE

SLAB IN

BUILDING

CHAMFER EDGE

COMPRESSOR UNIT

FOUNDATION

ISOLATION JOINT,

1" MINIMUM

THICKNESS

6”

Figure 3-4. Interior Foundation Isolation

Leveling and Grouting

The unit should be level in all directions. Wet the

concrete pad according to the grout manufacturer’s

directions. Mix a sufﬁ cient amount of grout. The grout

must be an expanding grout rather than shrinking to

provide a tighter bond. Follow the manufacturer’s

recommendations for setting, precautions, mixing, and

grout placement, ﬁ nishing 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.

Section 3 • Installation

3 – 8 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Additional Information

Codes and Standards

Vilter followed the following codes and standards when

designing your foundation:

• ACI

• ASTM

• ASCE 7

• IBC 2006

Operation and Performance

The foundation was designed for:

• Outside environment severe exposure

• Ambient temperature -10 degrees F to 105 degrees F

• Unit 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 permanently rigid support

• Provide sufﬁ cient depth to dampen vibrations.

CENTER LINE GAS

COMPRESSION

SYSTEM

10'-0"

5'-0"

OVER ALL G.A. LENGTH + 4'-0"

Figure 3-5. Foundation with Housekeeping Pads Dimensions - Top View

Section 3 • Installation

3 – 9

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Figure 3-7. Level Compressor Unit Using Top Surface of Spherical Washers

Section 3 • Installation

SPHERICAL

WASHERS

LEVEL

Figure 3-6. Housekeeping Pad Dimension Detail - Top View

5/8" DIA. HILTI HAS SS THREADED 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.)

HOLES TO BE INSTALLED WITH HAMMER DRILL.

DO NOT DIAMOND CORE. (TYP.)

CENTER LINE

G.A.

G.A. + 2"

G.A.G.A.

1" (TYP.)

(5) - # 6 VERT.

WITH STD. 90° HOOK

AT BOTTOM EACH

FACE

(2) - # 4

CLOSED TIES

COMPRESSOR UNIT

HOUSEKEEPING PADS

3 – 10 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

010Ä5*4+0-

'21:;)4176

4'%1//'0&'&

(14

*175'-''2+0)

%10%4'6'

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Figure 3-8. Concrete Pad Housekeeping Detail

Section 3 • Installation

Piping

The ideal load applied to ﬂ anges of the compressor unit

is zero. However, it’s not practical to expect that no loads

will be applied to unit connections. Thermal, dead, live,

wind & seismic loads must be considered and even toler-

ated. Well supported external piping connected to the

compressor will still result in some loads applying forces

and moments in three axes to unit ﬂ anges.

The most important issue is the motor-compressor mis-

alignment caused by external forces (F in lbf) and mo-

ments (M in ft-lbf) imposed by plant piping. In Figure

3-9 and Table 3-2, are the maximum allowable forces

and moments that can be applied to compressor ﬂ anges

when the compressor is mounted on an oil separator.

It must be noted that it is necessary to check for com-

pressor shaft movement when the job is complete. In

no case shall the attached piping be allowed to cause

more than 0.002” movement at the compressor shaft.

If more than 0.002” movement is detected the piping

must be adjusted to reduce the compressor shaft move-

ment to less than 0.002”. For example, the compressor

shaft should not move more than 0.002” when piping is

removed or connected to the compressor.

IMPORTANT – piping elements shall be supported per

the requirements of ASME B31.5 / B31.3 as applicable.

See guidelines below, particularly with concern to mini-

mizing loads on check valves.

Header Piping and Drains

Header drains should also be installed to allow drainage

of liquids from the discharge and suction headers. See

Appendices for Recommended Header Piping.

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.

Failure to comply may result in damage to equipment.

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.

See Appendices for Recommended Air Cooled Oil Cooler

Piping.

3 – 11

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Figure 3-9. Maximum Allowable Flange Loads

DISCHARGE

LINE

5 PIPE

DIAMETERS

CUSTOMER

SUPPORT

3-4 PIPE

DIAMETERS

SUCTION

LINE

CUSTOMER

SUPPORT

HANGER

CHECK

VALVE

CUSTOMER SUPPORTS

WHEN CHECK VALVE

IS MOUNTED HERE

5 PIPE

DIAMETERS

5 PIPE

DIAMETERS

Nozzle Dia. (in.) Fz (lbf) Fy (lbf) Fx (ft-lbf) Mzz (ft-lbf) Myy (ft-lbf) Mxx (ft-lbf)

4 400 400 400 300 300 300

6600 600 600 500 500 500

8 900 900 900 1000 1000 1000

10 1200 1200 1200 1200 1200 1200

12 1500 1500 1500 1500 1500 1500

14 2000 2000 2000 2000 2000 2000

Section 3 • Installation

Table 3-2. Maximum Allowable Flange Loads

3 – 12 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 3 • Installation

General Installation Guideline for

Multiple Air Coolers Installed in a

Common Area

NOTE

This general installation guideline applies to all air

coolers on site, whether if they are supplied by or

not supplied by Vilter.

The purpose of this guideline is providing design infor-

mation when multiple air cooled heat exchangers are

installed in a common area. There are two main focal

points of this guideline. One area is free ﬂ ow area which

addresses how much free area is required to prevent air

ﬂ ow “starvation” of the units. The second item provides

a guideline as to how multiple air cooled heat exchang-

ers should be arranged to minimize the potential of hot

air recirculation due to the environment.

FREE FLOW

There are two basic guidelines that we follow to address

free ﬂ ow area when multiple designs are being installed

in a common area.

• Air coolers should be placed at least 1 fan diameter

away from the nearest obstruction. This is based on

the largest fan diameter in the bay of coolers.

• Intake area to the air cooler should have an intake

velocity equal to or below 500FPM as the as the dis-

charge velocity is above 500FPM.

We will look at each rule and provide pictorials and

calculations for each guideline. Let’s assume the follow-

ing coolers are being installed in a common area:

• Cooler 1 - 7’ wide x 10’ long with a 6’ fan moving

55,000CFM of air. Face velocity is 785FPM.

• Cooler 2- 8’ wide x 12’ long with a 7’ fan moving

72,000CFM of air. Face velocity is 750FPM.

• Cooler 3- 10’ wide x 16’ long with a 9’ fan moving

120,000CFM of air. Face velocity is 750FPM.

ONE FAN DIAMETER

In order to keep the leg height of the installation to a

minimum we want to install the coolers at least 1 fan di-

ameter from the nearest obstruction. Referring to Figure

3-10, the nearest obstruction is the building.

Based on the information above, the largest fan diame-

ter in the installation is 9ft. Therefore, the coolers should

be placed at least 9’ away from the building.

INTAKE VELOCITY

Based on the information above, we are going to solve

for the leg height that will provide an intake velocity of

500FPM. We know the following:

• The total airﬂ ow of the installation is 247,000CFM

• We have an intake perimeter of 82’ for all 4 sides

based on the cooler placement.

• Our intake velocity guideline is 500FPM

Figure 3-10. Installation of Coolers - One Fan Diameter Next to Building

TOTAL INTAKE PERIMETER = 82 FEET

PREFERRED

3 – 13

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 3 • Installation

The equation used to calculate the leg height in Figure

3-11 is as follows:

Leg Height = (Total Airﬂ ow/Intake velocity)/Intake Perimeter

Leg Height = (247,000CFM/500FPM)/82ft

Leg Height = 6ft

In this particular case the calculated minimum height is

6 feet to maintain an intake velocity of 500FPM or less

based on having the coolers place 1 fan diameter away

from the nearest obstruction. Let’s look at an instal-

lation where the coolers need to be placed next to the

building as in Figure 3-12.

Based on the information above, we are going to solve

for the leg height that will provide an intake velocity of

500FPM. We know the following:

• The total airﬂ ow of the installation is 247,000CFM

• We have an intake perimeter of 3 sides 16ft, 16ft, and

25ft which totals 57’

• Our intake velocity guideline is 500FPM

The equation used to calculate the leg height in Figure

3-11 is as follows:

Leg Height = (Total Airﬂ ow/Intake velocity)/Intake Perimeter

Leg Height = (247,000CFM/500FPM)/57ft

Leg Height = 8.667ft

We would round the leg height up to 9ft for this particu-

lar situation.

Figure 3-12. Installation of Coolers - Next to Buildling

TOTAL INTAKE PERIMETER = 57 FEET

Figure 3-11. Leg Height

NOT PREFERRED

Intake Velocity

Less

3 – 14 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

HOT AIR RECIRCULATION

There are two situations where hot recirculation could

occur.

• Intake velocity of the cooler is higher than the dis-

charge velocity

• Environmental issues such as strong cross winds

which is installation speciﬁ c

We addressed how to minimize the opportunity for hot

air recirculation involving the operation of the air cool-

ers under the guidelines for the Free Flow section above.

However, environmental hot air recirculation is some-

thing that is outside of the control of the cooler manu-

facturer. If the site has the potential for strong cross

winds or tunneling then you may want to consider the

following items to minimize the potential of hot air recir-

culation due to the environment.

• All air coolers should discharge at the same elevation.

• If feasible all of the air coolers in a common area

should be placed as close to the next cooler as

possible.

Unfortunately this comes with a cost. By reducing the in-

take perimeter available, the leg height increases, which

is a cost. In addition there is no guarantee that hot air

recirculation can be eliminated due to environmental

issues.

Discharge Elevation

In order to minimize the potential for hot air recircula-

tion, it is recommended to install the air coolers so that

they all discharge at the same elevation. This is impor-

tant because not all air coolers have the same plenum

heights. You can satisfy the leg height requirements by

the calculation above but not satisfy the requirements

for discharge elevation. Based on the size of the cool-

ers above, cooler 1 has a plenum height of 36”, cooler

2 has a plenum height of 42”, and cooler 3 has a plenum

height of 54”. Plenum heights are calculated from the

standard of a 45 degree dispersion angle in API 661. If

you would like more details on this calculation please

contact engineering.

As you can see in Figure 3-13 in the not preferred con-

ﬁ guration. the leg height requirement in the ﬁ rst cal-

culation is satisﬁ ed. However, the coolers are not at the

same discharge elevation. This could be an issue if there

is a cross wind from left to right. Cooler 3 could block the

discharge air ﬂ ow from coolers 1 and 2 and recirculate it

back down to the intake of the coolers. The best way to

address this is to increase the leg heights on coolers 1

and 2 as shown in the preferred conﬁ guration.

This is especially critical if all of the air coolers are not

place as close together as possible.

Cooler Placement and Spacing

The concern about cooler placement as far as proximity

from one another has to do with the potential for hot

air recirculation due to cross winds. Let’s look at only

having coolers 1 and 3 in the same area. The leg height

requirement of cooler 1 is 3.23ft so we would use a 4ft

leg height. The leg height requirement for cooler 3 is

4.61ft but we would put a 7 foot leg height on the cooler

due to size and for serviceability. Figure F. shows this

installation.

In this case, if you get a strong cross wind from left to

right there is the potential that the discharge coming

from the top of cooler 1 could easily be pushed into the

intake of cooler 3. Thus, in Figure 3-14, the not preferred

conﬁ guration is more susceptible to the potential of hot

air recirculation due to the environment and is not rec-

ommended. The preferred conﬁ guration is the recom-

mended installation of the coolers with a space between

them.

All of the information provided is a general guideline for

installing multiple air coolers in a common area. If you

minimally follow all of the Free Flow requirements and

keep the air coolers discharging at the same elevation

then you have a good basis for site layout.

Sometimes due to extenuating circumstances, the

above guidelines cannot be followed. Please contact en-

gineering to discuss remedies to accommodate different

conﬁ gurations.

Section 3 • Installation

3 – 15

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Figure 3-13. Discharge Elevation of Coolers

Section 3 • Installation

NOT PREFERRED PREFERRED

Figure 3-14. Cooler Placement and Spacing

PREFERRED

NOT PREFERRED

3 – 16 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 3 • Installation

Initial Oil Charging

Using Non -Vilter Oils

CAUTION

Do not mix oils. Failure to comply may result in

damage to equipment.

NOTICE

Vilter does not approve non-Vilter oils for use with

Vilter compressors. Use of oils not speciﬁ ed or

supplied by Vilter will void the compressor warranty.

Due to the need for adequate lubrication, Vilter recom-

mends only the use of Vilter lubricants, designed spe-

ciﬁ cally for Vilter compressors. With extensive research

that has been performed, we are able to offer gas com-

pression lubricating oils. Use of oil not speciﬁ ed or sup-

plied by Vilter will void the compressor warranty.

Please contact your local Vilter representative or the

Home Ofﬁ ce for further information.

Unit Oil Charging and Priming

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.

Typically, the compressor unit is shipped from Vilter with

no oil charge. The normal operating level is between the

two sight glasses on the oil separator, see Figure 3-15.

Refer to supplied GA drawing for unit speciﬁ c oil charge

requirement.

For regular oil charging and draining procedures, see

Section 5.

Tool Required:

• Oil Pump, Maximum 2-3 GPM with Motor approved

for Division 1 or Division 2 and with ability to over-

come suction pressure.

(Reference Figure 3-17)

1. At initial start up, compressor unit must be off and

depressurized prior to initial oil charging.

2. Using a properly selected oil pump, connect oil

pump to oil separator drain valve (4). For oil separa-

tor drain valve location, see Figure 3-16.

3. Open oil separator drain valve (4) and ﬁ ll oil separa-

tor (3) to Maximum NON-Operating Level.

4. Once Maximum NON-Operating Level has been

reached, shut off oil pump, close oil separator drain

valve (4) and remove oil pump.

5. If equipped with remote oil cooler, refer to Priming

Remote Oil Cooler and Piping procedure.

PRIMING OIL COOLER (SHELL AND TUBE) AND PIPING

If equipped with a shell and tube oil cooler, continue

with the following steps:

6. Close shut-off valve (8) at oil ﬁ lter inlet. Do the same

for second oil ﬁ lter, if equipped with dual oil ﬁ lters.

For shut-off valve location, see Figure 3-16.

7. Open oil bypass shut-off valve (5). For oil cooler by-

pass valve location, see Figure 3-16.

8. Energize compressor unit.

9. Close oil mixing valve (oil temp. control valve) (7) via

control panel. In Manual Mode, change “Manually

Open (%)” value to “0”.

NOTE

The oil cooler is considered primed when the oil

level in the separator is constant.

10. Run the oil pump (6) twice for 1-2 minutes. Repeat

this step until the oil level (9) is constant.

Pressure Testing

CAUTION

Do not hydro test compressur unit. Failure to comply

may result in damage to equipment.

CAUTION

The compressor unit along with other system units

contain many components with various pressure

ratings. Pressure relief protection provided considers

the design pressure of a system components.

Before replacing a pressure relief valve with a relie

valve having a higher presure setting, all system

components must be evaluated for acceptability.

Pressure test in compliance with Chapter VI of the ASME

B31.3 Process Piping Code.

3 – 17

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 3 • Installation

Figure 3-15. Oil Operating Levels

Normal Operating Level

Maximum NON-Operating Level

Minimum Operating Level

Figure 3-16. Suction Oil Charging Valve, Oil Cooler Drain Valve and Oil Filter Shut-Off Valves

Suction Oil

Charging Valve

View Rotate 180°

Oil Drain Valve

(Oil Separator)

Bypass Valve

(Oil Cooler)

View From Back - View Rotate 180°

Oil Filter

Shut-Off Valves

3 – 18 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

OIL

004

001

BLEED

DRAIN

002

BLEED

004

101

102

103

005

1000W 1000W 1000W

001

002

OIL CHARGE

002

COMPRESSOR

MOTOR

OIL COOLER

MOTOR

OIL PUMP

OIL FILTER

COALESCING OIL RETURN LINE PRESSURE

EQUALIZING LINE

SUCTION INLET

DISCHARGE OUTLET

OIL MIXING

VALVE

DRAIN

OPEN

OIL SEPARATOR

DRAIN

DRAINVENT

COOLING

WATER

DISCHARGE OUTLET

SUPPLY

RETURN

Figure 3-17. Priming Oil Cooler (Shell & Tube) and Piping

PRIMING COMPRESSOR AND OIL FILTERS

NOTE

Running the compressor oil pump at this point will

help lubricate the compressor bearings and shaft

seal surfaces.

(Reference Figure 3-19)

11. Open shut-off valve(s) (8) at oil ﬁ lter inlet(s).

12. Close oil bypass shut-off valve (5).

13. Open oil mixing valve (7) via control panel. In Manual

Mode, change “Manually Open (%)” value to “100”.

14. Run oil pump (6) for approximately 20 seconds only.

15. Stop oil pump (6) and wait for a minimum of 30 min-

utes. This will allow oil in the compressor (2) to drain

and oil level (9) in separator (2) to settle.

NOTE

Oil mixing valve can remain in Manual Mode since

the setpoint will change the mode to Auto when

reached. For further details, see PLC Compact Logix

manual.

16. Refer to Pre Start-Up Checklist and ensure all items

are ready prior to starting the compressor.

17. When ready, run compressor unit and allow it to

reach normal operating temperature.

18. Using a properly selected oil pump, connect oil

pump to suction oil charging valve (1). For suction

oil charging valve location, see Figure 3-16.

19. Open suction oil charging valve (1) and ﬁ ll oil separa-

tor (3) to Normal Operating Level.

20. Once the Normal Operating level has been reached,

shut off the oil pump and close the suction oil charg-

ing valve (1). Disconnect and remove oil pump.

Section 3 • Installation

3 – 19

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

OIL

004

001

BLEED

DRAIN

002

BLEED

004

101

102

103

005

1000W 1000W 1000W

001

002

OIL CHARGE

002

COMPRESSOR

MOTOR

OIL COOLER

MOTOR

OIL PUMP

OIL FILTER

COALESCING OIL RETURN LINE PRESSURE

EQUALIZING LINE

SUCTION INLET

DISCHARGE OUTLET

OIL MIXING

VALVE

DRAIN

OPEN

OIL SEPARATOR

DRAIN

DRAINVENT

COOLING

WATER

DISCHARGE OUTLET

SUPPLY

RETURN

Figure 3-18. Priming Compressor (with Shell & Tube Oil Cooler) and Piping

Section 3 • Installation

NOTE

Oil separator does not need to be ﬁ lled again until oil

level reaches Minimum Operating Level.

Every size of compressor will hold different amounts

of oil, so amount of oil draining back into oil

separator will vary.

21. More accurate ﬁ ll levels can be accomplished by

marking the level on the oil separator (2) after cor-

rect levels have been achieved during the unit oper-

ation and when the compressor unit has been down

for 1 hour.

3 – 20 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

OIL

004

001

BLEED

DRAIN

002

BLEED

004

101

102

103

005

1000W 1000W 1000W

001

002

OIL CHARGE

002

DRAIN

VENT

003

007

COMPRESSOR

MOTOR

REMOTE

OIL COOLER

MOTOR

OIL PUMP

OIL FILTER

COALESCING OIL RETURN LINE PRESSURE

EQUALIZING LINE

SUCTION INLET

DISCHARGE OUTLET

OIL MIXING

VALVE

DRAIN

OPEN

OIL SEPARATOR

Figure 3-19. Priming Remote Oil Cooler and Piping

Section 3 • Installation

Priming Remote Oil Cooler and Piping

(Initial Oil Charging)

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.

NOTE

This procedure is for remote oil coolers only.

Piping of oil must enter bottom connection of

remote oil cooler and leave from top connection.

For remote air cooled oil cooler piping, see Piping

section.

(Reference Figure 3-19)

1. Verify oil level (8) is at Maximum Non-Operating Oil

Level in separator (3). If oil level is not at Maximum

Non-Operating Oil Level, add oil, see Initial Oil

Charging - Unit Oil Charging procedure.

2. Close shut-off valve(s) (7) at oil ﬁ lter inlet(s).

3. Open oil bypass shut-off valve (4).

4. Energize compressor unit.

5. Close oil mixing valve (oil temp. control valve) (6) via

control panel. In Manual Mode, change “Manually

Open (%)” value to “0”.

NOTE

The oil cooler is considered primed when the oil

level in the separator is constant.

6. Run oil pump (5) for a minimum of 5 minutes and as

long as needed to purge all gas from oil cooler and

piping.

7. When all gas is purged, stop oil pump.

3 – 21

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 3 • Installation

PRIMING COMPRESSOR AND OIL FILTERS

NOTE

Running the compressor oil pump at this point will

help lubricate the compressor bearings and shaft

seal surfaces.

(Reference Figure 3-20)

8. Open shut-off valve(s) (7) at oil ﬁ lter inlet(s).

9. Close oil bypass shut-off valve (4).

10. Open oil mixing valve (6) via control panel. In Manual

Mode, change “Manually Open (%)” value to “100”.

11. Run oil pump (5) for approximately 20 seconds only.

12. Stop oil pump and wait for a minimum of 30 min-

utes. This will allow oil in the compressor (2) to drain

and oil level (8) in separator (3) to settle.

NOTE

Oil mixing valve can remain in Manual Mode since

the setpoint will change it to Auto mode. For further

details, see PLC Compact Logix manual.

13. Refer to Pre Start-Up Checklist and ensure all items

are ready prior to starting the compressor.

14. When ready, run compressor unit and allow it to

reach normal operating temperature.

15. Using a properly selected oil pump, connect oil

pump to suction oil charging valve (1). For suction

oil charging valve location, see Figure 3-16.

16. Open suction oil charging valve (1) and ﬁ ll oil separa-

tor (3) to Normal Operating Level.

17. Once the Normal Operating level has been reached,

shut off the oil pump and close the suction oil charg-

ing valve (1). Disconnect and remove oil pump.

NOTE

Oil separator does not need to be ﬁ lled again until oil

level reaches Minimum Operating Level.

Every size of compressor will hold different amounts

of oil, so amount of oil draining back into oil

separator will vary.

18. More accurate ﬁ ll levels can be accomplished by

marking the level on the oil separator (2) after cor-

rect levels have been achieved during the unit oper-

ation and when the compressor unit has been down

for 1 hour.

Figure 3-20. Priming Compressor and Oil Filters

004

001

BLEED

DRAIN

002

BLEED

004

101

102

103

005

1000W 1000W 1000W

001

002

OIL CHARGE

002

DRAIN

VENT

003

007

OIL SEPARATOR

OIL

COMPRESSOR

MOTOR

REMOTE

OIL COOLER

MOTOR

OIL PUMP

OIL FILTER

COALESCING OIL RETURN LINE PRESSURE

EQUALIZING LINE

SUCTION INLET

DISCHARGE OUTLET

OIL MIXING

VALVE

DRAIN

OPEN

3 – 22 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 3 • Installation

Pre Start-Up

The following check list is to help prepare the equipment before the Vilter technician arrives at the jobsite. Vilter

recommends that a trained technician go through the following tasks. The operating manuals provided by Vilter can

be referenced for any type of questions or special instructions.

Every gas compressor unit includes a Vilter start-up (confirm on P.O.). The following tasks are not included in the

Vilter start-up provided in your equipment purchase. Any tasks below that are done by the Vilter technician will take

away from the pre-determined time that was provided with the equipment purchase. Vilter suggests that the Vilter

technician’s time be used during the start-up of the system and not for the below system preparation.

NOTICE

Each item below must be checked-off, signed and

returned to Vilter Service Department. Failure to do

so will “Null & Void” future warranty considerations.

Pre Start-Up Checklist

Name (Please Print): Signature:

Company: Vilter Sales Order Number:

Equipment Description: Date (M/D/Y):

1. The unit should be leveled and secured to the concrete pad foundation.

2. Proper electric supply and grounding need to be supplied to the unit. All power and control lines should be

wired to unit. Electric supply to be veriﬁ ed at each device requiring power.

3. Verify any type of level switches that are on a vessel before the compressor are hardwired and able to shut

off the compressor (should be wired to “Aux” on micro-controller and starter).

4. The suction and discharge line must be piped and properly supported independent of the unit.

5. The discharge stop and check valve is shipped loose and must be installed. During off periods, liquid can

condense in the line downstream of the discharge stop and check valve. It is recommended that the stop and

check valve be located horizontally to minimize the quantity of liquid that can accumulate downstream of the

check valve.

6. A dual safety relief valve is shipped loose for ﬁ eld installation. A connection is provided on the oil separator

for the relief valve. Refer to ASME Code for proper sizing of relief valves and vent lines.

7. On water cooled oil coolers, the water lines must be connected to the front head of the oil cooler. Water

regulating and solenoid valves are recommended.

(Continued on next page)

3 – 23

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

8. On air cooled oil coolers, the oil lines from the compressor must be connected to the air cooled oil cooler. Oil

cooler fans will need to be wired and checked for proper rotation. Refer to supplied GA drawing for connection

points and piping sizes.

9. The oil separator should be charged with oil to the Maximum NON-Operating Level.

10. The center member of the compressor is shipped loose to help facilitate ﬁ nal ﬁ eld alignment and allow for

motor rotation check.

11. Both the compressor and motor hubs should be checked for concentricity and perpendicularity.

12. The motor should be checked and shimmed for a soft foot prior to attempting ﬁ nal alignment.

13. The motor should be checked to make sure that it is lubricated properly. Proper re-lubrication amounts/

types are provided on the motor’s lubrication plate. These instructions should be closely followed to achieve

optimum bearing life and to avoid consequential damage to the bearings and motor.

14. The center section of the coupling should be left out to allow the start-up technician to verify the ﬁ nal

alignment and motor rotations.

15. Verify that all valves are in the open position.

16. Verﬁ y that the visual indicator on the Oil Temperature Control Valve (Oil Mixing Valve) position corresponds

with “% OPEN” on the control panel. CLOSE position is 0% OPEN, OPEN position is 100% OPEN.

17. A system load should be available at the time of start-up.

18. The unit should be pressure tested and purged with a dry gas. Care should be taken to not pressurize exces-

sively from the suction end of the compressor, as this will drive the compressor in a forward motion without

lubrication and may cause damage.

19. Have a qualiﬁ ed electrician present to verify wiring during start-up.

20. Keep a hard copy of the ﬁ nal set points in case the micro-controller gets corrupted or if they are required by

Vilter technicians for troubleshooting.

Section 3 • Installation

3 – 24 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Start-Up

The following check list is to help verify and check equipment prior to start-up. This is the responsibility of the Vilter

Technician.

1. Review pre start-up checklist.

2. Check oil pump rotation. This can be done by using the “Diagnostic Force Outputs” from Main Menu. Refer

to Compact Logix PLC Software Manual.

3. Check compressor motor rotation (CCW or CW rotation facing compressor shaft). This can be done by using

the “Diagnostic Force Outputs” from Main Menu. Refer to Compact Logix PLC Software Manual.

4. Cold and hot alignment. Verify with manufacturer’s limits.

5. Verify capacity slide calibration and correct command shaft rotation, even though it is factory calibrated.

6. Verify volume slide calibration and correct command shaft rotation, even though it is factory calibrated.

7. Check motorized oil mixing valve for proper setup.

8. Starter set up by vendor technician.

9. Blower set up by vendor technician.

10. Verify correct direction of ﬂ ow for the oil line check valve.

11. Run oil pump to pre-lube the compressor (oil level in the oil separator should drop as lines are ﬁ lled).

12. Calibrate transducers to atmosphere.

13. Verify operation of all safeties.

14. Set scaling for main motor amps in PLC.

15. Record running data and ﬁ nal set points on data sheets.

16. Instruct Operators.

Section 3 • Installation

4 – 1

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 4 • Operation

Operation

All operation (setpoint adjustments, calibrations,

monitoring) of the compressor unit is done through

the Compact Logix PLC. For additional procedural

information, refer to Compact Logix PLC Software

Manual (35391CL).

Oil Inspection

WARNING

When working with LFG, NG or other dangerous

or ﬂ ammable gases, ensure there are adequate

ventilation and vapor detectors. Refer to national ﬁ re

and building codes. Failure to comply may result in

serious injury or death.

WARNING

Avoid skin contact with any condensate or oil. Wear

rubber gloves and a face shield when working with

condensate or oil. Failure to comply may result in

serious injury or death.

Inspect oil level through sight glasses on the oil

Figure 4-1. Oil Operating Levels

Normal Operating Level

Maximum NON-Operating Level

Minimum Operating Level

separator, see Figure 4-1. Oil Operating Levels. Drain or

ﬁ ll oil as required. For oil draining and ﬁ lling procedure,

see Oil Charging and Oil Draining in Section 5.Oil Flow

with Dual Oil Filters

Dual Oil Filters

On compressor units equipped with dual oil ﬁ lters, only

one ﬁ lter should be in operation at a time.

NOTE

During operation, both oil ﬁ lter outlet shut-off valves

should be open. This will help minimize the sudden loss

of oil pressure when switching between oil ﬁ lters for

servicing.

Refer to Oil Filter Replacement in Section 5 for further

details.

4 – 2 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 4 • Operation

Control System Calibration

Equipped for automatic operation, the screw compres-

sor unit has safety controls to protect it from irregular

operating conditions, an automatic starting and stop-

ping sequence, capacity and volume ratio control

systems.

Check all pressure controls with a remote pressure

source, to assure that all safety and operating control lim-

its operate at the point indicated on the microprocessor.

The unit is equipped with block and bleed valves that

are used to recalibrate the pressure transducers. To use

the block and bleed valves to recalibrate the pressure

transducers, the block valve is shut off at the unit and

the pressure is allowed to bleed off by opening the bleed

valve near the pressure transducer enclosure. The trans-

ducer can then be calibrated at atmospheric pressure (0

psig), or an external pressure source with an accurate

gauge may be attached at the bleed valve.

The discharge pressure transducer cannot be isolated

from its pressure source, so it is equipped with only a

valve to allow an accurate pressure gauge to be attached

and the pressure transducer calibrated at unit pressure.

Recheck the transducers periodically for any drift of cali-

bration, refer to maintenance/service interval table in

Section 5.

Starting, Stopping and Restarting the

Compressor

Starting

Before the screw compressor unit can start, certain

conditions must be met. All of the safety setpoints must

be in a normal condition, and the suction pressure must

be above the low suction pressure setpoint to ensure a

load is present. When the “ON/OFF” switch or “Manual-

Auto” button is pressed, the oil pump will start. When

sufﬁ cient oil pressure has built up and the compressor

capacity control and volume ratio slide valves are at or

below 10%, the compressor unit will start.

NOTE

The amount of oil pressure that needs to be achieved

before compressor start is at least 6 psig above the

discharge pressure. For additional information on

Low Oil Pressure at Start, see Troubleshooting Guide -

General Problems and Solutions in Section 6.

If the compressor is in the automatic mode, it will now

load and unload and vary the volume ratio in response

to the system demands.

Stopping/Restarting

Stopping the compressor unit can be accomplished a

number of ways. Any of the safety setpoints will stop

the compressor unit if an abnormal operating condition

exists. The compressor unit “On-Off” or stop button

will turn the compressor unit off as will the low pressure

setpoint. If any of these conditions turns the compres-

sor unit off, the slide valve motors will immediately

energize to drive the slide valves back to 5% limit. The

control motors will be de-energized when the respec-

tive slide valve moves back below 5%. If there is a power

failure, the compressor unit will stop. If the manual

start on power failure option is selected (see appropri-

ate Microprocessor Instruction Manual), restarting from

this condition is accomplished by pushing the reset but-

ton to insure positive operator control. If the auto start

on power failure option is selected (see Compact Logix

PLC manual), the compressor unit will start up after

a waiting period. With both options, the compressor

slide valves must return below their respective 5% limits

before the compressor unit can be restarted.

NOTE

Wait a minimum of 20 minutes (to allow the

compressor unit to equalize to suction pressure)

between pre-lubing or pushing the start button.

Calibrate Slide Valve Actuators

Slide valve actuators must be installed prior to calibra-

tion. Refer to Slide Valve Actuator Installation proce-

dure. The following steps pertain to calibrating one slide

valve actuator. Repeat procedure to calibrate other slide

valve actuator.

WARNING

After stopping the compressor, allow the compressor

and surrounding components to cool down prior

to servicing. Failure to comply may result in serious

injury.

CAUTION

Do not calibrate in direct sunlight. Failure to comply

may result in damage to equipment.

Both the capacity and volume slide actuators should be

calibrated when one or more of these have occurred:

• Compressor unit starting up for the ﬁ rst time.

• A new actuator motor has been installed.

4 – 3

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 4 • Operation

• There is an error code ﬂ ashing 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 working properly such as the actua-

tors, RTDs or transducers.

To calibrate optical actuators, continue with the follow-

ing steps:

1. Stop compressor unit and allow to cool.

2. Remove screws securing actuator cover to actuator

assembly. As a reference see Figure 4-2.

CAUTION

Wires are attached to the connector on the actuator

cover. Handle actuator cover with care to prevent

damage to wires. Failure to comply may result in

damage to equipment.

3. Carefully lift actuator cover from actuator assembly

and tilt towards Turck 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.

4. On the main screen of the PLC, press “Menu” then

press the “Slide Calibration” button to enter the

slide calibration screen, see Figure 4-3.

5. Logging on with high-level access will prompt the

Calibrate button to appear, see Figure 4-4.

6. Press Calibrate button to initiate calibration mode.

The Calibrate button turns green and Set Max and

Set Min buttons appear.

NOTE

If the INC (increase) and DEC (decrease) buttons do not

correspond to increase or decrease shaft rotation, swap

the blue and brown wires of the “power cable”. This will

reverse the rotation of the actuator/command shaft.

7. Press INC and DEC to move the slide valve and

check for the correct rotation, see Table 4-1.

NOTE

When the actuator is in calibration mode, it outputs

0V when the actuator is running and 5V when it is

still. Thus, as stated earlier, the actuator voltage will

ﬂ uctuate during calibration. After the actuator has been

calibrated, 0V output will correspond to the minimum

position and 5V to the maximum position.

Figure 4-2. Actuator Assembly

Blue

Calibrate

Button

Red LED

Actuator

Plastic Cover

Actuator

Assembly

View Rotate 180°

4 – 4 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 4 • Operation

Figure 4-3. Menu Screen and Slide Calibration Button (Compact Logix PLC)

4 – 5

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

8. Quickly press and release the blue push button on

the actuator one time. This places the actuator in

calibration mode. The red LED will begin ﬂ ashing

rapidly.

CAUTION

DO NOT CONTINUE TO ENERGIZE THE ACTUATO

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 of the

photochopper to release the brake, and thereby

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.

9. Use the DEC button on the Control panel to drive

the slide valve to its minimum “mechanical stop”

position. Do not continue to run the actuator in this

direction after the slide valve has reached the stop.

Doing so may cause damage to the actuator or the

slide valve. Press down on the photo-chopper shaft

to disengage the brake, releasing tension from the

motor mount, see Figure 4-5. Use the INC button

to pulse the actuator to where the slide is just off of

the mechanical stop and there is no tension on the

motor shaft.

10. Quickly press and release the blue button on the ac-

tuator again. The red LED will now ﬂ ash at a slower

rate, indication that the minimum slide valve posi-

tion (zero position) has been set.

Section 4 • Operation

Figure 4-4. Slide Valve Calibration Screen (Compact Logix PLC)

Figure 4-5. Photo-chopper

Press down on

Photo-chopper

4 – 6 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Compressor

Model

Command Shaft Rotation No. of Turns/Rotation Angle/Slide Travel

Capacity Volume Capacity Volume

INC DEC INC DEC Turns Degrees Travel Turns Degrees Travel

VSSG 291

VSSG 341

VSSG 451

VSSG 601

CW CCW CW CCW 0.91 328 3.568” 0.52 187 2.045”

VSG 301

VSG361

VSG 401

CW CCW CW CCW 0.80 288 3.141” 0.45 162 1.767”

VSG 501

VSG 601

VSG 701

CCW CW CCW CW 0.91 328 3.568” 0.52 187 2.045”

VSG 751

VSG 901 CCW CW CCW CW 1.09 392 4.283” 0.63 227 2.473”

VSG 791

VSG 891

VSG 1051

VSG 1201

VSG 1301

CCW CW CCW CW 1.22 439 4.777” 0.74 266 2.889”

VSG 1551

VSG 1851

VSG 2101

CCW CW CCW CW 1.48 533 5.823” 0.87 313 3.433”

VSG 2401

VSG 2601

VSG 2801

VSG 3001

CCW CW CCW CW 1.80 648 7.072” 1.36 490 5.341”

Table 4-1. Command Shaft Rotation Speciﬁ cations*

Section 4 • Operation

*The large gear on the command shaft has 50 teeth. The teeth are counted when moving the command shaft from

the minimum stop position to the maximum stop position.

The manual operating shaft on the gear motor should be turned the opposite direction of the desired command shaft

rotation.

The capacity and volume control motors are equipped with a brake, if it is necessary to operate the control motors

manually, the brake must be disengaged. The brake can be disengaged by pushing on the motor shaft on the cone

end. The shaft should be centered in its travel. Do not use excessive force manually operating the motor or damage

may result.

4 – 7

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 4 • Operation

11. Use the INC button on the Control panel to drive

the slide to its maximum “mechanical stop” posi-

tion. Do not continue to run the actuator in this di-

rection after the slide valve has reached the stop.

Doing so may cause damage to the actuator or the

slide valve. Press down on the photo-chopper shaft

to disengage the brake, releasing tension from the

motor mount. Use the DEC button to pulse the ac-

tuator to where the slide is just off of its mechanical

stop and there is no tension on the motor shaft.

12. Quickly press and release the blue button on the

actuator one more time. The red LED will stop

ﬂ ashing. The actuator is now calibrated and knows

the minimum and maximum positions of the slide

valve it controls. Now the capacity or volume chan-

nel of the PLC can be calibrated.

13. Use the DEC button to move the actuator towards

its minimum position while watching the mV

readout on the Control Panel screen. Discontinue

pressing the DEC button when the mV reading the

“Current” window above the “Set Min” button is

approximately 500 mV.

14. Now use the DEC and INC buttons to position the

slide valve until a value close to 300 mV is on the

screen. Then, press the “Set Min” button in the ca-

pacity or volume slide valve window to tell the con-

troller that this is the minimum mV position. Note:

The value in the “Current Cap” or “Current Vol” win-

dow has no meaning right now.

15. Use the INC button to rotate the actuator towards

its maximum position while watching the mV read-

out on the controller screen. Discontinue press-

ing the INC button when the mV reading in the

“Current” window is approximately 4800 mV. You

are nearing the mechanical stop position.

16. Pulse the INC button to carefully move the slide

valve until the mV readout “saturates”, or stops in-

creasing. This is around 4800 mV Record mV maxi-

mum reading.

17. Pulse the DEC button until the mV just start to de-

crease. (This is the point where the channel drops

out of saturation). Adjust mV value to 300 mV be-

low recorded maximum mV.

18. Press the “Set Max” button.

19. 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” screen.

20. Gently lower the plastic cover over the top of the

actuator to where it contacts the base and O-ring

seal. After making sure the cover is seated prop-

erly, gently tighten the four #10 screws. Caution:

The plastic cover will crack if the screws are over

tightened.

21. Enable the “Slide Non-Movement Alarm” by going

to the “Setup” menu and choosing “Alarm Enable”

for the “Slide Non-Movement Option”.

22. Repeat procedure to calibrate other slide valve

actuator.

Oil Temperature Control Valve (Oil

Mixing Valve) Operation

Initial Position

The temperature control valve is in the closed position

when initially installed.

With the temperature control valve de-energized, the

valve is set to its initial position. The temperature con-

trol valve will be in the closed position with the actuator

indicator displaying CLOSED.

When the temperature control valve is energized, the

valve will rotate to fully OPEN.

Operation

With the compressor not running, when electrically en-

ergized, the PLC will turn the temperature control valve

to fully open (100%).

When the compressor starts, the valve remains fully

open (100%) until the oil injection temperature rises

above the control setpoint. When the oil injection tem-

perature rises above the control setpoint, the oil temper-

ature control valve will begin to close. The hot oil from

the oil separator begins to divert to the oil cooler, mix-

ing the hot and cooled oil ﬂ ow streams together down-

stream of the oil temperature control valve. The valve

can fully close (0%) diverting the entire oil ﬂ ow stream

to the oil cooler.

As the oil injection temperature drops below the set-

point, the oil temperature control valve begins to open

so that the oil injection temperature does not become

too cold.

When the compressor stops, the valve returns to fully

open (100%).

4 – 8 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 4 • Operation

Fail Position

The temperature control valve remains in the last posi-

tion when power is removed.

Screen Display

The oil temperature control valve, identiﬁ ed as “OIL MIX”

on the main PLC display screen, shows a numerical value

with “%” as units. This is to be understood as “% OPEN.”

It is a direct indication of the position of the ball valve.

100% OPEN

Oil ﬂ ow stream is entirely bypassing the oil cooler.

99% to 1% OPEN

Oil ﬂ ow stream is partially bypassing the oil cooler and

partially diverted to the oil cooler.

0% OPEN

Oil ﬂ ow stream is entirely diverted to the oil cooler.

Figure 4-6. Oil Temperature Control Valve (Oil Mixing Valve)

MANUAL OVERRIDE

The actuator of the oil temperature control valve has a

handwheel that can be engaged to override the electri-

cally determined position of the ball valve.

1. Push handwheel down and rotate to engage inter-

nal slot with ﬂ ats, see Figure 4-6.

NOTE

Actuator does not have mechanical stops. Do Not

rotate past open or close position. Use visual indicator

to position actuator.

2. Once engaged, push down handwheel a second

time to disengage gear train and rotate CLOCKWISE

to OPEN or COUNTER CLOCKWISE to CLOSE.

3. To return actuator to normal operation, ﬁ rst check

“% OPEN” on control panel. If value is 100%, return

actuator to OPEN position as shown on the visual

indicator. If value is 0%, return actuator to CLOSE

position as shown on the visual indicator.

Handwheel Visual Indicator

Actuator

4 – 9

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Purging with Dry Nitrogen

Purging is recommended if the compressor will be

inactive for 12 hours or more. For additional long

term storage information, refer to Long Term Storage

Recommendations in Section 3.

PREPARATION

WARNING

When working with LFG, NG or other dangerous

or ﬂ ammable gases, ensure there are adequate

ventilation and vapor detectors. Refer to national ﬁ re

and building codes. Failure to comply may result in

serious injury or death.

WARNING

When working pressured systems, always wear

safety glasses and/or face shield. Failure to comply

may result in serious injury.

1. Press “Stop” button to stop compressor unit, see

Figure 4-7.

2. If equipped with equalizing solenoid, allow pres-

sure in compressor unit to equalize to suction pres-

sure, see Figure 4-8.

3. If equipped with manual suction bypass valve and

it is not open, open suction bypass valve. Allow

pressure in compressor unit to equalize to suction

pressure.

Figure 4-7. PLC Main Screen

Stop Button

Discharge

Status

4. Close suction and discharge shut-off valves to

isolate the compressor unit from house system.

Lockout/tagout valves.

5. Slowly open suction oil charging valve to depres-

surize compressor unit to atmosphere, see Figure

4-8. Keep valve in open position.

NOTE

Plugs are installed on bleed valves. Remove and install

plugs prior to and after bleeding. Ensure to keep valves

closed when removing and installing plugs.

6. Open discharge bleed valve to allow nitrogen to

purge through compressor unit, see Figure 4-8.

7. Refer to PLC main screen for discharge pressure

when purging.

PURGE

CAUTION

Do not purge compressor unit with oxygen. Failure to

comply may result in damage to equipment.

CAUTION

Do not allow compressor to spin while purging.

Regulate purging pressure as needed. Failure to

comply may result in damage to equipment.

8. Connect purging hose from nitrogen cylinder to

suction oil charging valve.

Section 4 • Operation

4 – 10 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 4 • Operation

NOTE

Purging is performed through the suction oil charging

valve so that trapped gas can be pushed out of the

compressor. This will help minimize metal surface

oxidation of the compressor (due to the gas) while not

in service.

9. Purge compressor unit for 5 minutes. Check dis-

charge pressure on PLC main screen to make sure

pressure is increasing.

10. Close discharge bleed valve while still purging.

11. Observe discharge pressure through the PLC main

screen. Allow pressure to build to approximately 10

psig.

Equalizing Solenoid

for Suction Bypass

Figure 4-8. Suction Bypass Valve and Equalizing Solenoid

Suction Bypass Valve

(Manual)

View Rotate 180°

Suction Oil

Charging Valve

View Rotate 180°

Figure 4-9. Suction Oil Charging Valve and Discharge Bleed Valve

Discharge

Bleed Valve

12. Once pressure is reached, stop purging and close

suction oil charging valve. If pressure is greater

than 10 psig, crack open discharge bleed valve,

as needed, to slowly bleed the system to approxi-

mately 10 psig.

13. Wait 10 minutes to make sure there are no leaks

and that the pressure is holding.

14. Remove purging hose from suction oil charging

valve.

4 – 11

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

NOTICE

To purge the compressor unit using a dry gas (i.e.

methane), a purge line must be installed. If there is

not enough purge pressure, connect purge line to a

lower pressure line or to atmosphere. The purge line,

associated valves and gauges are not provided from the

factory and must be installed by the customer.

1. Refer to Figure 4-10 for recommended purge line

design.

2. Press “Stop” button to stop compressor unit, see

Figure 4-11.

3. If equipped with equalizing solenoid, allow pres-

sure in compressor unit to equalize to suction pres-

sure, see Figure 4-12.

4. If equipped with manual suction bypass valve and

it is not open, open suction bypass valve. Allow

pressure in compressor unit to equalize to suction

pressure.

5. Close suction and discharge shut-off valves to

isolate the compressor unit from house system.

Lockout/tagout valves.

Section 4 • Operation

Purging with Dry Gas

Purging is recommended if the compressor will be

inactive for 12 hours or more. For additional long

term storage information, refer to Long Term Storage

Recommendations in Section 3.

PREPARATION

WARNING

When working with LFG, NG or other dangerous

or ﬂ ammable gases, ensure there are adequate

ventilation and vapor detectors. Refer to national ﬁ re

and building codes. Failure to comply may result in

serious injury or death.

WARNING

When working pressured systems, always wear

safety glasses and/or face shield. Failure to comply

may result in serious injury.

Figure 4-10. Customer Purge Line

002

Shut-off Valve Check Valve

Shut-off Valve

Pressure Indicator

Drain Valve

001

BLEED

DRAIN

002

BLEED

004

101

102

103

005

1000W 1000W 1000W

001

002

OIL CHARGE

002

DRAIN

VENT

003

007

OIL SEPARATOR

COMPRESSOR

MOTOR

REMOTE

OIL COOLER

COALESCING OIL RETURN LINE

PURGE LINE

PRESSURE

EQUALIZING LINE

SUCTION INLET

DISCHARGE OUTLET

To Lower Pressure Line or

Atmosphere. See NOTICE.

4 – 12 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Figure 4-11. PLC Main Screen

Section 4 • Operation

Stop Button

Discharge

Status

9. Connect purging hose from gas cylinder to suction

oil charging valve.

NOTE

Purging is performed through the suction oil charging

valve so that trapped gas can be pushed out of the

compressor. This will help minimize metal surface

oxidation of the compressor (due to the gas) while not

in service.

10. Purge compressor unit for 4 minutes. Check pres-

sure indicator or discharge status on PLC main

screen to make sure pressure is increasing.

11. Close shut-off valve on purge line while still purging.

12. Observe discharge pressure of compressor unit

through the PLC main screen.

13. Allow pressure to build to approximately 10 psig in

the compressor unit.

14. Once pressure is reached, stop purging and close

suction oil charging valve.

15. Wait 10 minutes to make sure there are no leaks

and that the pressure is holding.

16. Remove purging hose from suction oil charging

valve.

NOTE

Plugs are installed on bleed valves. Remove and install

plugs prior to and after bleeding. Ensure to keep valves

closed when removing and installing plugs.

6. Slowly open suction oil charging valve and bleed

remaining pressure in compressor unit to atmo-

sphere, see Figure 4-13. Leave suction oil charging

valve in open position.

7. If equipped with pressure indicator on purge line,

open shut-off valve to pressure indicator.

8. If not equipped with pressure indicator, refer to PLC

main screen for discharge pressure when purging.

PURGE

CAUTION

Do not purge compressor unit with oxygen. Failure to

comply may result in damage to equipment.

CAUTION

Do not allow compressor to spin while purging.

Regulate purging pressure as needed. Failure to

comply may result in damage to equipment.

4 – 13

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Suction Oil

Charging Valve

View Rotate 180°

Figure 4-13. Suction Oil Charging Valve

Section 4 • Operation

Equalizing Solenoid

for Suction Bypass

Figure 4-12. Suction Bypass Valve and Equalizing Solenoid

Suction Bypass Valve

(Manual)

View Rotate 180°

4 – 14 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 4 • Operation

Figure 4-14. Coalescing Oil Return Line

Coalescing Oil Return Line

Needle

Valve

Sight-Glass

Shut-Off

Valve

Check Valve

Coalescing Oil Return Line Setup

Over time, oil will accumulate on the coalescing side

of the oil separator. As a result, an oil return line with a

shut-off valve, sight-glass, check valve and needle valve

are installed between the coalescing side and compres-

sor to return this oil back to the compressor.

To adjust the return ﬂ ow, proceed with the follow

procedure:

NOTE

Do not fully open the needle valve unless directed by

Vilter Customer Service. Leaving the needle valve fully

open will reduce efﬁ ciency of the compressor unit.

1. Open shut-off valve on coalescing side of oil separa-

tor, see Figure 4-14.

2. While the unit is in operation, crack open needle

valve and observe oil ﬂ ow through sight-glass.

3. Slowly open needle valve more until a small amount

of oil is seen in the sight-glass.

NOTE

The sight-glass should never be full with oil.

4. Periodically check oil in the sight-glass and ensure

that there is ﬂ ow.

5 – 1

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Maintenance and Service Schedule

Follow this table for maintaining and servicing the compressor unit at hourly intervals.

Table 5-1. Maintenance/Service Schedule

Section 5 • Maintenance/Service

Group Inspection/

Maintenance (2)

Service Interval (Hours) (¹)

(Based on dry clean gas)

200

2,500

5,000

10,000

15,000

20,000

25,000

30,000

35,000

40,000

45,000

50,000

55,000

60,000

Oil Circuit

Oil Change Replace oil based on oil analysis report or visual contamination.

Oil Analysis

Oil sampling is recommended every 2 to 3 months for the ﬁ rst year. Thereafter, as required, increase

sampling time period if contamination of oil is unlikely or decrease sampling time period if contami-

nation of oil is evident. Take an oil sample any time during operation If there’s reason to believe that

the oil is contaminated. For additional information on oil, refer to Oil and Oil Flow operation.

Oil Filters (3) ----R--R--R--R

Oil Strainer IIIIIIIIIIIIII

Compressor

Unit

Coalescing Filter ----R--R--R--R

Coalescing Drain Line IIIIIIIIIIIIII

Suction Screen I - - I - I - I - I - I - I

Coupling Alignment

and Integrity IIIIIIIIIIIIII

Motor (Compressor) See Motor Manual for proper lubrication procedures and service intervals.

Control

Calibration

Transducers IIIIIIIIIIIIII

RTDs IIIIIIIIIIIIII

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 (4) (5) Compressor (6) -I-I-I-I-I-I-I

Bearings -------------I

I = Inspect S = Sampling R = Replace

(1) Vilter recommends that a Preventative Maintenance Program be developed by Vilter GC (Gas Compression) Service Center.

(2) Daily records should be kept on suction, discharge, oil pressures & temperatures, along with ensuring Temp Leaving Oil Separator is above Dew Point.

(3) Replace oil ﬁ lters when pressure drop reaches 7 PSID (maximum allowable pressure drop is 15 PSID).

(4) The life of the compressor will be increased by purging the compressor unit with dry nitrogen or sweet, dry natural gas at shutdown.

(5) Header drains should periodically be drained for liquid build-up to prevent compressor damage, see Piping in Section 3.

(6) Inspections include: gate rotor inspection, backlash measurement, shelf clearance, end play measurement (main rotor & gate rotor), gate rotor ﬂ oat, slide valve inspection.

5 – 2 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Maintaining Proper Operation

To ensure proper operation, the following items should

be checked:

• Calibrate all transducer and RTDs.

• Check capacity and volume actuator calibration.

• Check fuses in the PLC panel.

• Check for loose wiring connections in the PLC panel.

• Check relay and contact operation for relays in the

PLC panel.

• Verify the operation of the suction and discharge

check valves.

• Check for correct rotation of all motors on the pack-

age (compressor, oil pump, and fan motors).

• Check that the piping to the oil cooler is correct.

• Check setup of soft starts and VFDs.

• Verify set points in the PLC.

• Check oil heater operation.

• Verify oil line check valve is installed for correct ﬂ ow .

• Check for loose bolts on the compressor unit. Tighten

any loose bolts.

Compressor Unit Isolation for

Maintenance/Service

WARNING

When working with LFG, NG or other dangerous

or ﬂ ammable gases, ensure there are adequate

ventilation and vapor detectors. Refer to national ﬁ re

and building codes. Failure to comply may result in

serious injury or death.

WARNING

Avoid skin contact with any condensate or oil. Wear

rubber gloves and a face shield when working with

condensate or oil. Failure to comply may result in

serious injury or death.

WARNING

At shutdown, open any other valves that may trap

liquids to prevent serious injury and/or damage to

equipment.

WARNING

Follow local lockout/tagout procedure. Failure to

comply may result in serious injury, death and/or

damage to equipment.

NOTICE

Recover or transfer all gas vapor in accordance with

local ordinances before opening compressor 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.

Figure 5-1. Suction By-Pass Valve Location (Manual) (1 of 2)

Suction By-Pass Valve

Section 5 • Maintenance/Service

5 – 3

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

2. If equipped with equalizing solenoid to control suc-

tion by-pass, allow solenoid to remain open until

pressures equalize, see Figure 5-1 (2 of 2).

3. Turn motor and oil pump starter disconnect switch-

es into the OFF position. Lockout/tagout discon-

nect switches.

4. If equipped with manual suction by-pass valve and

it is not open, open suction by-pass valve to allow

oil separator pressure to vent to low-side system

pressure, see Figure 5-1 (1 of 2). Close suction by-

pass valve when complete.

5. Isolate the compressor unit by closing all valves to

the house system. Lockout/tagout valves.

NOTE

If drain valves are installed on suction and discharge

headers, open these valves too to remove build up

of liquid during shut-down periods.

6. Open any other valves that may trap liquid. Lockout/

tagout valves.

7. Recover or transfer all gas vapors.

8. Open discharge pressure bleed valve at block and

bleed assembly and allow remaining pressure in oil

separator to equalize to atmospheric pressure.

9. Servicing the compressor unit can proceed at this

point. After servicing, ensure to perform a leak

check, see Compressor Unit Leak Check procedure.

Section 5 • Maintenance/Service

Compressor Unit Leak Check

The compressor unit must be checked for leaks after ser-

vicing to ensure a tight system.

CAUTION

Do not hydro test compressur unit. Failure to comply

may result in damage to equipment.

1. If servicing the compressor unit was completed,

proceed to step 2. Otherwise, isolate the compres-

sor unit from the house system, see Compressor

Unit Isolation procedure.

2. Slowly pressurize compressor unit through suction

oil charging port.

3. Check for leaks.

4. Typically, no evacuation is required for open loop

systems. If dry nitrogen was used, it can be bled off

to atmosphere.

5. If evacuation is required, evacuate from suction oil

charging port.

6. Open all valves previously closed and close all

valves previously opened. Remove tags as per the

local lockout/tagout procedure.

7. Turn the motor and oil pump disconnect switches

to the ON position.

8. The compressor unit can now be started, refer to

Start-Up procedure in Section 4.

Solenoid

Shut-off

Valve

Needle

Valve

Line to

Suction

Line

from Oil

Separator

Line from Needle

Valve to Suction

Line from Oil Separator

to Shut-off Valve

Figure 5-1. Suction By-Pass Valve Location (Equalizing Solenoid) (2 of 2)

5 – 4 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Oil System Components

Oil Sampling

WARNING

When working with LFG, NG or other dangerous

or ﬂ ammable gases, ensure there are adequate

ventilation and vapor detectors. Refer to national ﬁ re

and building codes. Failure to comply may result in

serious injury or death.

WARNING

Avoid skin contact with any condensate or oil. Wear

rubber gloves and a face shield when working with

condensate or oil. Failure to comply may result in

serious injury or death.

Use Vilter Oil Analysis Kit (VPN 3097A) to collect an oil

sample for analysis. For an example, see Figure 5-2. Fill

out label for bottle. Place in mailing tube and seal with

the preaddressed mailing label. Below are a few points

to remember when taking a sample:

• Sample running compressor units, not cold units.

• Sample upstream of the oil ﬁ lter.

• Create speciﬁ c written procedures for sampling.

• Ensure sampling valves and devices are thoroughly

ﬂ ushed prior to taking a sample.

• Ensure samples are taken as scheduled in the

Maintenance and Service Schedule.

• Send samples immediately to the oil analysis lab after

sampling, do not wait 24 hours.

Section 5 • Maintenance/Service

NOTE

A copy of the oil analysis report is also sent to Vilter. See

Appendices for a sample of the oil analysis report.

An oil analysis report will show the physical properties of

the oil, such as:

• Water content

• Viscosity

• Acid number

• Particle count

• Antioxidant level

• Wear metals

• Contaminate/additive metals

Figure 5-2. Oil Analysis Kit

5 – 5

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 5 • Maintenance/Service

Oil Charging

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.

CAUTION

Do not add oil to the coalescent side of the oil

separator. Failure to comply may result in damage to

equipment.

Normal oil level operating range must be maintained for

optimum performance and to prevent damage to equip-

ment. See Figure 4-1. for normal operating levels. There

are a couple of ways to maintain oil, while the compres-

sor unit is in operation and during shutdown.

Tool Required:

• Oil Pump, Maximum 2-3 GPM with Motor approved

for Division 1 or Division 2 and with ability to over-

come suction pressure.

Charging During Operation:

During operation, if the oil level is low, add oil to the

operating compressor through the suction oil charging

valve, see Figure 5-3. Pump oil into the compressor until

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

efﬁ ciency.

1. Using a properly selected oil pump, connect oil

pump to suction oil charging valve, see Figure 5-3.

2. Open suction oil charging valve and ﬁ ll oil separator

to Normal Operating Level.

3. Once the Normal Operating Level has been reached,

shut off the oil pump and close the valve. Disconnect

and remove oil pump.

Charging During Shutdown:

During shutdown, if oil is to be added, charging can be

performed through the drain valve located underneath

the oil separator, see Figure 5-3. During shutdown, oil

can be added to the Maximum Non-Operating Level.

For shutdown procedure, see Compressor Unit Isolation

procedure.

1. Using a properly selected oil pump, connect oil

pump to oil separator drain valve.

2. Open oil separator drain valve and ﬁ ll oil separator to

Maximum NON-Operating Level.

3. Once Maximum NON-Operating Level has been

reached, shut off oil pump, close oil separator drain

valve and remove oil pump.

Figure 5-3. Suction Oil Charging Valve, Oil Cooler Drain Valve and Oil Filter Shut-Off Valves

Suction Oil

Charging Valve

View Rotate 180°

Oil Drain Valve

(Oil Separator)

Oil Drain Valve

(Oil Cooler)

View From Back - View Rotate 180°

Oil Filter

Shut-Off Valves

5 – 6 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 5 • Maintenance/Service

Figure 5-4. Oil Filter Assemblies (Single and Dual)

Cover Flange

Spring Plate

Element

Canister Spring Plate

Elements

Single Oil Filter Assembly Dual Oil Filter Assembly

Outlet

Inlet Outlet

Element

Centering

Piece

Inlet

Canister

Cover Flange

Oil Draining

WARNING

Do not drain oil from drain valve while the compressor

unit is running. Shutdown the unit and allow pressures

to equalize to suction pressure prior to draining.

Failure to comply may result in serious injury.

The compressor unit must be shut down prior to draining

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 oil separator, see Figure 5-3. A

drain valve is also provided underneath the shell and

tube oil cooler.

Draining of the remote oil cooler can be performed at

the remote oil cooler drain valves. If equipped with lower

level drains on the supply and return lines, these too can

be utilized for draining. For additional information, see

Recommended Remote Air Cooled Oil Cooler Piping in

Appendices.

Oil Filter Replacement

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 ﬁ lter as outlined in the Maintenance and

Service Interval, see Table 5-1. Maintenance & Service

Interval.

NOTE

Ensure to check the oil pressure drop and record it

daily.

If the compressor unit is equipped with only a single oil

ﬁ lter, the compressor unit must be shut down prior to

servicing, see Stopping/Restarting procedure in Section

If the compressor unit is equipped with dual oil ﬁ lters,

then one oil ﬁ lter can be isolated and serviced one at a

time during operation. Each oil ﬁ lter can have single or

dual oil ﬁ lter elements depending on the size of com-

pressor used, see Table 5-2 and Figure 5-4.

Table 5-2. Oil Filter Elements and Compressor Models

Oil Filter Element Qty. VSG/VSSG Models

Single Element 301 - 701

Dual Elements 751 - 3001

To replace an oil ﬁ lter element, continue with the follow-

ing steps:

Parts Required:

• Oil Filter Element (VPN 1833G)

REMOVAL

NOTE

Both outlet shut-off valves should be open. If the

outlet valve is closed for the oil ﬁ lter that is not in

operation, slowly open the outlet shut-off valve until

fully open. This will help reduce a sudden pressure

drop when switching oil ﬁ lters for servicing.

5 – 7

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 5 • Maintenance/Service

1. If equipped with dual oil ﬁ lters, open inlet shut-off

valve for non-operating oil ﬁ lter to put it into opera-

tion, see Figure 5-5.

2. To isolate oil ﬁ lter for servicing, close inlet and out-

let shut-off valves for the oil ﬁ lter.

NOTE

To reduce unwanted oil splash from a vent or drain

valve, connect a hose to the valve port and direct

the gas and oil into a drain pan.

3. Slowly release pressure in the oil ﬁ lter canister by

opening the vent valve. Allow pressures to equalize

to atmosphere.

NOTICE

Dispose of the oil in a appropriate manner following

all Local, State and Federal ordinances regarding the

disposal of used oil.

4. Using an drain pan, open drain valve and allow the

oil to completely drain from the oil ﬁ lter canister.

NOTE

Note orientation of components to aid in installation.

5. Remove bolts and nuts securing cover ﬂ ange to the

oil ﬁ lter canister. Remove cover ﬂ ange and spring

plate. Retain spring plate.

6. If equipped with a single oil ﬁ lter element, remove

ﬁ lter element from oil ﬁ lter canister.

7. If equipped with dual oil ﬁ lter elements, remove

two ﬁ lter elements and ﬁ lter element centering

piece from oil ﬁ lter canister. Retain ﬁ lter element

centering piece.

8. Thoroughly clean the oil ﬁ lter canister, spring

plate and centering piece. Inspect spring plate and

Figure 5-5. Oil Filter Drain, Vent and Shut-Off Valves

Drain Valve

Inlet Shut-Off Valves

Vent Valve

Drain Valve

Vent Valve Outlet Shut-Off Valves

centering piece, if damaged, replace as required.

INSTALLATION

NOTE

Ensure oil ﬁ lter element on the outlet side is fully

seated on the outlet pipe when installed.

9. If equipped with single oil ﬁ lter element, install oil

ﬁ lter element in canister in orientation noted dur-

ing removal.

10. If equipped with dual oil ﬁ lter elements, install two

oil ﬁ lter elements and centering piece in orientation

noted during removal.

11. Position spring plate in orientation noted during

removal and install bolts and nuts to secure cover

ﬂ ange to oil ﬁ lter canister.

12. Tighten nuts, see Appendix A.

13. Using dry nitrogen gas, pressurize oil ﬁ lter canister

through vent valve and check for leaks.

14. Close the vent valve and drain valve.

15. Open outlet shut-off valve for the oil ﬁ lter that is not

in operation.

16. Repeat for second oil ﬁ lter, as required.

5 – 8 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 5 • Maintenance/Service

Coalescing Filter Replacement

WARNING

Use appropriate lifting devices and additional

personnel when lifting heavy components. Ensure

lifting devices are capable of lifting the weight o

the component. Use lifting points (i.e. bolt holes

designated for lifting eye bolts) that are provided

on the component. Failure to comply may result in

serious injury.

WARNING

Avoid skin contact with any condensate or oil. Wear

rubber gloves and a face shield when working with

condensate or oil. Failure to comply may result in

serious injury or death.

NOTE

For coalescing oil ﬁ lters (11-7/8 in. O.D.), a tubing

(3/4 in. O.D. x 6 ft. long ) can be used to aid in

removal and installation of the element.

REMOVAL

1. Isolate the compressor unit, see Compressor Unit

Isolation procedure.

2. If required, install lifting eyes on oil separator man-

hole cover, see Figure 5-6.

3. Secure appropriate lifting device to oil separator

manhole cover.

4. Remove all bolts except top four bolts securing oil

separator manhole cover to oil separator vessel.

5. Adjust lifting device as needed to hold weight of oil

separator manhole cover.

6. Remove remaining four bolts and oil separator

manhole cover from oil separator vessel.

7. Remove nuts, ﬂ at washer and cover plate securing

coalescing oil ﬁ lter to hold-down rod.

8. With assistance of second person, remove coalesc-

ing ﬁ lter from oil separator vessel.

9. Repeat steps 7 and 8 to remove additional coalesc-

ing ﬁ lters, as required.

INSTALLATION

10. Install tubing over hold-down rod. Position tubing

as far back as possible.

11. With assistance of second person, position coalesc-

ing element over tubing and through hole of cen-

tering strap.

12. Push coalescing ﬁ lter into vessel until fully seated

Oil Separator

Manhole Cover

Figure 5-6. Oil Separator Manhole Cover and Coalescing Filter Assembly

Centering Strap

Nuts

Coalescing Filter Hold-Down Rod

3/4 in. O.D.

Tubing, 6 ft. long

Flat Washer

Oil Separator Vessel

Pipe Stub

5 – 9

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Figure 5-7. Oil Pump Strainer and Drain Valve

Strainer

Drain Valve

Oil Pump

Strainer

Bolts Strainer CoverNuts

WARNING

Avoid skin contact with any condensate or oil. Wear

rubber gloves and a face shield when working with

condensate or oil. Failure to comply may result in

serious injury or death.

1. Shut down the compressor unit, refer to Stopping/

Restarting procedure in Section 4.

2. Turn disconnect switches to the OFF position for

the compressor unit and oil pump motor starter, if

equipped.

3. Close shut-off valves located before the strainer

and at the oil ﬁ lter(s) inlet.

4. Position drain pan under drain valve.

5. Open strainer drain valve and allow oil to complete-

ly drain, see Figure 5-7.

6. Remove bolts securing strainer cover to strainer.

Remove strainer cover, gasket and element. Retain

gasket.

7. Inspect gasket for damage, replace as required.

8. Wash element in solvent and blow it with clean air.

9. Inspect element for damage, replace as required.

10. Clean strainer cavity with clean lint-free cloth.

11. Install in reverse order of removal. For torque speci-

ﬁ cations, see Appendix A.

12. Close strainer drain valve.

13. Open shut-off valves.

14. Check replaced components for leaks.

15. Turn disconnect switches to the ON position for

the compressor unit and oil pump motor starter, if

equipped.

16. Start compressor unit.

Section 5 • Maintenance/Service

Oil Pump Strainer

NOTICE

Dispose of the oil in a appropriate manner following

all Local, State and Federal ordinances regarding the

disposal of used oil.

To clean the oil pump strainer, proceed with the follow-

ing steps.

WARNING

At shutdown, open any other valves that may trap

liquids to prevent serious injury and/or damage to

equipment.

WARNING

Follow local lockout/tagout procedure. Failure to

comply may result in serious injury, death and/or

damage to equipment.

on pipe stub.

13. Remove tubing.

14. Position cover plate and ﬂ at washer on hold-down

rod on end of the coalescing ﬁ lter.

15. Install nut to secure ﬂ at washer and cover plate to

coalescing ﬁ lter. Tighten nut to 25 ft-lbs.

16. Install second nut to prevent ﬁ rst nut from moving.

17. Repeat steps 10 to 16 for installing additional co-

alescing ﬁ lters.

18. Position oil separator manhole cover on oil separa-

tor vessel.

19. Install bolts to secure oil separator manhole cover

to oil separator vessel.

20. Tighten bolts, see Appendix A.

21. Perform Compressor Unit Leak Check procedure.

View From Back of Oil Pump Strainer

5 – 10 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 5 • Maintenance/Service

with a small clearance over the top.

NOTE

If hub position on shaft does not allow enough room

to install bolts, install bolts and disc pack before

mounting hub on shaft.

Hubs come in two different types, straight bore and

tapered bore. Tapered bore hubs have additional

hardware. Typically, a compressor will have a

tapered shaft and therefore use a tapered bore hub.

STRAIGHT BORE HUBS

5. For straight bore hubs, install key in keyway of shaft.

6. Install hub on shaft. If installing straight bore hubs

on motor and compressor shafts, allow 1/16” gap

between the outer face of the hub to the outer face

of the shaft for both hub installation. This will allow

some play when installing the spacer. If installing

a straight bore hub and a taper bore hub, allow a

1/8” gap between the outer face of the straight

bore hub to the outer face of the straight shaft, see

Table 5-3.

7. Install clamping bolts in hub.

8. Tighten clamping bolts, see Table 5-4.

9. Install set screw in hub to secure key.

10. Tighten set screw, see Table 5-4. Repeat steps for

second straight bore hub.

TAPERED BORE HUBS

11. For taper bore hubs, install key in keyway of shaft.

12. Install hub on shaft.

13. If lock washers are being used, install hub cap, lock

washers and bolt on shaft.

14. If locking tab is being used, install hub cap, locking

tab and bolt on shaft.

15. Tighten bolt and draw hub up shaft to a stop.

Drive Coupling (Form-Flex BPU) Hub

Installation

On all single screw units, the coupling assembly is

shipped loose and will have to be installed and aligned

on site. This is to allow a check of proper electrical phas-

ing and direction of motor rotation. The motor and

compressor have been aligned from the factory with the

coupling hubs already installed. Using a dial indicator for

aligning is recommended.

NOTE

Drive coupling type and size can be determined

by the information on the compressor nameplate

when ordering; Order Number and Compressor

Model Number.

To install the coupling, proceed with the following steps:

WARNING

Follow local lockout/tagout procedure. Failure to

comply may result in serious injury, death and/or

damage to equipment.

1. Ensure disconnect switches are in the OFF position

for the compressor unit and oil pump motor start-

er, if equipped.

2. If hubs are already installed on motor shaft and

compressor shaft, proceed to Drive Center Member

Installation and Alignment procedure.

3. If coupling assembly is already assembled, the lock

nuts are not torqued. Remove lock nuts and bolts

securing hubs to disc packs. Remove both hubs.

Leave the disc packs attached to center member.

4. Clean hub bores and shafts. Remove any nicks

or burrs. If bore is tapered, check for good con-

tact pattern. If bore is straight, measure bore and

shaft diameters to ensure proper ﬁ tment. The keys

should have a snug side-to-side ﬁ t in the keyway

Coupling

Size

Shaft Gap for Tapered

Compressor &

Straight Motor Shaft

Combination

Shaft Gap for Straight

Compressor &

Straight Motor Shaft

Combination

Distance

Between Hub

Faces

BP38U

6.25”

(158.75 mm)

5.125”

(130.18 mm)

5.00”

(127 mm)

BP41U

BP47U

BP54U

BP56U

Table 5-3. Shaft and Hub Distances

5 – 11

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 5 • Maintenance/Service

16. If locking tab is being used, bend locking tabs in

gap towards shaft and around bolt.

17. Install set screw in hub cap to secure key in keyway

of shaft.

18. Tighten set screw, see Table 5-4.

Drive Center Member Installation and

Alignment

NOTE

Always adjust motor to the compressor. The

compressor is aligned to the frame.

19. Adjust motor position as needed to obtain a dis-

tance of 5” between both hub faces.

20. Soft Foot. The motor must sit ﬂ at on its base (+/-

0.002”). Any soft foot must be corrected prior to

center member installation.

NOTE

If the driver or driven equipment alignment

speciﬁ cation is tighter than these recommendations,

the speciﬁ cation should be used. Also, be sure

to compensate for thermal movement in the

equipment. The coupling is capable of approximately

four time the above shaft alignment tolerances.

However, close alignment at installation will provide

longer service with smoother operation.

The ﬂ ex 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 ﬂ ex disc packs are ﬂ at

when the equipment is running under normal op-

erating conditions. This means there is a minimal

amount of waviness in the ﬂ ex disc pack when

viewed from the side. This will result in a ﬂ ex disc

pack that is centered and parallel to its mating

ﬂ ange faces. Move the motor to obtain the correct

axial spacing, see Table 5-3 and Figure 5-8.

22. Angular Alignment. Rigidly mount a dial indicator on

one hub or shaft, reading the face of the other hub

ﬂ ange. Rotate both shafts together, making sure

the shaft axial spacing remains constant. Adjust the

motor by shimming and/or moving so that the indi-

cator reading is within 0.002” per inch of coupling

ﬂ ange, see Figure 5-9.

23. Parallel Offset. Rigidly mount a dial indicator on one

hub or shaft, reading the other hub ﬂ ange outside

diameter. Indicator set-up sag must be compen-

sated for. Rotate both shafts together. Adjust the

equipment by shimming and/or moving so that the

indicator reading is within 0.002” per inch of the

axial length between ﬂ ex disc packs, see Figure 5-9.

With the coupling in good alignment the bolts will ﬁ t

through the holes in the ﬂ anges and the disc packs more

easily.

NOTE

All bolt threads should be lubricated. A clean motor

oil is recommended. On size 226 and larger, a link

must be put on bolt ﬁ rst. Remove 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

Hub Distance

Figure 5-8. Hub Distance (Axial Spacing)

5 – 12 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 5 • Maintenance/Service

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 straight bores, adjust either

hubs. If one hub is tapered and the other a straight,

adjust the straight bore hub.

27. Using additional supports supporting center mem-

ber. Install bolts and locking nuts to secure center

member to compressor hub.

28. Tighten locking nuts.

29. Position hubs, ensure distance between face of

both hubs is 5”.

NOTE

If there is waviness with the disc pack installed, adjust

distance accordingly until disc pack is straight.

30. Install bolts and locking nuts to secure disc pack to

motor hub.

31. Tighten locking nuts, see Table 5-4.

Coupling

Size

Lock Nut

Size

Tightening

Torque

ft-lbs (Nm)

BP38U 5/16-24 22 (30)

BP41U 7/16-20 55 (75)

BP47U 9/16-18 120 (163)

BP54U 9/16-18 120 (163)

BP56U 9/16-18 120 (163)

Table 5-5. Disc Pack Installation Torque

Speciﬁ cations

Table 5-4. Hub Clamp Bolt and Set Screw Torque Speciﬁ cations

Coupling

Series/Size

Clamping Bolt Set Screw

# Bolts Size-Pitch Torque

ft-lbs (Nm) Size Torque

ft-lbs (Nm)

BH38U 4 1/4-28 12 (16) 3/8 10 (13)

BH41U 4 5/16-24 23 (31) 3/8 10 (13)

BH47U 4 3/8-24 49 (66) 1/2 20 (27)

BH54U 4 7/16-20 78 (106) 1/2 20 (27)

BH56U 4 1/2-20 120 (163) 5/8 40 (54)

DP42 4 1/2-20 120 (163) 1/2 20 (27)

Figure 5-9. Angular Alignment and Parallel Offset

Angular Alignment Parallel Offset

5 – 13

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 5 • Maintenance/Service

32. Perform hot alignment. Run compressor unit and

allow to warm up completely.

33. Power down compressor unit and re-check align-

ments. Loosen motor mounting nuts to add shims

or to adjust alignments as required.

34. Install coupling guard.

Drive Coupling (Form-Flex BPU)

Center Member and Hub Removal

To remove coupling assembly, proceed with the follow-

ing steps:

WARNING

At shutdown, open any other valves that may trap

liquids to prevent serious injury and/or damage to

equipment.

WARNING

Follow local lockout/tagout procedure. Failure to

comply may result in serious injury, death and/or

damage to equipment.

NOTE

Drive coupling type and size can be determined

by the information on the compressor nameplate

when ordering; Order Number and Compressor

Model Number.

1. Shut down the compressor unit, refer to Stopping/

Restarting procedure in Section 4.

2. Turn disconnect switches to the OFF position for

the compressor unit and oil pump motor starter, if

equipped.

3. Allow compressor, motor and surrounding compo-

nents to cool prior to servicing.

4. Remove coupling guard.

5. Remove lock nuts and bolts securing disc pack to

hub on compressor shaft.

6. If additional room is required to remove the center

member, loosen clamping bolts on straight bore

hub(s).

7. Move straight bore hub on shaft as required to al-

low center member removal.

8. Remove lock nuts and bolts securing disc pack to

hub on motor shaft. Remove 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-ﬂ ange between the compres-

sor and motor. The coupling assembly alignments are

built into the design and therefore, should not require

alignment.

NOTE

Drive coupling type and size can be determined

by the information on the compressor nameplate

when ordering; Order Number and Compressor

Model Number.

REMOVAL

To remove Type C Sure-Flex coupling, proceed with the

following steps:

WARNING

At shutdown, open any other valves that may trap

liquids to prevent serious injury and/or damage to

equipment.

WARNING

Follow local lockout/tagout procedure. Failure to

comply may result in serious injury, death and/or

damage to equipment.

1. Shut down the compressor unit, refer to Stopping/

Restarting procedure in Section 4.

2. Turn disconnect switches to the OFF position for

the compressor unit and oil pump motor starter, if

equipped.

3. Allow compressor, motor and surrounding compo-

nents to cool prior to servicing.

4. Remove C-ﬂ ange access cover.

NOTE

Mark locations of hubs prior to removal.

5. Loosen set screw in motor hub securing key in

keyway.

6. Loosen clamping bolts securing hub to motor shaft.

7. Pry hub up motor shaft for space to remove cou-

pling sleeve.

8. Remove coupling sleeve from hub.

9. Remove hub and key from motor shaft.

10. Loosen set screw in compressor hub securing key

in keyway.

11. Loosen clamping bolts securing hub from

5 – 14 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

compressor shaft.

12. Remove hub and key from compressor shaft.

INSTALLATION

13. Install key and hub on compressor shaft as noted

during removal.

14. Install set screw in compressor hub to secure key in

keyway, see Table 5-6,

15. Install clamping bolts to secure hub on compressor

shaft. Tighten clamping bolts, see Table 5-6,

16. Install key and hub on motor shaft as noted during

removal. Allow gap to install coupling sleeve.

17. Install coupling sleeve on hubs. Position hub on

motor shaft on coupling sleeve as noted during

removal.

18. Install set screw in compressor hub to secure key in

keyway. Tighten set screw, see Table 5-6,

19. Install clamping bolts to secure hub to motor shaft.

Tighten clamping bolts, see Table 5-6.

Coupling

Size

Type C

ft-lbs (Nm)

Clamping

Bolts

Key Set

Screw

6 13 (18)

13 (18)

713 (18)

8 23 (31)

9 23 (31)

10 50 (68)

11 50 (68)

Table 5-6. Clamping Bolts and Set

Screw Torque Speciﬁ cations

Section 5 • Maintenance/Service

Compressor Replacement

Notify Vilter prior to performing a compressor replace-

ment. See Warranty instructions in Section 7.

REMOVAL

To replace a compressor on a unit, proceed with the fol-

lowing steps:

NOTICE

Dispose of the oil in a appropriate manner following

all Local, State and Federal ordinances regarding the

disposal of used oil.

1. Shut down and isolate the compressor unit, see

Compressor Unit Isolation for Maintenance and

Service procedure.

NOTE

Note location of cables to aid in installation.

2. Disconnect all cables from sensors on compressor

and actuators.

3. Remove drive coupling, see appropriate Drive

Coupling Replacement procedure.

4. If equipped with C-ﬂ ange, remove bolts securing

C-ﬂ ange to compressor.

5. Remove center member, see Drive Coupling

Removal procedure.

6. Using appropriate drain pan, drain oil by removing

drain plugs from under compressor housing and

discharge manifold. Allow oil to completely drain.

7. Remove all oil lines from the compressor.

8. Support suction line with appropriate supporting

equipment.

9. Remove nuts and bolts securing suction strainer/

check valve assembly to suction stop valve and

compressor.

10. Using appropriate lifting device, remove suction

strainer/check valve assembly from compressor.

11. Remove nuts and bolts securing discharge pipe to

compressor and oil separator, see Figure 5-10.

12. Remove discharge pipe and gaskets from compres-

sor and oil separator.

13. Remove nuts, ﬂ at washers, lock washers and studs

securing compressor to frame.

14. Remove any additional lines and/or components to

allow removal of compressor as required.

15. Install appropriate lifting eyes on top of compressor.

16. Using appropriate lifting device and additional

5 – 15

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 5 • Maintenance/Service

26. If equipped with C-ﬂ ange, install C-ﬂ ange coupling,

refer to C-ﬂ ange Coupling Replacement procedure.

27. Install coupling, see Drive Coupling Installation and

Alignment procedure .

28. Install coupling guard.

29. Install nuts and bolts to secure discharge pipe to oil

separator and compressor.

30. Tighten nuts on ‘discharge pipe-to-compressor

ﬂ ange’ ﬁ rst, then tighten nuts on ‘discharge pipe-

to-oil separator ﬂ ange’, see Appendix A.

31. Install nuts to secure suction strainer/check valve

assembly to compressor and suction stop valve.

32. Tighten nuts on ‘suction strainer/check valve as-

sembly-to-compressor’ ﬁ rst, then tighten nuts on

‘suction strainer/check valve assembly-to-suction

stop valve’, refer to Appendix A.

33. Install all lines to compressor.

34. Install all cables to sensors on compressor and

actuator.

35. Perform leak check, see Compressor Unit Leak

Check procedure.

personnel, remove compressor from frame.

17. Remove shims and spherical washers from com-

pressor mounting locations.

18. Inspect shims and spherical washers for damage,

replace as required.

INSTALLATION

19. Install shims and spherical washers on compressor

mounting locations, see Figure 5-10.

20. Install appropriate lifting eyes on top of compressor.

21. Using appropriate lifting device, position compres-

sor on compressor mounting locations on frame.

22. Loosely install studs, lock washers, ﬂ at washers and

nuts to secure compressor to frame until alignment

is correct.

23. Check compressor for soft foot. Add or remove

shims as required until measurements are within

+/- 0.002”.

24. Tighten nuts to secure compressor to frame, refer

to Appendix A.

25. If equipped with C-ﬂ ange, install bolts to se-

cure C-ﬂ ange to compressor. Tighten bolts, see

Appendix A.

Figure 5-10. Compressor Replacement and Hardware Assembly (Models 2401-3001 Shown)

Nut

Lock Washer

Flat Washer

Spherical

Washer

Assembly

Stud

Flat Washer

Lock Washer

Nut

Shim

Frame

Compressor

5 – 16 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

motor and use the lever arm to push the input shaft

towards the compressor. Record measurement

5. Add both measurements. If measurement is out of

allowable tolerance shown in Table 5-7, the bearing

may need to be replaced. Contact Vilter Customer

Service.

BEARING RADIAL FLOAT INSPECTION

6. Install dial indicator to the compressor frame and

zero indicator, see Figure 5-12.

NOTE

Do not exceed maximum applied force. For

maximum applied forces of all compressor models,

see Table 5-7.

7. Place lever arm and fulcrum underneath hub and

push hub upwards. Record measurement.

8. If measurement is out of allowable tolerance shown

in Table 5-7, the bearing may need to be replaced.

Contact Vilter Customer Service.

Top View

Small wooden block or fulcrum.

Direction of

shaft movement.

Shaft being pushed by use of lever.

Applied Force

Rigidly attach dial indicator.

Position on axis of compressor.

Top 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 5-11. Bearing Axial Float Inspection

Compressor Shaft Bearing Float

Inspections

If ﬂ oat measurements are out of tolerance, contact Vilter

Customer Service for further assistance.

BEARING AXIAL FLOAT INSPECTION

CAUTION

When taking the measurements, do not exceed

300 lbs of force at point of contact or damage may

result to the bearings.

DETERMINE MAXIMUM APPLIED FORCE

To determine maximum applied force, take maximum

applied force at hub/shaft multiplied by length of A

and divide by length B. This is the maximum force that

should be applied on the lever.

(Applied Force x A)/B = Applied Force (Maximum)

So, using a 36” (or 1 m) lever with pivot space of 6” (or

15 cm) would make the maximum applied force to be 60

lbf (or 235 N). Calculation is as follows:

(300 lbf x 6”)/30” = 60 lbf (Max. Applied Force)

(1335 N x 15 cm)/85 cm = 235 N (Max. Applied Force)

Lever

Wooden Block

or Fulcrum

Applied

Force

Force at

Hub/Shaft

Pivot Point

As a quick reference, Table 5-7 shows maximum applied

forces for 36” lever with 6” pivot for all compressor

models.

MEASURE

To inspect bearing axial ﬂ oat, proceed with the following

steps:

1. Remove center member, see appropriate Drive

Coupling Replacement procedure.

2. Install dial indicator to the compressor frame and

zero indicator, see Figure 5-11.

3. Place lever arm and fulcrum behind compressor

coupling half and push the coupling towards the

motor. Record measurement.

4. Re-zero indicator, now position the fulcrum on the

Section 5 • Maintenance/Service

5 – 17

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Gate Rotor Float and Gate Rotor

Bearing Float Inspection

GATE ROTOR FLOAT INSPECTION

To inspect gate rotor ﬂ oat and bearing ﬂ oat, proceed

with the following steps:

1. Remove center member, see appropriate Drive

Coupling Replacement procedure.

2. Remove the side covers from compressor.

3. Position gate rotor blade and damper pin at 90° to

the main rotor, see Figure 5-13.

Figure 5-13. Gate Rotor Float

Dial Indicator

Gate Rotor

Support

Gate Rotor Blade

Main Rotor

Float

Damper Pin

and Bushing

Bushing

Damper Pin

Section 5 • Maintenance/Service

Table 5-7. Maximum Bearing Float

Compressor

Model

Max.

Axial

Float

in. (mm)

Max.

Radial

Float

in. (mm)

Max.

Force

at Hub/

Shaft

lbf (N)

Max.

Applied

Force

(36” Lever, 6”

Pivot)

lbf (N)

All 0.002

(0.051) -300

(1335)

(267)

151, 181, 201,

152, 182, 202,

301, 361, 401

0.006

(0.152)

100

(444)

(89)

501, 601, 701 0.007

(0.178)

150

(667)

(133)

291, 341, 451,

601

0.007

(0.178)

150

(667)

(133)

751, 901 0.006

(0.152)

200

(890)

(178)

791, 891,

1051, 1201,

1301

0.006

(0.152)

300

(1335)

(267)

1501, 1551,

1801, 1851,

2101

0.007

(0.178)

400

(1780)

(356)

2401, 2601,

2801, 3001

0.006

(0.152)

600

(2670)

120

(534)

Side View

Rigidly attach dial indicator.

Direction of shaft

movement.

Applied Force

Shaft being pushed by use of lever.

Figure 5-12. Bearing Radial Float Inspection

5 – 18 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

NOTE

Measurements can be an additional 0.020” higher

than ﬂ oat dimensions on Table 5-8. If measurement

is an additional 0.030” greater than ﬂ oat dimensions,

contact Vilter for further assistance.

Total movement of damper pin in bushing is the

gate rotor ﬂ oat.

4. Using dial indicator, take measurement of gate ro-

tor ﬂ oat. Measurement should not exceed values as

noted above.

Table 5-8. Gate Rotor Float

Model Float

in. (mm)

VSSG 291-601 0.045 (1.143)

VSG 301-401 0.045 (1.143)

VSG 501-701 0.045 (1.143)

VSG 751-901 0.055 (1.397)

VSG 1051-1301 0.060 (1.524)

VSG 1551-2101 0.060 (1.524)

VSG 2401-3001 0.060 (1.524)

NOTE

Some movement between blade and support is

necessary to prevent damage to the compressor

blade; however at no time should the blade uncover

the support.

5. Inspect main rotor and gate rotor for abnormal

wear due to dirt or other contaminants. If dam-

aged, replace gate rotor and/or main rotor.

Section 5 • Maintenance/Service

GATE ROTOR BEARING FLOAT INSPECTION

6. Using dial indicator, position a dial indicator on the

gate rotor, see Figure 5-14.

Side View

Wooden block to prevent

damage to gate rotor blade.

Direction of rotor movement.

Axial force at gate rotor to not

exceed 100 lbs.

Gate rotor bearing float being measured.

Use bolt for fulcurm.

Rigidly attach dial indicator.

Applied

Force

Figure 5-14. Gate Rotor Bearing Float

7. Use a lever arm pivoting on a bolt with a small block

of wood against the gate rotor blade to protect the

blade.

8. Gently apply pressure to lever and take measure-

ment. Maximum amount of gate rotor bearing ﬂ oat

should not exceed 0.002” (0.051 mm).

9. Install gate rotor cover.

10. Install center member, see Drive Coupling

Replacement procedure.

11. Perform compressor unit leak check, see

Compressor Unit Leak Check procedure.

5 – 19

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Gate Rotor and Support Clearance

When measuring, push the gate rotor against the pin to

remove ﬂ oat.

1. Place a straight edge along the side of the gate ro-

tor, see Figure 5-16.

2. Measure the gap from the straight edge to the peak

of the gate rotor support. For minimum distance,

see Figure 5-15.

3. Repeat steps 1 to 2 to check gap along entire gate

rotor edge on both sides.

Section 5 • Maintenance/Service

Figure 5-15. Gate Rotor and Support Clearance - Minimum Clearances

5 – 20 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 5 • Maintenance/Service

Figure 5-16. Gate Rotor and Support Clearance - Measuring

Gate Rotor

Support

Gate Rotor

Straight Edge

Gate Rotor

Support

Gate Rotor

Straight Edge

Gate Rotor

Support

Gate Rotor

Straight Edge

5 – 21

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Gate Rotor Assembly Replacement

(All VSG & VSSG Compressors Except

VSG 301-701 Compressors)

The following table lists the gate rotor tool sets needed

to remove and install gate rotor assemblies.

Table 5-9. Gate Rotor Tool Sets

Model Tool Set VPN

VSSG 291-601 A25205B

VSG 301-401 N/A

VSG 501-701 A25205B

VSG 751-1301 A2520 5C

VSG 1551-2101 A25205E

VSG 2401-3001 A25205F

REMOVAL

1. Remove center member, see appropriate Drive

Coupling Replacement procedure.

NOTE

All parts must be kept with their appropriate side

and not mixed when the compressor is reassembled.

2. Remove two upper bolts from side cover

3. Install guide studs in holes.

NOTE

There will be some oil drainage when the cover is

removed.

4. Remove remaining bolts and side cover.

5. Turn main rotor so a driving edge of any one of the

main rotor grooves is even with the back of the gate

rotor support.

NOTE

The gate rotor stabilizer is designed to hold the gate

rotor support in place and prevent damage to the

gate rotor blade as the thrust bearings and housing

is being removed.

6. Insert gate rotor stabilizer. The side rails are not re-

quired on VSSG 291 thru 601. For the VSG 751 thru

901 and VSG 1051 thru 1301 compressors, use the

side rails and assemble to the gate rotor stabilizer

as stamped. For the VSG 1551 thru 2101, use the

side rails and assemble to the gate rotor stabilizer.

7. Remove hex head bolts and socket head bolts from

thrust bearing cover.

8. Re-install two bolts into the threaded jacking holes

to assist in removing thrust bearing cover. Retain

the shim pack.

9. Hold gate rotor support with a suitable wrench on

the ﬂ ats provided near the roller bearing housing.

10. Remove the inner retainer bolts and retainer.

11. To remove the thrust bearing housing, install thrust

bearing removal and installation tool with smaller

puller shoe. Turn the jacking screw clockwise. The

thrust bearings and housing assembly will be pulled

off the shaft and out of the frame.

12. Remove bolts from roller bearing housing.

13. Re-install two bolts into jack bolt holes provided in

housing to aid in removal.

14. To remove the gate rotor support, carefully move

support in the 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

gate rotor support. On dual gate compressor units,

repeat the procedure for the remaining gate rotor

support assembly.

INSTALLATION

15. Install gate rotor support by carefully tilting the

roller bearing end of the gate rotor support towards

the suction end of the compressor. The compressor

input shaft may have to be rotated to facilitate the

installation of the gate rotor support. Install gate

rotor stabilizer. The gate rotor stabilizer (901) will

hold the gate rotor support in place as the thrust

bearing housing is being installed. If the gate rotor

support is not restricted from moving, the gate ro-

tor blade may be damaged.

16. Install the roller bearing housing (112) with a new

O-ring (141).

17. Tighten bolts (152), see Appendix A.

18. When installing the thrust bearing housing (113), a

new O-ring (142) must be used when the housing

is installed, see Figure 5-19. Lubricate the outside

of the housing and bearings with clean compres-

sor oil to aid in the installation. Due to the ﬁ t of the

bearings on the gate rotor shaft, the thrust bearing

removal and installation tool with the pusher shoe

must be used. Turn the jacking screw 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 gate rotor blade and shelf.

20. Place a piece of 0.003”-0.004” shim stock between

gate rotor blade and shelf.

Section 5 • Maintenance/Service

5 – 22 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

NOTE

This measurement determines the amount of shims

needed for the correct clearance.

21. Measure depth from top of compressor case to top

of thrust bearing housing.

22. Use factory installed shim pack (106) and bearing

housing cover (116) without the O-ring (143).

NOTE

Replacement blades are precisely the same

dimensionally as blades installed originally at

factory: Therefore, the same amount of shims will

be required for replacement blades.

Section 5 • Maintenance/Service

901C

90 1B

90 1A

Figure 5-17. Gate Rotor Assembly Removal

and Tools

Figure 5-18. Gate Rotor Assembly Removal

Use ﬂ ats provided on

gate rotor support to

prevent rotation when

removing bearing

retainer.

For VSSG 291-601

compressors, do not

use side rails.

For VSG 751/901 and

1051-1301compressors, use

side rails and assemble gate

rotor stabilizer as stamped.

Position leading edge of main rotor groove

ﬂ ush with or slightly below back of gate

rotor support.

5 – 23

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 5 • Maintenance/Service

Figure 5-19. Gate Rotor Assembly and Tools Figure 5-20. Gate Rotor and Shelf Clearance

Check for 0.003-0.004” (0.076- 0.102 mm) clearance between

gate rotor blade and partition.

23. Check the clearance between the entire gate rotor

blade and the shelf, rotate the gate rotor to ﬁ nd the

tightest spot. It should be between 0.003-0.004“

(0.076-0.102 mm). Make adjustments, if neces-

sary. It is preferable to shim the gate rotor blade

looser rather than tighter against the shelf, see

Figure 5-20.

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.

5 – 24 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

bearing end of the gate rotor support towards the

suction end of the compressor. The compressor

input shaft may have to be rotated to facilitate the

installation of the gate rotor support.

11. Install the roller bearing housing with a new O-ring.

Tighten the bolts to the recommended torque

value.

12. Install the spindle with shims and O-ring, tighten

bolts, see Appendix A. Measure the clearance be-

tween the shelf and blade.

13. Check the clearance between the entire gate ro-

tor blade and the shelf, rotate the gate rotor to

ﬁ nd the tightest spot. It should be between 0.003-

0.004“ (0.076-0.102 mm). Make adjustments, if

Figure 5-21. Gate Rotor Assembly Breakdown

Gate Rotor Assembly Replacement

(VSG 301-701 Compressors ONLY)

REMOVAL

The removal of the gate rotor assembly for the VSG 301-

701 compressors is similar for the VSG 901- 2101 com-

pressors except that the inner races are secured to the

stationary bearing spindle.

1. Remove center member, see appropriate Drive

Coupling Replacement procedure.

2. Remove the upper bolt from the side cover and in-

stall a guide stud in the hole.

3. Remove remaining bolts and side cover. There will

be some oil drainage when the cover is removed.

4. The side cover that contains the suction strainer

should have the suction line properly supported

before the bolts securing the line to the cover can

be removed. After the line is removed, the cover

can be removed per paragraph B.

5. Turn the main rotor so the driving edge of the

groove is between the top of the shelf or slightly

below the back of the gate rotor support. At this

point install the gate rotor stabilizing tool.

6. Remove plug on the thrust bearing housing. Loosen

the socket head cap screw that is located under-

neath the plug. This secures the inner races of the

thrust bearings to the spindle.

7. Remove bolts that hold the thrust bearing housing

to the compressor. Insert two of the bolts into the

threaded jacking holes to assist in removing the

bearing housing from the compressor. When the

housing is removed, there will be shims between

the spindle and thrust bearings. These control the

clearance between the shelf and gate rotor blades.

These must be kept with their respective parts for

that side of the compressor.

8. Remove the bolts from the roller bearing housing.

After the bolts have been removed, the housing

can be removed from the compressor.

9. To remove the gate rotor support, carefully move

the support opposite the direction of rotation and

tilt the 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

gate rotor support. On dual gate versions, repeat

the procedure for the remaining gate rotor support

assembly.

INSTALLATION

10. Install the gate rotor support. Carefully tilt the roller

Section 5 • Maintenance/Service

5 – 25

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 5 • Maintenance/Service

Figure 5-22. Gate Rotor Thrust Bearing

necessary. It is preferable to shim the gate rotor

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 bear-

ings to the spindle. Torque all bolts, see Appendix

15. Install side covers with new gaskets. Tighten bolts,

see Appendix A. The unit can now be evacuated

and leak checked.

Check for 0.003-0.004” (0.076- 0.102 mm) clearance between

gate rotor blade and partition.

Figure 5-23. Gate Rotor and Shelf Clearance

5 – 26 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

GATE ROTOR BLADE REMOVAL

2. Remove the snap ring and washer from the gate ro-

tor assembly. Lift gate rotor blade assembly off the

gate rotor support, see Figure 5-24.

3. Check damper pin and bushing for excessive wear.

Replace if required.

GATE ROTOR BLADE INSTALLATION

4. Install damper pin bushing (120) in gate rotor blade

(111) from the back side of the blade. Be sure bush-

ing is fully seated.

5. Place blade assembly on gate rotor support.

Locating damper over pin.

6. Install washer (119) and snap ring (130) on gate ro-

tor assembly. The bevel on the snap ring must face

away from the gate rotor blade. After the gate rotor

blade and support are assembled, there should be

a small amount of rotational movement between

the gate rotor and support.

Figure 5-25. Gate Rotor Blade Installation

Gate Rotor Disassembly

1. To perform gate rotor disassembly, remove

gate rotor from compressor, see Gate Rotor

Assembly Replacement procedure (All VSG-VSSG

Compressors Except VSG 301-701 Compressors)

or Gate Rotor Assembly procedure (VSG 301-701

Compressors ONLY).

Section 5 • Maintenance/Service

Figure 5-24. Gate Rotor Blade Assembly

5 – 27

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

GATE ROTOR THRUST BEARING REMOVAL

For removal of thrust bearings on VSG units:

7. Remove bolts (150) from the clamping ring (114),

see Figure 5-26.

8. Remove thrust bearing clamping ring.

9. Remove thrust bearings (126) from housing (113).

For removal of thrust bearings on VSSG units:

10. Remove retaining ring from gate rotor support.

11. Remove bearings from support.

12. Remove bearing retainer from inner race.

Figure 5-26. Gate Rotor Thrust Bearing

GATE ROTOR THRUST BEARING INSTALLATION

For installation of thrust bearings on VSG and VSSG units:

13. Install thrust bearings (126) in the housing so the

bearings are face to face. The larger sides of the in-

ner races are placed together. A light application

of clean compressor lubricating oil should be used

to ease the installation of the bearings into the

housing.

14. Center the bearing retainer ring on housing, use

Loctite® 242-thread locker and evenly tighten the

bolts to the recommended torque value, see Figure

5-27.

For installation of thrust bearings on VSG 301- 701 units:

15. Install retainer in the back of the inner race of one

of the thrust bearings. The back of the inner race is

the narrower of the two sides.

16. The bearing with the retainer should be placed in

the housing ﬁ rst, retainer towards the support.

Install the second bearing. The bearings should be

positioned face to face. This means that the larger

sides of the inner races are placed together. A light

application of clean compressor lubricating oil

should be used to ease the installation of the bear-

ings into the gate rotor support.

17. Install the bearing retaining snap ring.

Figure 5-27. Thrust Bearing Installation

GATE ROTOR ROLLER BEARING REMOVAL

18. Remove the snap ring (131), which retains the roll-

er bearing in the bearing housing, see Figure 5-28.

19. Remove the roller bearing (125) from the bearing

housing (112).

20. Use a bearing puller to remove the roller bearing

race (125) from the gate rotor support (110).

GATE ROTOR ROLLER BEARING INSTALLATION

21. Match up the part numbers on the inner race to

the part numbers outer race. Press the bearing race

(numbers visible) onto the gate rotor support.

22. 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.

Section 5 • Maintenance/Service

5 – 28 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

The bevel on the snap ring must face away from the

roller bearing.

Figure 5-28. Roller Bearing Assembly

Section 5 • Maintenance/Service

Slide Valve Actuator Assembly

Replacement

To replace slide valve actuator assembly, proceed with

the following steps:

REMOVAL

WARNING

At shutdown, open any other valves that may trap

liquids to prevent serious injury and/or damage to

equipment.

WARNING

Follow local lockout/tagout procedure. Failure to

comply may result in serious injury, death and/or

damage to equipment.

NOTE

This procedure is applicable to both capacity and

volume slide valve actuator assemblies.

1. Shut down the compressor unit, refer to Stopping/

Restarting procedure in Section 4.

2. Turn disconnect switches to the OFF position for

the compressor unit and oil pump motor starter, if

equipped.

3. Allow compressor, motor and surrounding compo-

nents to cool prior to servicing.

4. Disconnect connectors from actuator.

NOTE

Note orientation of components to aid in installation.

5. Remove screws and lock washers securing actuator

assembly to actuator mount.

6. Remove actuator assembly from actuator mount.

INSTALLATION

CAUTION

When installing the slide valve actuator assembly,

loosen locking collar down the shaft. Do not use a

screwdriver to pry locking collar into position.

7. Position actuator assembly on mount as noted in

removal.

8. Install lock washers and screws to secure actuator

assembly to actuator mount.

9. Tighten screws, see Appendix A.

10. Connect connectors to actuator assembly.

11. Calibrate actuator assembly, see Slide Valve

Calibration procedure in Section 4.

5 – 29

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Command Shaft Assembly

Replacement

REMOVAL

NOTE

The following steps can be used to remove or install

either the capacity or volume command shaft

assemblies.

1. Shut down and isolate compressor unit, see

Compressor Unit Shutdown and Isolation

procedure.

2. Remove actuator, see Actuator Assembly

Replacement procedure.

3. Remove four socket head cap screws (457) and

Nord-Lock washers (477) securing mounting plate

(415) to manifold.

4. The command shaft and mounting plate may now

be removed from the compressor.

INSTALLATION

5. Install the command shaft assembly with a new

O-ring (446) on the manifold. Make sure that the

command shaft tongue is engaged in the cross

shaft slot. Rotate the bearing housing so the vent

holes point down, this will prevent water and dust

from entering the vents.

6. Install the actuator mounting plate with the four

socket head cap screws and Nord-Lock washers se-

curing it with proper torque.

7. Perform leak check, see Compressor Unit Leak

Check procedure.

Command Shaft Seal Replacement

REMOVAL

1. Remove bolts (281) holding the shaft seal cover

(218). Insert two of the bolts into the threaded

jacking holes to assist in removing the cover. There

will be a small amount of oil drainage as the cover

is removed.

2. Remove the rotating portion of the shaft seal

(219C).

3. Remove oil seal (230) from cover.

4. Remove the stationary portion of the shaft seal

(219B) from the seal cover using a brass drift and

hammer to tap it out from the back side of the seal

cover.

5. Seal with stationary carbon face (219B) and rotat-

ing mirror face (219C).

Figure 5-29. Command Shaft Seal

INSTALLATION

CAUTION

Care must be taken when handling the shaft seal and

mirror face so it is not damaged. Do not touch the

carbon or mirror face as body oil and sweat will cause

the mirror face to corrode.

NOTE

When replacing the stationary members of the seal

on the VSSG 291 thru VSSG 601 the roll pin in the

cover is used only with the seal assembly having a

stationary mirror face. If a seal assembly with a

stationary carbon face is installed, the roll pin must

be removed.

6. To install the carbon cartridge part of the seal in the

seal cover; clean the seal cover, remove protective

plastic from the carbon cartridge, do not wipe or

touch the carbon face. Lubricate the sealing O-ring

with clean compressor lubricating oil. If applicable,

align the hole on the back of the carbon cartridge

with the dowel pin in the seal cover. Install car-

tridge using seal installation tool or similar (see tool

lists).

7. Wipe clean, the compressor input shaft and the

Section 5 • Maintenance/Service

5 – 30 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

shaft seal cavity in the compressor housing. Apply

clean compressor oil to the shaft seal seating area

on input shaft.

8. Lubricate the inside area of the rotating seal with

clean compressor lubricating oil, do not wipe or

touch the face of the rotating portion of the seal.

Align the slot in the rotating seal with the drive pin

on the compressor input shaft, see Figure 5-30.

Carefully push the seal on, holding onto the out-

side area of the seal until the seal seats against the

shoulder on the input shaft. Make sure the seal is

seated against the shoulder. If the seal is not fully

seated against the shoulder, the shaft seal carbon

will be damaged when the seal cover is installed.

Section 5 • Maintenance/Service

Figure 5-30. Command Shaft Seal Installation

6 – 1

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Table 6-1. Slide Valve Actuator Troubleshooting Guide (1 of 2)

Section 6 • Troubleshooting

Problem Reason Solution

The actuator cannot be calibrated or

exit calibration mode

Dirt or debris is blocking one or both

optocoupler slots

Clean the optocoupler slots with a

Q-Tip and rubbing alcohol.

The photochopper fence extends

less than about half way into the

optocoupler slots

Adjust the photochopper so that

the fence extends further into the

optocoupler slots. Make sure the

motor brake operates freely and

the photochopper 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 compressed air.

The calibrate button is stuck down Try to free the stuck button.

The position sensor has failed Replace the actuator.

Push button is being held down for

more that ¾ second when going

through the calibration proce-

dure

Depress the button quickly and then

let go. Each ¾ second the button is

held down counts as another press.

The actuator goes into calibration

mode spontaneously

The white calibrate wire in the

grey Turck cable is grounding

intermittently

Tape the end of the white wire in the

panel and make sure that it cannot

touch metal.

A very strong source of electromag-

netic interference (EMI), such as a

contactor, is in the vicinity of the ac-

tuator or grey cable

Tape the end of the white wire in the

panel and make sure that it cannot

touch metal.

Install additional metal shielding ma-

terial between the EMI source and

the actuator or cable.

There is an intermittent failure of the

position sensor Replace the actuator.

The actuator goes into calibration

mode every time power is restored

after a power loss

The motor brake is not working prop-

erly (see theory section above.) Get the motor brake to where it

operates freely and recalibrate.

The actuator does not transmit the

correct position after a power loss

The motor was manually moved

while the position sensor was not

powered.

Recalibrate.

The motor brake is not working

properly

Get the motor brake to where it op-

erates freely and then recalibrate.

The position sensor’s EEPROM

memory has failed Replace the actuator.

6 – 2 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 6 • Troubleshooting

Problem Reason Solution

The actuator does not transmit the

correct position after a power loss

The motor was manually moved

while the position sensor was not

powered.

Recalibrate.

The motor brake is not working

properly

Get the motor brake to where it op-

erates freely and then recalibrate.

The position sensor’s EEPROM

memory has failed Replace the actuator.

There is a rapid clicking noise when

the motor is operating

The photochopper is misaligned

with the slotted optocouplers Try to realign or replace the actuator.

The photochopper is positioned too

low on the motor shaft.

Adjust the photochopper so that

the fence extends further into the

optocoupler slots.

A motor bearing has failed Replace the actuator.

The motor operates in one direction

only

There is a loose connection in the

screw terminal blocks Tighten.

There is a loose or dirty connection

in the yellow Turck cable Clean and tighten.

The position sensor has failed Replace the actuator.

There is a broken motor lead or

winding Replace the actuator.

The motor will not move in either

direction

The thermal switch has tripped be-

cause the motor is overheated

The motor will resume operation

when it cools. This could be caused

by a malfunctioning control panel.

Consult the factory.

Any of the reasons listed in “The mo-

tor operates in one direction only” See above.

The command shaft is jammed Free the command shaft.

Broken gears in the gearmotor Replace the actuator.

Blown relay or fuse. Check and replace blown relay and/

or fuse.

The motor runs intermittently, sev-

eral minutes on, several minutes off

Motor is overheating and the ther-

mal switch is tripping

This could be caused by a malfunc-

tioning control panel. Consult the

factory.

The motor runs sporadically

Bad thermal switch Replace the actuator.

Any of the reasons listed in “The mo-

tor will not move in either direction” See above.

The motor runs but output shaft will

not turn

Stripped gears inside the gear

motor or the armature has come un-

pressed from the armature shaft

Replace the actuator.

Table 6-1. Slide Valve Actuator Troubleshooting Guide (2 of 2)

6 – 3

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Slide Valve Actuators communicate problems discovered by internal diagnostics via LED blink codes. Only one blink

code is displayed, even though it is possible that more than one problem has been detected.

Flash Pattern Meaning

*=ON

_=OFF

*_*_*_*_*_*_*_*_*_*_*_ Calibration step 1

*___*___*___*___*___ Calibration step 2

*__*________________

This indicates a zero span. This error can only occur during calibration. The typi-

cal cause is forgetting to move the actuator when setting the upper limit of the

span. If this is the case, press the blue button to restart the calibration proce-

dure. This error can also occur if either or both of the slotted optocouplers are

not working. If this is the case, the slide valve actuator will have to be replaced.

The operation of the slotted optocouplers is tested as follows:

1. Manually rotate the motor shaft until the aluminum photochopper fence is

not blocking either of the optocoupler slots.

2. Using a digital multi-meter, measure the DC voltage between terminal 3 of

the small terminal block and TP1 on the circuit board (see Note 1). You should

measure between 0.1 and 0.2 Volts.

3. Next, measure the DC voltage between terminal 3 and TP2 on the circuit

board. You should measure between 0.1 and 0.2 Volts.

*__________________

This indicates a skipped state in the patterns generated by the optocouplers as

the motor moves. This error means that the slide valve actuator is no longer

transmitting accurate position information. The actuator should be recalibrated

as soon as possible. This code will not clear until the actuator is recalibrated.

This code can be caused by:

1. The motor speed exceeding the position sensors ability to measure it

at some time during operation. A non-functioning motor brake is usually to

blame.

2. The actuator is being operated where strong infrared light can falsely

trigger the slotted optocouplers, such as direct sunlight. Shade the actuator

when the cover is off for service and calibration. Do not operate the actuator

with the cover off.

Section 6 • Troubleshooting

Table 6-2. Slide Valve Actuator LED Blink Codes* (1 of 2)

6 – 4 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

*There are two versions of slide valve actuators, version A and B. Only version B is able to display LED blink codes. Slide valve actuator version B can

be distinguished by only having a single circuit board as supposed to two circuit boards in version A.

Note 1: TP1 and TP2 are plated-thru holes located close to the slotted optocouplers on the board. They are clearly marked on the board silkscreen

legend.

Note 2: The TS1 wire pads are where the motor thermal switch leads solder into the circuit board. They are clearly marked on the board silkscreen

legend and are oriented at a 45 degree angle.

Flash Pattern Meaning

*__*__*____________

The motor has overheated. The actuator motor will not run until it cools. Once

the motor cools, the actuator will resume normal operation.

Motor overheating is sometimes a problem in hot and humid environments

when process conditions demand that the slide valve reposition often. Solutions

are available; consult your Vilter authorized distributor for details.

Another possible cause for this error is a stuck motor thermal switch. The ther-

mal switch can be tested by measuring the DC voltage with a digital multi-meter

between the two TS1 wire pads (see Note 2). If the switch is closed (normal

operation) you will measure 0 Volts.

********************

The 24V supply is voltage is low. This will occur momentarily when the actuator

is powered up and on power down.

If the problem persists, measure the voltage using a digital multi-meter be-

tween terminals 3 and 4 of the small terminal block. If the voltage is >= 24V,

replace the actuator.

_*******************

The EEPROM data is bad. This is usually caused by loss of 24V pow-

er before the calibration procedure was completed. The actuator

will not move while this error code is displayed. To clear the error,

calibrate the actuator. If this error has occurred and the cause was

not the loss of 24V power during calibration, possible causes are:

1. The EEPROM memory in the micro-controller is bad.

2. The large blue capacitor is bad or has a cracked lead.

*****____*__________ Micro-controller program failure. Replace the actuator.

Section 6 • Troubleshooting

Table 6-2. Slide Valve Actuator LED Blink Codes (2 of 2)

6 – 5

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Problem Solution

Low Oil Pressure at Start

• After failing to start compressor with “Prelube Oil Pump Inhibit”, ﬁ rst allow

Discharge pressure, Oil Filter In pressure and Out pressure to equalize. Then

restart compressor. If compressor fails to start due to low oil pressure, contin-

ue troubleshooting with items below.

• Reset Prelube Oil Pressure Setpoint in Alarms and Trip Setpoints screen to

lowest recommended setpoints.

• Check calibration of oil manifold transducer, discharge pressure transducer,

and suction transducer.

• Check for correct oil pump motor rotation and operation.

• Ensure transducer isolation valves are open.

• Verify that the correct transducer ranges are selected.

• Check to see all oil line valves are open except the oil dump valve used to ﬁ ll

the lines and oil cooler.

• Check oil strainer for dirt.

• Check oil ﬁ lter pressure drop.

• Check “Prelube Oil Pump Time Limit” setpoint is sufﬁ cient in Compressor

Timer Setpoints screen.

• Prelube 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 differential pres-

sure, otherwise oil pressure can’t be maintained. Oil pressure is manifold oil

pressure minus the suction pressure. It is a net pressure.

• If the oil pump is selected to be a part time oil pump in the “Setup” menu,

then ensure that it only shuts off at an appropriate pressure ration that takes

into account pressure drops through the oil cooler. This is a set point in the

“Compressor Control Setpoints” menu called “Oil Pump Restart.” It is a pres-

sure ratio. (discharge pressure in psia/suction pressure in psia) Default ratio

is a pressure ratio of 3.00:1 that stops the pump and 2.80:1 that restarts the

pump. This ratio can be increased. Do not decrease without consulting Vilter.

Oil ﬂ ow or oil pressure

problems

• Clean oil strainer screen.

• Change oil ﬁ lter, maybe plugged or collapsed.

• Oil pump gears worn internally, excessive end-clearance.

• Oil priming valve used on air-cooled cooler units is open.

• Relief in-line check valve stuck open.

• Pressure ratio too low, oil pump should be on.

Faulty pressure or temperature

readings

• Check that the correct pressure or temperature range is selected in the

Instrument Calibration menu.

• Check cable connections at device, terminal strips, and PLC input card for

correct wiring and shielding (RF noise).

• Check calibration of RTDs and transducers.

Section 6 • Troubleshooting

Table 6-3. Troubleshooting Guide - General Problems & Solutions (1 of 3)

6 – 6 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 6 • Troubleshooting

Problem Solution

Oil Loss Issues

• Oil return line from coalescing side of oil separator to suction is closed, not

open enough (.75 turns should be sufﬁ cient), or plugged with debris

• The check valve in the oil return line could be stuck closed or the ﬂ ow is in the

wrong direction

• There may be water in the oil affecting the coalescing elements

• Coalescent elements in need of replacement due to age or damage (water

contamination)

• The operating conditions are not correct (too high of suction and/or too low

discharge pressure) This creates increased gas ﬂ ow which could make the oil

separator too small

• The suction or discharge check valve is not working correctly causing oil to

escape when the unit stops

• Viscosity of oil incorrect; send sample for testing

• There is an oil leak somewhere in the system

High oil temperature (liquid

injection)

• Check for correct setting of all manual values.

• Check for correct operation of 2-way automatic oil mixing valve.

• In the “Vilter Only” menu, ensure that you select “Yes this unit has the oil

mixing valve” to enable it.

• If your are controlling a step type oil cooler or a VFD oil cooler, verify the

correct one is selected in the “Vilter Only” menu and the amount of steps are

entered in the menu screen “Oil Cooler Step Control” menu.

• Check the oil cooler and associated piping to make sure it is full of oil before

starting.

• Check the oil strainer for debris and clean if necessary.

• Verify that the volume slide actuator is functioning correctly and that the

correct compressor size (type) is selected in the “Vilter Only” menu.

• Check that all fans are working.

• Check for correct fan rotation on the oil cooler.

• Check that your operating conditions are within the “As Sold” design

conditions.

Capacity/Volume Slide

Actuator Alarms/Trips/

Symptoms:

• Calibration method not correct

• Actuator or Gear motor not working, or off on overload

• Slide valve carriage assembly out of position, slides binding

• Cross-shaft gears, broken pins

• Command shaft broken

• Slide valve rack or rack shaft damaged

• Check balance piston movement

• Reference Slide Valve Actuator Troubleshooting Guide

• Check I/O fusing

Table 6-3. Troubleshooting Guide - General Problems & Solutions (2 of 3)

6 – 7

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Problem Solution

High Amp Draw • Check Main Motor Amps scaling and PLC.

Vibration

• Check that unit is leveled and secured to mounting pad or ﬂ oor.

• Check supported pipes (i.e. suction and discharge pipe) and make sure they

are adequately supported.

• Check for loose bolts and nuts.

• Check condition of compressor and motor (i.e. alignments)

Excessive Motor Backspin • If there is more than normal motor backspin at shutdown, check suction

check valve for proper operation.

Table 6-3. Troubleshooting Guide - General Problems & Solutions (3 of 3)

Section 6 • Troubleshooting

6 – 8 / Blank VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

7 – 1

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 7 • Warranty and Parts

Warranty Claim Processing

This section explains how the warranty claim is pro-

cessed and to help clear any questions that may arise

prior to contacting customer service. For additional war-

ranty information, refer to the VSG/VSSG Standard Vilter

Warranty Statement on page i. Vilter contact informa-

tion can be found on page ii.

1. The warranty process starts with contacting a Vilter

Service and Warranty (S&W) department represen-

tative. Ensure to have the original Vilter sales order

number for the equipment available to better assist

you.

2. Our Vilter S&W representative will conﬁ rm if the

equipment is within the warranty time frame as de-

scribed in the warranty statement.

If the equipment (Part/Compressor/Compressor Motor)

is within the warranty time frame, proceed to the follow-

ing section regarding the type of equipment:

PART

1. Submit a Purchase Order (PO) to procure the re-

placement part:

• The correct Vilter part number and the

quantity.

• The original Vilter sales order for the

equipment.

2. Request a Return Material Authorization (RMA)

number:

• Please provide as much information describ-

ing the mode of failure to be recorded on the

RMA document. This will assist us with pro-

viding a quicker review once we have received

the warranty part (ex. Part does not calibrate,

part does not read correct temperature, etc.).

• Any additional parts returned on the RMA

that is not listed, will be returned freight col-

lect or scrapped. The RMA is valid for 60 days

from the RMA request date.

3. After replacing the warranty part:

• Ship the part to Vilter per the instructions on

the RMA document.

• Please include a copy of the RMA document

in the box for identiﬁ cation purposes when

the part is received.

4. Part to be evaluated.

5. Warranty Consideration:

• Acceptance – A credit will be provided for the

customer part sales order.

• Denial – Notiﬁ cation of denial will be provid-

ed to the customer.

COMPRESSOR

• Due to the site speciﬁ c nature of compressor warran-

ty, all warranty responses must be mitigated through

a Vilter S&W department representative.

COMPRESSOR MOTOR

The warrany is a pass through warranty as stated in the

equipment warranty and as such will be determined by

the manufacturer. All extraneous expenses (i.e. shipping,

removal/installation, alignment) are not covered by Vilter’s

nor the manufacturer’s warranty.

1. The motor will need to be taken to the nearest

Electrical Apparatus Service Association (EASA) re-

pair facility or motor manufacturer approved repair

facility.

2. The motor shop will provide the motor manufac-

turer with the failure analysis.

3. The motor manufacturer will make the warranty

disposition.

On Site Service Support

If on site support is required, contact a Vilter S&W de-

partment representative to start this process.

Warranty does not cover labor and extraneous expenses.

1. A quote, a service rate sheet, and the service terms

and conditions will be provided.

2. Submit a PO.

3. Schedule the service visit.

7 – 2 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 7 • Warranty and Parts

Remanufactured Gas Bare Shaft

Compressor Process

These instructions are an overview of how the process

works when a bare shaft compressor is in need of being

remanufactured. This is to help clear any questions that

may arise prior to contacting customer service.

The process begins by contacting Vilter’s Customer

Service Department. Vilter contact information can be

found on page ii.

• Request a “VSG Single Screw Compressor Rebuild

Form”.

• Submit the Rebuild Form and a Purchase Order

(PO) for the inspection. A fee is required for the ini-

tial inspection and teardown report; contact Vilter

Customer Service representative for the latest 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, contact Vilter

Customer Service representative for further details.

• Submit a new PO for the amount that will be needed

for the rebuild. The inspection cost will be waived

upon receipt of the new PO. Make sure to provide

your “Ship to Address” and “Billing Address”.

EXPLANATION OF REBUILD LEVELS

Level 1

Compressor is in good condition. Replace bearings, gas-

kets, shaft seal and o-rings. All hardware is intended to

be re-used (when possible). Parts are organized in part

kit form.

Level 2

Compressor is in good condition, but requires new gate

rotor blades. Replace all items in Level 1 plus new gate

rotor blades and bushings.

Level 3 - Current Reman Compressor requires complete

rebuilding and re-conditioning to “as-new” condition.

All the components listed in Level 2 are replaced plus all

hardware, slide assemblies, pistons, and a main rotor (if

damaged) and/or gate rotor supports.

NOTE

A Level 1 and Level 2 rebuild will include washing

the housing and repainting over the current paint.

A Level 3 rebuild will include blasting all the current

paint off before repainting.

BARE SHAFT COMPRESSOR DESCRIPTION

Single Screw Bare Shaft Compressor features include:

• Cast grey iron frame with cast ductile iron discharge

manifold and gate rotor covers with discharge con-

nection horizontal.

• Standard drive shaft is tapered.

• Standard slide assembly.

• Viton shaft seal O-rings.

• Crating with Purge & Gauge.

• Does not include handwheels or slide valve motors.

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Torque Specifications (ft-lbs)

Type

Bolt

Head

Markings

Nominal Size Numbers 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

Coarse (UNC) --18-------

SAE Grade 8

Coarse (UNF) - 11 22 39 63 96 138 191 338 546

Socket Head

Cap Screw

(ASTM A574)

Coarse (UNC)

5 13 26 46 73 112 115 215 380 614

1) Torque values in this table are not to override other speciﬁ c torque speciﬁ cations when supplied.

2) When using loctite, torque values in this table are only accurate if bolts are tightened immediately after

loctite is applied.

* The proof strength of Grade 2 bolts is less for sizes 7/8 and above and therefore the torque values are less

than smaller sizes of the same grade.

Torque Specifications for 17-4 Stainless Steel Fasteners (ft-lbs)

Type

Bolt/Nut

Head

Markings

Nominal Size Numbers or Inches

#10 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4

Hex & Socket

Head Cap Screws 3 8 14 25 40 60 101 137 245

Nut -8-25-----

NOTE: Continue use of red loctite #271 (VPN 2205E) on currently applied locations. Use blue loctite #243

(VPN 2205F or 2205G) on all remaining locations.

Appendix A • Torque Specifications

BVSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Short Term Storage

If the equipment is not put into immediate use it should

be stored in a clean, dry location. For all Weather

Protected Type II (WPII) motors, motor heaters should

be activated upon arriving at the jobsite to prevent con-

densation. This is required for warranty considerations.

Care should be taken to keep the equipment covered

when moving from a cold location to a warm location,

otherwise condensation may occur. If condensation

does occur, and the equipment is moist, allow it to dry

thoroughly before applying power.

Long Term Storage

1. Cover machined metal parts with weatherproof cover,

but leave ventilating area exposed.

2. Make certain unpainted portions are covered and re-

touch any scratches or ﬂ aked areas.

3. If condensate plugs or drain plugs have been used,

make sure they are operative.

4. Cover completely with plastic cover and insert silica-

gel bags inside the cover for moisture control.

5. If motor is equipped with space heaters make sure

space heaters are properly connected and operative.

The motor interior temperature should be maintained

approximately 10 °F (5.6 °C) above ambient.

6. For all Weather Protected Type II (WPII) motors, motor

heaters should be activated upon arriving at the jobsite

to prevent condensation. This is required for warranty

considerations.

7. A systematic inspection and maintenance schedule

should be established. If rotating apparatus is to be

stored for 6 months or longer, it should, in addition to

the minor precautions above, be given a megger test ev-

ery 3 to 6 months. A minimum reading of 10 megohoms

is recommended. A record of insulation values, temper-

ature, time, humidity and length of voltage application

should be recorded to show winding conditions prior to

start up.

8. If windings are designed for outdoor operation, they

will not be affected by extreme or sudden temperature

changes or inclement weather in general. However a

weather proof cover with provisions for adequate venti-

lation should be used to guard against intrusion of salt,

dust, or other abrasive or corrosive material.

9. It is recommended that the rotor be turned every

month to redistribute the lubricant in the bearings and

oil or grease be added every 6 six months.

10. Preferably, storage would be in a warehouse or en-

closed building but the same precautions should be

followed.

Lubrication

Refer to manufacturer’s lubrication instructions.

Appendix B • Motor (Compressor) - General Storage Instructions

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Appendix C • Oil Analysis Report

I.D. # *********

Customer Name

Comp. Mfr. Vilter

Serial Number ****-***

Model Number VSM-601

Hrs. on Fluid 6049

Hrs. on Machine 11239

Sample Date Feb 21, 2013

Water by Karl Fischer (ppm)

Viscosity 40 C (cSt)

TAN Total Acid #

ISO Code

Sample Date (Lube Hours)

Silver (Ag)

Aluminum (Al)

Chromium (Cr)

Copper (Cu)

Iron (Fe)

Nickel (Ni)

Lead (Pb)

Tin (Sn)

Titanium (Ti)

Vanadium (V)

Barium (Ba)

Calcium (Ca)

Magnesium (Mg)

Molybdenum (Mo)

Sodium (Na)

Phosphorus (P)

Silicon (Si)

Zinc (Zn)

The fluid is in good condition. Sample again in 6 months.

Customer Customer

Oil Type VILTER-717

Customer Address

PRODUCT ANALYSIS REPORT

Report Number: *********

Report Date: 3/4/2013

Evaluation:

Physical Properties Results *

Spectrochemical Analysis

21/20/16

0.077

64.23

19.5

Feb 21, 2013 (6049)

Wear Metals (ppm)

Contaminant/Additive Metals (ppm)

21/19/16

0.106

64.47

147.7

Oct 19, 2012 (4809)

21/19/14

0.080

66.00

41.4

Jul 26, 2010 (5190)

Accuracy of recommendations is dependent on representative oil samples

and complete correct data on both unit and oil

Thank you for this opportunity to provide technical assistance to your company. If you have any questions about this report, please contact us

at 1-800-637-8628, or fax 1-989-496-2313 or email us at tslab@oil-services-lab.com CC List

* Property values should not be construed as specifications

No Action Required

Receive Date Mar 01, 2013

DVSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Appendix D • Recommended Header Piping

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Appendix E • Recommended Remote Air Cooled Oil Cooler Piping

OUTLET ON TOP

INLET ON BOTTOM

• Vertical drops should be no higher than 8 to 10 feet.

• If there is no choice and the vertical drops need to be higher, then an electronic service

valve needs to be installed in the return line at the compressor. Consult Factory.

• If ambient temperatures get below 50° F, heat trace and insulation on oil lines and air

cooler headers needs to be used.

• Maximum pressure drop on oil lines to and from air cooler and compressor should not

exceed anymore than 5 to 10 psi.

Recommended location of drain

connections as required.

Blank VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Emerson Vsg Users Manual 35391SSG VSG/VSSG Compressor Unit Installation, Operation And Maintenance

e5abe301-38b9-4590-9bae-108c13d9dff7 Emerson Air Compressor VSSG User Guide |

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